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FIELD OF THE INVENTION
This invention relates to an apparatus and method for continuously producing a thin metallic strip, and more spcifically to improvements in the continuous production of a thin metallic strip in which a casting is drawn through a mold for guided withdrawal movement along a path provided by plural pairs of guide rolls.
BACKGROUND OF THE INVENTION
A typical apparatus for continuously producing a metal strip comprises a mold including a pair of mold rolls opposed to each other with a clearance defining an outlet opening, and a melt receiver arranged above the rolls in contact therewith. Molten metal supplied into the mold is withdrawn under solidification through the outlet opening to produce a casting which is thereafter guided along a path provided by plural pairs of guide rolls.
As is well known, a casting (metal strip) produced by such an apparatus usually has on the opposite surfaces thereof depressions of about 0.1 mm in depth extending widthwise of the casting and spaced longitudinally at intervals of about 0.1 to 0.4 mm. These depressions, which are known as "tear marks" degrading the product value, are believed to be formed for the following reason. The molten metal in the mold continuously solidifies on the relatively cold rotating mold rolls to form a shell bifurcated from the upper end of the casting, whereas the melt also forms into a solidified shell on the interior surface of the melt receiver adjacent the mold rolls to ultimately merge into the bifurcated shell on the mold roll side. As the casting is continuously withdrawn at a constant speed, the thus merged shells are immediately torn apart, and they join together again after a certain interval. Such process repeatedly occurs at intervals to form a tear mark every time both shells are torn apart.
In case a casting has a large thickness, such tear marks can be eliminated by rolling the casting to provide an improved quality. But in the case of a thin casting, there is virtually no room for rolling to remove the tear marks, thus leading to a deteriorated product quality.
SUMMARY OF THE INVENTION
It is, therefore, an object of present invention to provide an apparatus and method for continuously producing a thin metallic strip which is free of tear marks.
According to one aspect of the present invention, an apparatus is provided for continuously producing a thin metallic strip, which comprises a mold adapted to receive molten metal and having an outlet opening through which the molten metal under solidification is drawn out as a casting for guided withdrawal movement along a predetermined path, and surface smoothing means for substantially continuously impacting both opposite surfaces of the casting adjacent the outlet opening of the mold.
With the above construction, since the surface smoothing means is arranged adjacent the outlet opening of the mold, it can impact the casting in a still hot and soft state and thereby smooth the opposite surfaces of the casting enough to eliminate tear marks.
The surface smoothing means may comprise at least a pair of rotary beaters, shot blast devices, or hammering devices.
According to another aspect of present invention, a method is provided for continuously producing a thin metallic strip, which comprises generally continuously impacting both opposite surfaces of a casting being drawn through a mold along a predetermined path while the casting is still incompletely hardened.
A best result for a casting of a steel alloy is obtained by conducting the impacting operation while the casting has a surface temperature of 1200° to 1350° C. No noticeable effect is achieved by impacting the casting having its surface temperature lowered to less than 1000° C.
Numerous features and advantages of the present invention will be readily understood from the following description of preferred embodiments given with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings
FIG. 1 is a schematic side elevation, partly in section, of a continuous casting apparatus embodying the invention with rotary beaters incorporated as surface smoothing means;
FIG. 2 is a schematic perspective view of the rotary beater;
FIG. 3 is a side view showing one form of the rotary beater in greater detail;
FIG. 4 is a view similar to FIG. 3 but showing another form of the rotary beater;
FIG. 5 is a schematic side elevation showing another continuous casting apparatus embodying the invention with shot blast devices incorporated as the surface smoothing means;
FIG. 6 is a schematic side elevation of a further continuous casting apparatus embodying the invention with hammering devices employed as the surface smoothing means.
DETAILED DESCRIPTION
Referring now to FIG. 1, numeral 1 represents a pair of mold rolls opposed to each other with a predetermined clearance to define an outlet opening 1a. A melt receiver 2 is arranged above the mold rolls 1 in contact therewith. The mold rolls 1 and the receiver 2 constitute a mold 3. Plural pairs (only 3 pairs shown in FIG. 1) of opposed guide rollers 4 are arranged below the mold 3 to form a withdrawal path. According to this embodiment, three pairs of opposed rotary beaters 5 are disposed immediately below the mold rolls 1 in three stages on both sides of the withdrawal path.
As shown in FIG. 2, each rotary beater 5 comprises a rotary shaft 6 and plural beating portions 7 equidistantly spaced axially of the shaft 6. Each beating portion 7, as shown in FIG. 3, includes a plurality of branched chains 8 each fixed at one end to the rotary shaft 6 at each of equiangularly spaced positions and having chain branches 8a flaring to give an increased beating range. Although not clearly illustrated, it should be understood that the beating portions 7 in one stage are positioned between the beating portions 7 in an adjacent stage, so that the rotary beaters 5 altogether provide a combined beating range enough to cover the entire width of a casting 10 without omission.
The continuous casting apparatus having the above construction operates as follows.
First, a dummy bar (not shown) is inserted between the mold rolls 1 from below to plug the outlet opening 1a, and a steel alloy melt 9 is supplied into the melt receiver 2. The melt 9 forms a bifurcated shell 10a upon contact with the mold rolls 1 under cooling. Subsequently, with the mold rolls 1 in rotation as indicated by arrow A, the dummy bar is pulled downward to cause the casting (thin metallic strip) 10 to be withdrawn along the drawing path provided by the guide rollers 4 as indicated by arrow B. During the above descibed continuous casting operation, the rotary beaters 5 are continuously rotated as indicated by arrow C. As a result, the branched chains 8 of each rotary beater 5 are centrifugally stretched radially, so that the branched chain free ends 8a successively collide against a corresponding surface of the still incompletely hardened casting 10. Thus, the casting 10 is substantially continuously impacted, and depressions thereon, i.e., tear marks, are eliminated (refer to FIG. 3).
Casting conditions which would lead to a good result are given below by way of example.
______________________________________Thickness of casting 10 20 mmWithdrawal speed of casting 10 5 m/min.Surface temperature of casting 10 1200 to 1350° C.Depth of depressions 11 0.02 to 0.1 mmInterval between depressions 11 2.0 to 3.0 mmNumber of rotory beaters 5 2 pairsNumber of chain branches 8a in each 40beating portion 7Weight of each chain link in each 1.5 gchain branch 8aDiameter of each rotory beater 5 100 mmin rotationRotational speed of each rotary 400 rpmbeater 5______________________________________
The number of the beating portions 7 in each rotary beater 5 may be varied depending on the width of the casting 10 to be produced. The number of the rotary beater pairs may also be altered to match the other casting conditions.
Each branched chain 8 shown in FIG. 3 may be replaced by a branched wire rope 12 as shown in FIG. 4. The wire rope 12 comprises a multiplicity of stranded metal filaments and has rope branches 12a at the free end thereof.
In another embodiment shown in FIG. 5, plural pairs of opposed shot blast devices 13 are arranged in three stages on both sides of the withdrawal path for a casting 10. Each blast device 13 comprises a blasting nozzle 14 connected to an unillustrated supply source and adapted to shoot hard solids such as steel beads or balls 15 to the casting 10. After having collided against the casting 10, the solids 15 are guided along a corresponding guide plate 13a to a collecting device (not shown). Depending on the width of the casting 10, each stage may incorporate plural pairs of such shot blast devices 13 spaced widthwise of the casting 10.
FIG. 6 shows a further embodiment in which plural pairs of opposed hammering devices 16 are disposed in three stages on both sides of the withdrawal path for a casting 10. Each hammering device 16 has a vibrator 17 which is adapted to oscilate a hammering head 18 through a rod 17a. As in the embodiment of FIG. 5, plural pairs of such hammering devices 16 may be provided in each stage as spaced apart widthwise of the casting 10 in consideration of the width of the casting 10.
The present invention is not limited to the illustrated embodiments but can be modified within the scope obvious to those skilled in the art. For example, the embodiment of FIGS. 1 to 3 may be modified so that one or more spiral rows of branched chains are provided on the rotary shaft 6. Thus, it should be understood that the present invention is restricted only by the appended claims. | An apparatus for continuously producing a thin metallic strip comprises a mold 3 adapted to receive molten metal and having an outlet opening 1a through which the molten metal under solidification is drawn out as a casting 10 for guided withdrawal movement along a predetermined path, and surface smoothing devices 5 for generally continuously impacting both opposite surfaces of the casting 10 adjacent the outlet opening of the mold. | 1 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No. 10/719,770, filed on Nov. 21, 2003, which claims benefit of priority from U.S. Provisional application No. 60/417,068, filed Oct. 8, 2002, both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] In one embodiment, the disclosed invention relates to a microarray with markers for rheumatoid arthritis and a method for detection of rheumatoid arthritis. In another embodiment, the invention relates to treatment for the disease.
[0004] 2. Description of the Related Art
[0005] Rheumatoid arthritis (RA) is a chronic systemic disorder that affects joints and surrounding tissues as well as other organ systems. The cause is unknown. Infectious, genetic and hormonal factors have been suggested. RA eventually effects the ability to perform daily activities and overall quality of life.
[0006] RA effects both sides of the body equally, most commonly wrists, fingers, knees, feet and ankles. When the synovium (joint lining) is affected, the synovium becomes inflamed, secretes more fluid and the joint becomes swollen. Later, the cartilage becomes rough and pitted and the underlying bone becomes affected. Joint destruction typically begins 1-2 years after the appearance of the disease. Organs may also be affected, particularly the lungs, heart and vascular system.
[0007] There is no cure for RA although intervention can delay onset of symptoms. Consequently, an early marker for the disease would be useful to provide an early diagnosis. A rheumatoid factor test is available. However, this test is positive in only about 75% of people with symptoms.
[0008] Recent technological advances enable high throughput screening of proteins. These include the sequencing of the human genome and the development of high throughput, robotic screening methods required to handle the numbers of samples involved in a “genome” or “proteome” screen. Characterization of the human genome is clearly the first step towards characterization of the human proteome. The use of the genome to characterize the proteome is commonly referred to as “reverse genomics.”
[0009] Mitochondrial dysfunction contributes to cell damage in a number of human diseases. One significant mechanism by which mitochondria damage cells is by producing reactive oxygen species from the respiratory chain. (AugMiesel R, et al, Free Radical Research. 25(2):161-9, 1996.). The studies on synovial fibroblast cultures from patients with rheumatoid or reactive arthritis suggested involvement of mitochondria in the disease process. (Eerola E, et al (1988) Br. J. Rheumatol. (1988) vol 27. Suppl 2:128-31.
[0010] A ribosomal protein from the mitochondrial large subunit is described. Antibodies to this protein are expressed at elevated levels in patients suffering from RA. This protein has been identified as the L35 protein of the large (39S) subunit of the mammalian mitochondrial ribosome. It is suggested that this species may serve as a useful marker for RA.
[0011] Binding of L35 to killer T-cells (HLA-DR) has been described (Gordon, et al. (1995) Eur. J. Immunol. (1995) vol. 25(5): 1473-1476)). Interference with this interaction may provide relief to persons suffering from RA. Also, autoantibodies against cytoplasmic ribosomes have been implicated in patients suffering from systemic lupus erythematosus (Bonfa, et al. (1987) New England Journal of Medicine vol. 317: pages 265-271). If the L35 protein acts in a similar manner in RA patients, the L35 protein may serve as a possible treatment to relieve disease symptoms. Thus, compositions containing the L35 protein may be useful in the treatment of RA. Other mitochondrial proteins which are useful in the treatment and/or diagnosis of RA are described which include eukaryotic translation elongation factor 1 alpha 2; NADH dehydrogenase 3 (NADH dehydrogenase, subunit 3 (complex I)); Homo sapiens gene for 24-kDa subunit of complex I, exon 7; Homo sapiens mRNA for mitotic kinesin-like protein-1 (MKLP-1 gene); Homo sapiens TBXAS1 gene for thromboxane synthase, exon 2; and Homo sapiens uncoupling protein homolog (UCPH) mRNA.
SUMMARY OF THE INVENTION
[0012] In one embodiment, the present invention is drawn to a protein microarray including mitochondrial proteins as markers of RA. Preferably, the protein microarray includes at least a portion of at least two of the following proteins: L35 protein, eukaryotic translation elongation factor 1 α-2; NADH dehydrogenase 3 (complex I), 24-kDa subunit of complex I, mitotic kinesin-like protein-1, thromboxane synthase, and uncoupling protein homolog. More preferably, the protein microarray includes at least a portion of at least four of the above listed proteins. Even more preferably, the protein microarray includes at least a portion of all of the proteins including L35 protein, eukaryotic translation elongation factor I α-2; NADH dehydrogenase 3 (complex I), 24-kDa subunit of complex I, mitotic kinesin-like protein-1, thromboxane synthase, and uncoupling protein homolog.
[0013] In a preferred embodiment, the proteins of the protein microarray are His-tagged. In a preferred embodiment, the proteins of the protein microarray are printed on a charged nickel slide.
[0014] In a preferred embodiment, the L35 protein of the protein microarray is represented by a sequence which includes at least a part of the sequence shown in SEQ ID NO: 2.
[0015] In a preferred embodiment, the eukaryotic translation elongation factor I α-2 of the protein microarray is represented by a sequence which includes at least a part of the sequence shown in SEQ ID NO: 4.
[0016] In a preferred embodiment, the NADH dehydrogenase 3 (Complex I) protein of the protein microarray is represented by a sequence which includes at least a part of the sequence shown in SEQ ID NO: 6.
[0017] In a preferred embodiment, the 24-kD subunit of Complex I of the protein microarray is represented by a sequence which includes at least a part of a protein encoded by the sequence shown in SEQ ID NO: 7.
[0018] In a preferred embodiment, the mitotic kinesin-like protein-1 of the protein microarray is represented by a sequence which includes at least a part of the sequence shown in SEQ ID NO: 9.
[0019] In a preferred embodiment, the thromboxane synthase protein of the protein microarray is represented by a sequence which includes at least a part of the sequence shown in SEQ ID NO: 11.
[0020] In a preferred embodiment, the uncoupling protein homolog of the protein microarray is represented by a sequence which includes at least a part of the sequence shown in SEQ ID NO: 13.
[0021] In one embodiment, the invention is drawn to a method of screening for rheumatoid arthritis in a mammal including the steps of:
contacting a sample from said mammal to an immobilized polypeptide or fragment thereof homologous to at least a portion of at least one protein selected from the group consisting of L35 protein, eukaryotic translation elongation factor 1 α-2; NADH dehydrogenase 3 (complex I), 24-kDa subunit of complex I, mitotic kinesin-like protein-1, thromboxane synthase, and uncoupling protein homolog; and detecting binding of an antibody from said sample to said immobilized polypeptide or fragment thereof. In a preferred embodiment, the polypeptide or fragment thereof is immobilized on a microarray. Preferably, the proteins or fragments thereof are His-tagged. Preferably, the proteins or fragments thereof are printed on a charged nickel slide.
[0024] In another embodiment, the invention is drawn to a method of treating rheumatoid arthritis in a mammal which includes the steps of administering to said mammal a composition comprising a polypeptide or fragment thereof homologous to at least a portion of at least one protein selected from the group consisting of L35 protein, eukaryotic translation elongation factor 1 α-2; NADH dehydrogenase 3 (complex I), 24-kDa subunit of complex I, mitotic kinesin-like protein-1, thromboxane synthase, and uncoupling protein homolog, said polypeptide or fragment thereof being administered in an amount sufficient to interfere with the binding of an antibody from said mammal.
[0025] In another embodiment, the invention is directed to a kit for screening for Rheumatoid Arthritis in a mammal, which includes a mitochondrial marker, homolog or fragment thereof, selected from L35 protein, eukaryotic translation elongation factor 1 α-2, NADH dehydrogenase 3 (complex I), 24-kDa subunit of complex I, mitotic kinesin-like protein-1, thromboxane synthase, or uncoupling protein homolog. Preferably, the mitochondrial marker, homolog or fragment thereof is immobilized on a rigid white substrate. In a preferred embodiment, the mitochondrial marker, homolog or fragment thereof is immobilized on a hydrophobic substrate.
[0026] Further aspects, features and advantages of this invention will become apparent from the detailed description of the preferred embodiments which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 . Summary of the method to produce a large number of over-expression clones for a protein array.
[0028] FIG. 2 . Example Testing 6×His-tagged Proteins.
[0029] FIG. 3 . Nickel chip with Proteome library.
[0030] FIG. 4 . Microarrays showing RA positive tagged proteins. The top panel was screened with serum from control population. The bottom panel was screened with serum from RA population.
[0031] FIG. 5 shows three panels. All are spotted with the L35 protein. The upper panel is contacted with anti-His serum. The middles panel with serum from RA patients. The bottom panel is contacted with control serum.
[0032] FIGS. 6A-6C relate to a capture assay. FIG. 6A shows a schematic view of the procedure. FIG. 6B illustrates the antibody binding. FIG. 6C shows a P53 capture assay at three different dilutions.
[0033] FIGS. 7A-7G relate to a Western Blot-type assay. FIG. 7A shows a schematic view of a Western blot type assay for an auto-antigen panel. FIG. 7B shows a listing of autoimmune disease assay antigens. FIG. 7C shows serum for various autoimmune diseases. FIG. 7D shows a Lupus titration. FIG. 7E shows S.L.E. with corresponding markers. FIG. 7F shows a titration for Sjogrens syndrome. FIG. 7G shows an assay for Sjogrens syndrome.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] In one aspect, the present invention relates to a method of producing a microarray that can be used to screen for a disease condition. Preferably, the disease condition is an autoimmune disease. In a preferred embodiment, the disease condition is arthritis, diabetes, Lupus, Multiple sclerosis, Myasthenia gravis, Wegener's granulomatosis or Crohn's disease. More preferably, the disease condition is rheumatoid arthritis.
[0035] The microarray can be constructed in a number of ways. In one embodiment, a cDNA library is used to construct a “proteome” library. Each protein produced in the “protein library” can be traced back to a single clone that contains a recombinant human gene derived from the original cDNA library. Hence, each protein is “identified” by reverse genomics (i.e., sequencing of the gene from which it was derived). This allows an investigator to screen many recombinant proteins.
[0036] In a preferred embodiment, a cDNA library is obtained and cloned into a His vector such as PQE from Qiagen to create a His library. A suitable host cell is transformed with the cDNA library. The transformed cells are plated on selective media and may be induced to produce protein with a suitable inducer molecule. The colonies are then blotted onto a solid support such as a membrane made of nitrocellulose, nylon or polyvinylidene difluoride (PVDF) or a glass or plastic plate. In a most preferred embodiment, a charged nickel slide is used as a solid support. The colonies are identified using antiHis antibody. The His positive clones may be grown in appropriate media and transferred to a multiwell plate or charged nickel slide. Any 6×His tagged proteins may be bound and tested using the described system.
[0037] Ni 2+ slides can be used to determine disease markers and diseased patients. The His-tagged proteins are printed onto nickel-coated slides, washed and reacted with appropriate serum to identify potential disease markers. Preferably, the serum is from a population afflicted with autoimmune disease. In a preferred embodiment, the autoimmune disease is arthritis, diabetes, Lupus, Multiple sclerosis, Myasthenia gravis, Wegener's granulomatosis or Crohn's disease. More preferably, the autoimmune disease condition is rheumatoid arthritis.
[0038] In a preferred embodiment, one pool of serum from a disease population is compared to a pool of serum from a healthy (control) population for determination of possible disease markers. Proteins that react with serum from the diseased population but not from serum from the control population are potential disease markers once false positives have been eliminated. In a preferred embodiment, serum from rheumatoid arthritis patients was reacted with the protein array to identify markers for rheumatoid arthritis.
[0039] A method is described to produce a large number of over-expression clones for a protein microarray based screening of the “Proteome.” In the Examples that follow, new markers associated with Rheumatoid arthritis as well as other autoimmune diseases were found. FIG. 1 shows the major steps involved in this process.
[0040] The positive clone L-35 was obtained by the following steps. Vectors (His-tagged vector from Qiagen:PQE 30, 31, 32) and cDNA libraries were digested with the same restriction enzymes. The digested cDNA libraries were then ligated into the His-tagged vectors. The plasmid clones were transformed into competent cells. Transformants were detected by antibiotic-resistant colony selection. Protein production in the transformants was induced using IPTG. The protein products were screened using serum from rheumatoid arthritis patients. This was done using Ni2+ coated slides which are described below. The protein product was screened with RA and anti-His serum.
[0041] The positive clones eukaryotic translation elongation factor 1 alpha 2; NADH dehydrogenase 3/NADH dehydrogenase, subunit 3 (complex I); the human gene for 24-kDa subunit of complex I, exon 7; human mRNA for mitotic kinesin-like protein-1 (MKLP-1 gene); human TBXAS1 gene for thromboxane synthase, exon 2; and human uncoupling protein homolog (UCPH) mRNA were obtained by the following steps. Vectors pBAD-TOPO TA from Invitrogen were used to clone in the PCR product from the cDNA libraries. The selected universal primers were used for amplification. The plasmid clones were transformed into TOP10 competent cells. Transformants were detected by antibiotic-resistant colony selection. Protein production in the transformants was induced with L-arabinose. The protein products were screened using serum from rheumatoid arthritis patients. These were done using charged nickel slides (Z-grip® slides; Miragene Inc.).
[0042] The present invention is not limited to the above RA markers. Additional autoimmune markers have been identified as shown in FIG. 7B . These markers may also be used in the detection and treatment of autoimmune disease.
[0043] It will be understood by those of skill in the art that numerous and various modifications can be made without departing from the spirit of the present invention. Therefore, it should be clearly understood that the forms of the present invention are illustrative only and are not intended to limit the scope of the present invention.
EXAMPLES
Example 1
Production of Charged Nickel Slide
[0044] A glass surface such as a standard glass slide may be used. Depending upon its application, the glass slide can be chemically etched using hydrofluoric acid to give a white surface rather than a clear one. The first step is to produce amino groups on the glass substrate to allow Ni 2+ to be coated on the solid surface. This was accomplished by treating clean, dry glass with diluted 3-aminopropyltriethoxysilane (1-4% in dry acetone) for about 15 min, and then rinsing in dry acetone, followed by water. To get the charged nickel onto the surface, the previously treated substrate was soaked in a 20% solution of NiCl 2 for 24 hours, during which the substrate and solution were continuously agitated. After the 24-hour period, the substrate was simply washed away with water (discard the NiCl 2 solution, and agitate the substrate in water for 10 minutes and repeat three times), and air dried over night.
[0000]
TABLE 1
Formulations:
Product
Description
Formulation
Blocker
Casein in TBS
From 10X TBS, dilute to 1X TBS with ddH2O. Add 1 g
Fishersci. Cat#37532
Casein into 100 ml of 1XTBS = 1% Blocker. Shake
well and store at 4degree C.
IummunoPure Antibody
Anti-goat IgG labeled
Fishersci. Cat#31310
with Alkaline Phosphate
Developer
1-Step NBT/BCIP
Fishersci. Cat#34042
PBS
10X
80 g NaCl, 2 g KCl, 11.5 Na2HPO4•7H2O, 2 g KH2PO4
Fishersci. Cat#175170
Mix them into 800 ml of ddH2O, adjust the pH to 7.3 by
adding NaOH. After measured the pH, add ddH2O up
to 1000 ml
p53 purified protein
Santa Cruz Biotechnology,
Cat# sc4246
rabbit polyclonal IgG
Santa Cruz Biotechnology,
Cat# sc 6243
goat anti-rabbit IgG-AP
Santa Cruz Biotechnology,
Cat# sc2007
mouse monoclonal IgG
Santa Cruz Biotechnology,
Cat# sc126
abcam
anti-APCN-termius
www.abcam.com
[0045] To verify that Ni 2+ had bound to the glass substrate, a known 6×His tagged protein (w/known density) may be used. In one embodiment, a p 27 purified protein from Santa Cruz Biotechnologies (2161 Delaware Ave., Santa Cruz, Calif. 95060) such as sc4091 was used as a positive control (see Table 1). Self-fabricated proteins (from a RA diseased patient and a control patient) expressing the 6×His-tag were tested to determine if they can be used as disease markers. Two pools of patient serums (one pool of RA patients and one pool of undiseased [control] patients from ProMedDx) may be used. Blocker™—Casein in TBS (Pierce), Human IgG-AP (Immunopure Antibody from Pierce), sc2007—goat anti-rabbit IgG-AP and sc803—his-probe rabbit polyclonal IgG (both from Santa Cruz Biotechnologies), 1×PBS and 1-Step™ NBT/BCIP developer (Pierce) (see Table 1) may be used to develop the results.
[0046] To verify that Ni 2+ had successfully bonded to the glass substrate, and, to determine the sensitivity of the slide 6×His tagged protein (p27) was used. Dilutions of 1:10, 1:100, 1:1000, 1:10000, 1:100000, 1:1000000, 1:10000000, and 1:100000000 μl of p27 to PBS were prepared. These were hand spotted onto the Ni 2+ slides using a 1-11 pipette. The slide was developed by placing the spotted Ni 2+ slide into a Petri dish, filling with Blocker and agitating for 30 minutes to 2 hours. The primary antibody was added, in this case, his-probe rabbit polyclonal IgG, with continued shaking for 30 min. to 2 hours. The slide was washed several times with 1×PBS with shaking. The slide was then reacted with secondary antibody, in this case, goat anti-rabbit IgG-AP, in 1×PBS with agitation for 30 minutes to 2 hours. The slide is again washed several times with 1×PBS. Enough Developer was added to cover the slide and shaking was continued until spots began to appear (between 10 and 20-min). The Developer was discarded and enough tap water was added to cover the slide and allowed to sit for a few minutes (1 to 10 minutes) to stop further development. The slides were air-dried overnight. Optionally, the slides may be scanned to get a clearer view of the results. Purple spots indicated that binding between the 6×His and the Ni 2+ slide had occurred. Sensitivity was determined at the point where the last spot was visible.
[0047] The next step verifies that washing is adequate, and that untagged cells do not interfere with the signal. Therefore, control protein was added to each of the 6×His-tagged protein solutions. 1-μl of each of these solutions was then hand spotted onto a Ni 2+ slide, placed in a petri dish, and developed as was described in the previous experiment. The same spots (corresponding to the same dilutions) as the previous experiment should appear. If not, then further washing is necessary, as the cells are interfering and preventing the signal.
Example 2
Method of Using Nickel Coated Slides to Test for Disease Markers
[0048] Using the prepped 6×His-tagged protein, it is then possible to test whether or not a candidate protein is expressing the 6×His-tag, and to confirm that Elisa tested patients do, in fact, have an autoimmune disease. The tagged proteins were spotted onto three different Ni 2+ slides (one 1-μl spot of each protein on each slide), where each slide was then placed into its own petri dish. These slides were then developed as described above, with the exception of the added primary and secondary. In one embodiment, the first slide used 40-μl his-probe rabbit polyclonal IgG, as primary and 10-μl goat anti-rabbit IgG-AP as secondary; the second slide used about 10-μl diseased patient serum as primary, and 1-μl human IgG-AP as secondary; the third slide used about 10-μl control serum as primary, and 1-μl human IgG-AP as secondary. Any spots that appeared using the rabbit as primary and goat as secondary indicated that that particular protein was expressing the 6×His-tag. Any of those spots that also appeared on the second slide (when using the diseased patient serum as primary) confirmed that at least one patient from the pool does have the autoimmune disease. And any of those spots that also appeared on the third slide (when using control as primary) indicated that the protein could be a potential disease marker. Note that spotting can also be done by aliquotting about 40-μl of each protein into a well of a 384-wells dish, and using a “Spotbot” to spot onto the Ni 2+ slides.
[0049] One embodiment is shown in FIG. 2 . The top slide (hereafter referred to as “slide A”) consists of six different proteins, developed with 40-μl his probe rabbit polyclonal IgG as primary and 10-μl of goat anti-rabbit IgG-AP as secondary. The middle slide (now referred to as “slide B”) consists of the same six proteins developed with 100-μl of a pool of ten rheumatoid arthritis (RA) patients' serum as primary and 1-μl of human IgG-AP as secondary. The last slide (referred to as slide C) consists of the same six proteins developed with 100-μl of ten control patients' serum as primary, and 1-μl of human IgG-AP as secondary. “I” and “UI” refer to “induced” and “uninduced” respectively.
[0050] From slide A (top panel), it can be seen that protein 4.2 gives a strong signal, indicating that this protein is expressing the 6×His-tag. The same protein also gives a strong signal on slide B (middle panel), but a very weak signal on slide C (bottom panel), indicating that the protein is binding to diseased antibodies only. This protein could be a potential disease marker for RA. The appearance of spots on slide b for proteins 1.1, 3.2, 5.2, 5.3, and 5.4, but none on slide A indicates false signals.
Example 3
Growing and Maintaining the Host Strains
[0051] An aliquot of approximately 50-ul from the host cDNA library strains (an amplified pre-made library constructed in the Uni-Zap XR vector, Quiagen Inc.) was streaked onto LB agar plates (3% Lb etc) containing the appropriate antibiotics for approximately 14-hrs at 37 C. Plates were then sealed with Parafilm and stored at 4° C. for up to 1 week. Cells from the plates were restreaked onto fresh plates every week.
Example 4
In Vivo Excision of the pBluescript Phagemid from the Uni-Zap Vector
Mass Excision Protocol
[0052] After cultures of XL1-Blue MRF′ and SOLR cells were grown separately overnight in LB broth supplement with 0.2% (w/v) maltose and 10 mM MgSO 4 at 30° C., the cells were collected (1000×g, sorvall XYZ centrifuge) and re-suspended separately in 10-mM MgSO 4 to an OD 600 of 1.0 (8×10 8 cells/ml). In a 50-ml conical tube, a portion of the amplified bacteriophage library with XL1-Blue MRF′ (Qiagen, Inc) cells at MOI of 1:10 lambda phage to cell ratio was combined and then ExAssist lambda phage was added at a ratio of 10:1 helper phage to cells. To ensure that every cell was co-infected with lambda phage and helper phage, incubate at 37° C. for 15 min to allow for absorption. To this suspension, 20-ml of LB broth was added to the tube and incubated 2.5-3 hours with shaking (XYZ-rpm). After incubation, debris was removed by centrifugation (Sorvall centrifuge 1000×g for 10-min) the supernatant was collected into the sterile conical tube. 1-μl of this supernatant with 200 μl of SOLR cells described above was combined in a 1.5-ml microcentrifuge tube and incubated at 37° C. for 15-min. 100-μl was plated onto LB-ampicillin agar plate and incubated at 37° C. overnight, of which colonies may be selected for plasmid preparation. Otherwise, instead of plating, 100-μl into LB-ampicillin media can be inoculated and incubated at 37° C. overnight, and then the culture can be used for plasmid preparation to obtain cDNA libraries.
Example 5
Isolation of Plasmid DNA from Bacterial Colonies by QIAprep Spin Miniprep
[0053] The QIAprep miniprep procedure is based on alkaline lysis of bacterial cells followed by adsorption of DNA onto silica in the presence of high salt. The procedure consists of three basic steps—preparation and clearing of a bacterial lysate; adsorption of DNA onto the QIAprep membrane; washing and elution of plasmid DNA. After cDNA library cultures were inoculated into media, the cultures were incubated overnight in a 37° C. incubator with shaking. 1.5-ml of each culture was transferred into a 1.5 ml micro-centrifuge tube and centrifuged at maximum speed for 1-min in a tabletop micro-centrifuge. The supernatant was removed by aspiration. The bacterial cell pellets were re-suspended in 250-ul of Buffer P1 (Re-suspension buffer: 50-mM Tris-Cl, 10 mM EDTA, 100 ug/ml RNaseA) by pipetting up and down. 250-ul of Buffer P2 (Lysis buffer: 200 mM NaOH, 1% SDS) was added. The samples were mixed gently by inverting the tube 4-6 times because vortexing would result in shearing of genomic DNA. If necessary, the samples were continually mixed until the solution became viscous and slightly clear. The lysis reaction was not allowed to proceed for more than 5 minutes. Then, 350-ul of Buffer N3 (Neutralization buffer: 3.0 M potassium acetate, pH 5.5) was added and the samples were immediately mixed by gently inverting the tube 4-6 times to avoid localized precipitation. The samples were centrifuged for 10 minutes at maximum speed. During the centrifugation, QIAprep spin columns were placed into 2 ml collection tubes. After the centrifugation, a compact white pellet was formed. The supernatant was transferred to the QIAprep column by pipetting. The samples were centrifuged at maximum speed for 1 minute and the flow-through was discarded. To wash the QIAprep spin column, 0.75 ml of Buffer PE (Wash buffer: 96-100% ethanol added) was added. The samples were centrifuged for 30-60 seconds at maximum speed and the flow-through was discarded. The samples were then centrifuged for an additional 1-min to remove residual wash buffer (residual ethanol from Buffer PE may inhibit subsequent enzymatic reactions). QIAprep columns were placed in clean 1.5 ml microcentrifuge tubes. To elute DNA, 50-ul of Buffer EB (10 mM Tris-Cl, pH8.5) was added to the center of each QIAprep column and the column was incubated at room temperature for 1-min. Samples were centrifuged at maximum speed for 1-min. Approximately 50-ul of DNA in EB Buffer was obtained and the concentration was determined by UV spectrophotometry.
Example 6
PCR Amplification of Plasmid DNA (for TOPO TA Cloning)
[0054] The purified plasmid DNA from Unizap Libraries was used as template for amplification.
[0055] The PCR primers were designed or selected without adding of 5′ phosphates to the primers. This allowed the PCR product to be cloned into pBAD TOPO which have 3′-adenine overhang. Universal primers used included T3, T7, M13 forward, and M 13 Reverse primer. Primers were obtained from Operon. PCR was performed by Laragen, Inc. Los Angeles.
Example 7
Vectors Preparation (Qiagen, 2001)
[0056] The vectors from the QIAexpress Kit (PQE 30, PQE 31, PQE32) were prepared by first dissolving the vectors in TE buffer. A 1 μg aliquot of each then was linearized using the appropriate restriction enzymes. In this project, BamH I and Kpn I were used. The digestions were carried out separately with a clean-up step in between. After restriction digestion, the vector ends were dephosphorylated and ready to be inserted.
Example 8
Double Digestion of cDNA libraries and PQE vectors with BamH I/KpnI,
[0057] cDNA libraries in pBluescript plasmids were digested with BamH I/Kpn I restriction enzymes. These restriction digests resulted in fragments of pBluescript vector of about 3000 bp and inserted cDNA libraries sized from 0-10,000-bp. The digestion of PQE vectors with the same enzymes resulted in linearization of the vectors at the multiple cloning sites. The samples were separated by electrophoresis on a 1% agarose gel. The restriction digest reactions were set-up as follows in separate 1.5-ml microcentrifuges tubes:
[0000]
Plasmid DNA
2
ug
10X Reaction Buffer
2
ul
Restriction Enzymes
0.5
ul (each)
10X BSA
2
ul
ddH 2 O to Total Volume
20
ul
[0058] The restriction digest reactions were mixed well by vortexing. The samples were centrifuged at maximum speed to remove drops from the inside of the lid and were then incubated at 37° C. for 2 hours in a water bath.
[0059] After incubation, the digested samples were electrophoresed at 100 V for 1 hour on a 1% agarose gel to separate the resulting fragments. After electrophoresis, the selected fragments (0-10,000 kb minus the vectors at about 3000 kb) were excised from the gel. The DNA fragments were extracted from the agarose gel using a QIAquick Gel Extraction Kit, which can only purify DNA fragments up to 10 kb in size.
Example 9
Purification of the DNA Fragment from Restriction Enzyme Digestion Using a QIAquick Gel Extraction Kit
[0060] This protocol is designed to extract and purify DNA of 70-bp to 10-kb from standard or low-melt agarose gels in TAE or TBE buffer. DNA adsorbs to the silica-membrane in the presence of high salt while contaminants pass through the column. Impurities are efficiently washed away, and the pure DNA is eluted with Tris buffer.
[0061] First, a 1.5-ml microcentrifuge tube was weighed before obtaining the gel slice containing the DNA fragment of interest. The DNA fragment was excised from the agarose gel with a clean sharp scalpel, and extra agarose was removed to minimize the size of the gel slice. The gel slice was transferred into a 1.5 ml microcentrifuge tube and weighed. 3 volumes of Buffer QG was added to 1 volume of gel (100 mg˜100 ul) to solubilize the agarose gel slice and to provide the appropriate conditions for binding of DNA to the silica membrane. The gel slice in Buffer QG was incubated at 50° C. for 10 minutes (or until the gel slice had completely dissolved). To help dissolve the gel, the microcentrifuge tube was vortexed to mix the sample every 2-3 minutes during the incubation. After the gel slice had dissolved completely, the mixture should be yellow in color similar to Buffer QG without the dissolved agarose. If the color of the mixture was orange or violet, 10-ul of 3M sodium acetate, pH 5.0 was added and the color of the mixture then turned yellow. 1 gel volume of isopropanol was added and the sample was mixed thoroughly. This step increases the yield of DNA fragments <500 bp and >4 bp. Next, a QIAquick spin column was placed in a 2 ml collection tube. To bind DNA, the sample was applied to the QIAquick column and the column was centrifuged for 1 minute at maximum speed. After centrifugation, the flow-through was discarded. The QIAquick column was placed back in the same collection tube. To wash, 0.75 ml of Buffer PE (96-100% ethanol added) was added to the QIAquick column and the sample was centrifuged for 1 minute at maximum speed. The flow-through was again discarded. The QIAquick column was centrifuged for an additional 1 minute at maximum speed and then placed into a clean 1.5 ml microcentrifuge tube. To elute DNA, 30 ul of Buffer EB (10 mM Tris-Cl, pH8.5) was added to the center of the QIAquick membrane and the column was incubated for 1 minute at room temperature. The column was centrifuged at maximum speed for 1 minute, and approximately 30 ul of DNA sample was obtained.
Example 10
Ligation of cDNA Libraries and PQE Vectors (Fisher, 01)
[0062] The insert prepared from cDNA libraries was inserted to the vectors. As a negative control, the vector was ligated to itself. The negative control determined how effectively the vectors were dephosphorylated. The starting vector:insert ratio when cloning into a plasmid vector were 1:1, 1:3 or 3:1 molar ratio. The following reaction used 1:1 vectors:insert ratio. Typical ligation reaction used 100-200 ng of vector DNA. The following reaction was assembled in the microcentrifuge tube.
[0000] Vector DNA 100 ng Inserted DNA 17 ng Ligase 10X buffer 1 μl T4 DNA ligase (weiss unit) 0.1-1 u Nuclease-free water to the final volume 10 μl
Then the reaction was incubated at room temperature for 3 hours or at 4 C overnight and was ready to be transformed.
Example 11
Ligation of cDNA Libraries and TOPO-TA Vectors and Transformation of Ligation Product into JM 109 Competent Cells or TOP 10 competent Cells by the Heat-Shock Procedure
[0063] TOPO cloning reaction using pBAD-TOPO (Invitrogen,) was performed according to the manufacturer's instructions. After ligation, the samples were transformed into JM 109 or TOP 10 competent cells as selected. Before the transformation, competent cells were gently thawed on ice. A 200 ul aliquot of the cells was transferred into pre-chilled Falcon 2059 polypropylene tubes. 1 ul of the ligation samples was then added into 200 ul of the competent cells. The transformation reactions were gently mixed by swirling and incubated on ice for 45-60 minutes (5-30 min for TOP 10 cells). After incubation, the samples were heat shocked for 90 seconds at 42° C. in a water bath and immediately placed on ice for 2 minutes. 0.9 ml of room temperature S.O.C medium (0.2% bactotryptone, 0.06% yeast extract, 1 mM NaCl, 0.25 mM KCl, 1 mM MgCl 2 , 1 mM MgSO 4 , 2 mM Glucose) was added to the tube. The reaction tube was incubated in a 30° C. incubator to prevent potential DNA degrading enzymes from acting upon the unstable plasmid. The incubation was carried out for 90 minutes (60 minutes for TOP 10 competent cells) with shaking at 225 rpm. 200 ul, 300 ul and 500 ul of transformation reaction were plated on LB-Amp (100 ug/ml Amp) plates. The plates were incubated overnight at 30° C.
[0064] Protein production in the transformants was induced. IPTG was used for inducing the clones using PQE vectors and L-Arabinose was used for the clones using pBAD as vectors. The protein products were screened using serum from rheumatoid arthritis (RA) patients. This was done using Ni 2+ coated slides as described below ( FIG. 3 ). The protein product was screened with RA and anti-His serum.
Example 12
Spotting of 6×His-Tagged Proteins onto Nickel Slides
[0065] Spotting of the 6×His-tagged proteins onto the Ni 2+ slide can be achieved by hand spotting, or by using a commercially available device such as the SpotBot® device (SpotBot®, TeleChem Int., Inc.).
[0066] Using hand spotting, a pipette was used to drop 1 μL of the 6×His-tagged protein onto a Ni 2+ slide, taking note of what the protein is and where on the slide it is spotted. Spotting of 6×His-tagged proteins with SpotBot® was performed as follows. The wash buffer reservoir is filed with a wash buffer (TeleChem International, Inc.) and connected to a wash water container. A peristaltic pump is activated and run for about 5 minutes. Small (40 μl) aliquots of the 6×His-tagged proteins were transferred into the wells of a 384-well dish, and the dish was placed on the left side of the Spotbot®, noting which protein is in which well, as a reference. Ni 2+ slides were fitted on the right side of the Spotbot with plain microscope slides placed in the pre-print area. The software program “SPOCLE Generator” was used and the spotting procedure was performed according to the SPOTBOT® manual.
Example 13
Assay for Detection of Antibodies to 6×His-Tagged Proteins Using Spotbot®
[0067] After printing, the preprint slides were discarded and the Ni 2+ slides were labeled. Each slide was placed in a petri dish with 10 ml of Blocker (Blocker® Casein in TBS (Pierce)). The slides were incubated with shaking for about 1 hour. About 20 μl of Serum (primary antibody) from either the disease (RA) group or the control group was transferred directly into the Blocker® solution. After further incubation for about 1 hour, the slides were washed three times with wash buffer (20 mM imidazole in PBS) and shaking for about 10 minutes.
[0068] 10 ml of wash buffer and 1 μl of goat anti-human IgG/AP (Goat anti-human IgG labeled with Alkaline Phosphatase ImmunoPure® Antibody (Pierce)) were added to the wash solution. Again the slides were washed three times with wash buffer and shaking. 10 ml of Developer solution (1-Step™ NBT/BCIP (Pierce)) was added to each petri dish and incubated with shaking until spots began to appear (about 10-30 min.). Development was stopped with tap water. The slides were air-dried overnight. The slides were scanned using an EPSON PERFECTION 1650 scanner. 1600 dpi was used for scanning slides. All other scanner settings were factory default settings. Adobe Photoshop 6.0 was used to analyze the scanned files.
Example 14
Results
[0069] FIG. 4 shows the results of a screen for RA markers. The image on the bottom panel of FIG. 4 used rheumatoid arthritis patient serum as the primary antibody, where the image on the upper panel of FIG. 4 used control patient serum. As can be seen, there are 12 sets of spots using the patient serum, vs. 3 sets of spots using the control serum. On the control, only 2 sets show all 5 spots. This indicates that 2 different his tagged proteins are false positives, and 10 different proteins are rheumatoid arthritis positive.
[0070] For one of the positive results described above, the corresponding clone was located. This clone was amplified by inoculation into growth media. The recombinant plasmid was isolated, digested with restriction enzymes and size was determined by Agarose gel electrophoresis. The clone was sequenced using standard procedures. The DNA sequence is set forth below (Table 2; SEQ ID NO: 1). Comparison with available NCBI databases indicated that the isolated sequence encodes a protein of the large subunit of the human mitochondrial ribosome, the L35 protein (Koc, et al. (Nov. 23, 2001) The Journal of Biological Chemistry vol. 276 (47): 43958-43969).
[0071] FIG. 5 confirms that L35 is a marker for RA. FIG. 5 shows nickel coated slides that have been prepared as described above and spotted with L35 protein. The upper panel is then contacted with the anti-His serum to confirm the presence of a recombinant protein. The middle panel is contacted with serum from RA patients. The bottom panel is contacted with serum from a control population. It can be clearly seen that the L35 protein only reacts with the anti-His and RA serum, confirming that this protein is a marker for RA. There was no difference in expression between samples induced with IPTG and uninduced.
[0072] By the methods described above, a number of markers for RA have now been identified. These are:
[0073] Eukaryotic translation elongation factor 1 alpha 2 is encoded by the polynucleotide of SEQ ID NO: 3 (Table 4).
[0074] NADH dehydrogenase 3; NADH dehydrogenase, subunit 3 (complex I) is encoded by the polynucleotide of SEQ ID NO: 5 (TABLE 6).
[0075] Homo sapiens gene for 24-kDa subunit of complex I, exon 7 is encoded by the polynucleotide of SEQ ID NO: 7 (TABLE 8).
[0076] Homo sapiens mRNA for mitotic kinesin-like protein-1 (MKLP-1 gene) is encoded by the polynucleotide of SEQ ID NO: 8 (TABLE 10).
[0077] Homo sapiens TBXAS1 gene for thromboxane synthase, exon 2. is encoded by the polynucleotide of SEQ ID NO: 10 (TABLE 12).
[0078] Human uncoupling protein homolog (UCPH) mRNA is encoded by the polynucleotide of SEQ ID NO: 12 (TABLE 14).
[0079] Alternate methods of protein screening may also be used. In a method which is substantially similar to the method described by Chin et al. in U.S. Pat. No. 6,197,599, which is incorporated herein by reference (Appendix A), antibodies are attached in a microarray as shown in FIG. 6A . The antibody-treated surface is contacted with an unlabeled protein preparation. Detection is carried out with a labeled secondary antibody. See FIG. 6B which shows isolation and identification of the p53 protein. The p53 tumor-suppressor protein has been implicated in RA and overexpression of p53 is a characteristic feature of the disease (Sun et al. (April 2002) Semin Arthritis Rheum vol. 31 (5):299-310). FIG. 6C shows the sensitivity of the assay.
[0080] FIG. 7A shows another variation where a solid substrate presents an array of disease markers. Identification is carried out by treatment with auto-antibody. FIG. 7B presents some known autoimmune disease assay antigens and FIG. 7C shows graphically the number of patients in each disease population. FIGS. 7D-G show the feasibility of the method for other disease markers.
[0000]
TABLE 2
The DNA sequence of L35 (SEQ ID NO: 1).
GCNNTGCCGCCTATAATTAAGNNGAGAAATTAACTATGAGAGGATCGCAT
CACCATCACCATCACGGATCCCCCGGGCTGCAGGAATTCGGCACGAGGGC
TACTTGGGAGGCTGAAGTGGGAGGATGGCCTGAGCTCAAGGAGATGCAGG
CTGCAGTGGGCTGTGATTGTGCCACTGCACTCCAGCCTGGGCACCAATGT
GAGCCTCGTGCCGAATTCGGCACGAGGGCGGCGTTGGCGGCTTGTGCAGC
AATGGCCAAGATCAAGGCTCGAGATCTTCGCGGGAAGAAGAAGGAGGAGC
TGCTGAAACAGCTGGACGACCTGAAGGTGGAGCTGTCCCAGCTGCGCGTC
GCCAAAGTGACAGGCGGTGCGGCCTCCAAGCTCTCTAAGATCCGAGTCGT
CCGGAAATCCATTGCCCGTGTTCTCACAGTTATTAACCAGACTCAGAAAG
AAAACCTCAGGAAATTCTACAAGGGGCAAGAAGTACAAGCCCCTGGAACT
TGCGGCCTAAGAAGACACGTGCCATGCGCCGCCGGCTCAACAAGCACCAA
GAAAACCTGAANACCAAGAAGCAGCAANCNGGAAGGACCGGCTTGTAACC
CGCTTGCNGGAAATTACCCGGTCAAGGCCNTGAGGGGCGCATTGGTCAAT
AAAACCACAACCTGGCNTGAGAAACTCACCCCANNTNTNCCTNACTCGAG
GGGGGGGGCCCGGGTAANCCCCGGGGTTTCGAACCTTGCAAANCCAANCT
TTAATTTAACTTGAACCTTTGGGAACTTCCCTGGTTGNATTAANNTNCCA
ATTNAATGAACCNNNAAAAACCC
[0081] Table 3 shows the protein sequence for the L35 protein (SEQ ID NO: 2) identified and isolated as described herein. The first six residues represent the 6×His tag.
[0000]
TABLE 3
HHHHHHMAASAFAGAVRAASGILRPLNILASSTYRNCVKNASLISALSTG
FRSHIQTPVVSSTPRLTTSERNLTCGHTSVILNRMAPVLPSVLKLPVSLY
YFSARKGKRKTVKAVIDRFLRLHCGLWVRRKAGYKKKLWKKTPARKKRLR
EFCNKTQSKLLDKMTTSFWKRRNWYVDDPYQKYHDRTNLKV
[0000]
TABLE 4
The DNA sequence for eukaryotic translation factor
1 alpha (SEQ ID NO: 3).
GCNNNNNNGCNNNNNNNNGGGCNCCNANAAATAGCCGATCNACCTGGNGC
TTTTTATCGCAACTCTCTACTGTTTCTCCATACCCGTTTNTTTTGGGCTA
NAAATAATTTTGTTTAACTTTAAGAAGGAGATATACATACCCATGGGCTC
TGGATCCGGTGATGACGATGACAAGCTCGCCCTTAAACCCTCACTAAAGG
GAACAAAAGCTGGAGCTCCACGCGGTGGCGGCCGCTCTAGAACGTAGTGG
ATCCCCCGGGCTGCAGGAATTCGGCACGAGGGTTTGCCGCCAGAACACAG
GTGTCGTGAAAACTACCCCTAAAAGCCAAAATGGGAAAGGAAAAGACTCN
TATCAACATTGTCGTCATTGGACACGTAGATTCGGGCAAGTCCACCACTA
CTGGCCGTCGTNTTACAAGGGCGAGCTTGAAGGTAAGCCTATCCCTAACC
CTCTCCTCGGTCTCGATTCTACGCGTACCGGTCATCATCACCATCACCAT
TGAGTTTAAACGGTCTCCANCTTGGCTGTTTTTGGCGGATGAGAGAAGAT
TTTCAGCCTGATACAGATTAAAATCAGAACGCAGAAGCGGTCTGATAAAA
CAGAATTTGCCTGGCGGGNAGTNACCGCGGGTGGGTCCAACCTTGAACCC
CAATTGCCCGAACTCAGAAAGTGAAAACCGCCGGTAAGCCCCGAATTGGT
TAGTTGTTGGGGGTCTTCCCCATTTGCNAANAAGTTAGGGGAAA
[0000]
TABLE 5
shows the protein sequence for part of eukaryotic
translation factor 1 alpha 2 (SEQ ID NO: 4).
TLTKGNKSWSSTAVAAALELVDPPGCRNSARGFAARTQVSZKLPLKAKMG
KEKTXINIVVIGHVDSGKSTTTGRRX
[0000]
TABLE 6
The DNA sequence of NADH dehydrogenase 3
(SEQ ID NO: 5)
GTAAAACGACGGCCAGTGAATTGTAATACGACTCACTATAGGGCGAATTG
GGTACCGGGCCCCCCCGAGTTTTTTTTTTTTTTTTTATTCGGCTCNGTCT
AATCCTTTTTGTAGTCACTCATAGGCCAGACTTNGGGCTAGNATGATNGA
TTAATAAGAGGGATGACATAACTATTAGTGGNCAGGNTNGTTGTTTGTAG
NGGCTCNTGGCAGGGGNAAAAGGAGGGCAAATTTCTAGATCAAATAAATA
AGAAGGTAATAGCTACTAAANAAAGAATTTTAATGNAGAAAGGGACCCGG
GCGGNNGGATATAGGGTCNAAGCCGCNCTCGTAAGGGGTGGGATTTTTCT
ATGTAGCCNNTNGAGTTGTGGTNAGTCNAAAATTTAATAAATTATTAGTA
GTAAAGGCCTAGGGAGGGNTGTTGCCCTCGTGCCCGAATTNCCTGCCAGC
CCGGGGGGAATCCNCCTAGTTCCTAAGAGCCGGCCCCCNCCCCNGAAGGG
ANGCTCCCAGCCTTTTTGATCCCTTTNGTGGNGNGTTAAT
[0000]
TABLE 7
shows the protein sequence for part of NADH
dehydrogenase 3; NADH dehydrogenase, subunit 3
(complex I) (SEQ ID NO: 6).
VKRRPVNCNTTHYRANWVPPPSSFFFFFYSAXSNPFCSHSZARLXAXMXD
ZZEGZHNYZWXXXLFVXAXGRXKRRANFZIKRRZZLLXKEFZXRKGPGRX
DIGXKPXSZGVGFFYVAXXVVXSXKFNKLLVVKAZGGXLPSCPNXLPARG
ESXZFLRAGPXPXRXAPSLFDPFXXXLIXGGAFKXKAYPXPXPX
[0000]
TABLE 8
The DNA sequence for the human gene for the 24 kD
subunit of Complex I (exon 7) (SEQ ID NO: 7).
ATTAACCCTCACTAAAGGGAACAAAAGCTGGAGCTCCACCGCGGTGGCGC
CGCTCTAGAACTAGTGGGATCCCCCGGGCTGCAGGAAATTCGGCACGAGG
GAANAATCCGNCGCGTCCACAANNACCNTTNNCCCCCAACCAACANNAAN
AACANTTCNNNCNNAAATCNAAGTNCTCCNAGACTNANAATCNNCCATNT
NATNTAAATTTTCNGGGGGGGGGNNCCCNGNAANCNAAATTCCCCCCTTA
NGGAAGGGGGNCCTTNTNNANANGNGNNATNCTTTAAAGNCNAAANGCCT
TTNTNCNNNATAANCCCNTTNTCTTTGGGGGCTCCCNAAATTTTATAACC
NCNAGGANCCNCGGGNTTCTTTNTTTANCNCCCCTTNNAAANTANTTCCC
GGTNTTNAANANCGGNTTCCCCCNCGGTTNTGGGCATNTNTTTTTNCGCG
NCGNTTATAGAGANAAAAAAAAANTTTTNTTCNCCCTTTATACACCGGCA
NTTAAAANTTNGAAAANCNGGGNAANNGGGNGTTTNTTNNAAAAAACNAA
ATNTTTTNTTTNAGCCNCNAAAAAAANCTGAGTTGGCCCCCNCTNNAACC
CCNTTGGNGGGAAAANTNAAAAAGTGCAAACCCCCNCTCTNCCCCNATCT
AGANAAGTAGNNTCCTCCCCCCCTCCCNNAAAANNTAGGGAGNNNCTCCC
GNNNC
[0000]
TABLE 9
The protein sequence for part of the human gene
for the 24 kD subunit of Complex I (exon 7)
(SEQ ID NO: 14).
LTLTKGNKSWSSTAVAPLNWDPPGCRKFEFPAARGIPLVLERRHRGGAPA
FVPFSEG
[0000]
TABLE 10
The DNA sequence for the human mitotic
kinesin-like protein-1 (MKLP-1) gene
(SEQ ID NO: 8).
ATTAACCCTCACTAAAGGGAACAAAAGCTGGAGCTCCACCGCGGTGGCGG
CCGCTCTAGAACTAGTGGATCCCCCGGGGNGCNCGAATTCNGAANGAGGC
CTCNTGCCNANTNCTNATGANAGCGAAGGANGTANNNCAGNTCGNACCNG
ATTGACCNTNAGGATATCCANTACNCNANGGGGGGCCCGGNNCCCAATNC
NCCCTATAGTGAGTCNNATCACAATTCACTGGACCGNCGTTTCAAAGGGN
GAGNTTTGGGGGTAAGNCTATACCTAACCCNCTCTCGGNNTTGANTTACA
CGTNCNCGGTCNGTCATTCANCAANCACCAATTGAGTNTTNANCNGGTCC
TCCAGGCTNGNGGTTGCNTNNGGGGGNNCTNAGNANNAAGAATTTTCAAG
GCTGAAATCCCNNTTTAACCCCCAANTNGNNNAGNAAGGGNGGTNCTGCC
CAANNACAAAAAATTTGGGGATANNNGGCAAGGTNANNCCANGTTGNANC
CCAACAGGGTNCCCCCNNGNACAGNAACNTGGGGNNATNTNGAAAACNTC
NNCTNTTNNCNCCCNAATNGNGAGTNAATGGGGGCNNNCCCCCATTTGGN
GAAAAATTNCGNGGANCCGGNCCNCGGGANTTTNAAATNAAANC
[0000]
TABLE 11
shows the protein sequence for part of mitotic
kinesin-like protein-1 (MKLP-1 gene)
(SEQ ID NO: 9).
INPHZREQKLELHRGGGRSRTSGSPGXXEFXXXRPXAXXXZXRRXXXXXS
XXIDXXDIXYXXGGPXPNXPYSEXXHNSLDXRFKGXXLGVXLYLTXSRXZ
XTRXRXVIXQXPIEXXXGPPGXXLXXGXXXXKNFQGZNPXLTPXXXXKXG
XAQXQKIWGXXARXXXVXXQQGXPXXXNXGXXXKXXXXXPXXXXNGGXPP
FXEKXXGXXXRXFXXKX
[0000]
TABLE 12
The DNA sequence for exon 2 of human thromboxane
synthase (TBXAS1) (SEQ ID NO: 10).
ATTAACCCTCACTAAAGGGAACAAAAGCTGGAGCTCCACCGCGGTGGCGG
GCCGCTCTAGAACTAGTGGATCCCCCGGGCTGCCCGGTACCCAATTCGCC
CTATAGTGAGTCGTATTACAATTCACTGGCCGTCGTTTTACAAGGGCGAG
CTTGAAGGTAAGCCTATCCCTAACCCTCTCCTCGGTCTCGATTCTACGCG
TACCGGTCATCATCACCATCACCATTGAGTTTAAACGGTCTCCAGCTTGG
CTGTTTTGGCGGATGAGAGAAGATTTTCAGCCTGATACAGATTAAATCAG
AAACGCANGAAGNGGGTCTTGATAAAAACAAGAAATTTGGCCTTGGCGGG
NAGTTAGCNGCGGGTNGGTNCCCACCCTNGACCCCATTGCCCGAAACTCA
CGNAAGNTGAAAACCGCCCGGNAACCGCCCGNATTGGGTAAGTGGTGGGG
GGTCCTTCCCCCATTGCCGAANAAGNTNNGGGGAAACTNGCCCAGGGCAC
TTCAAAATNAAAAAACGNAAAGGGGCTNNANGTCCGAAAAANAAATTGGG
GGCCTTTCCCGGGTTGNAAACCTGGTTGGGTTTGGGGCCGGGGGGAACNC
CTCNTCCTNGNAGTTTNGGACAAAAATCCCGCCNGGGGNNCGCGGGATTT
TGAAACCGTTNTGCNN
[0000]
TABLE 13
shows the protein sequence for part of Homo
sapiens TBXAS1 gene for thromboxane synthase,
exon 2 (SEQ ID NO: 11).
INPHZREQKLELHRGGGRSRTSGSPGLPGTQFALZZVVLQFTGRRFTRAS
LKVSLSLTLSSVSILRVPVIITITIEFKRSPAWLFWRMREDFQPDTDZIR
NAXXGSZZKQEIWPWRXVSXGXXPTXDPIARNSXKXKTARXPPXLGKWWG
VLPPLPXKXXGNXPRALQNXKTXRGXXSEKXIGGLSRVXNLVGFGAGGNX
XSXXFXTKIPXGXRGILKPXCX
[0000]
TABLE 14
The DNA sequence for human uncoupling protein
homolog (UCPH) (SEQ ID NO: 12).
TAATACGACTCACTATAGGGCGAATTGGGTACCGGGCCCCCCCTCGAGTT
TTTTTTTTTTTTNNTTNTTTTTTNTTTTNCTNCTTTTNTTTTNTTNTNNN
CTCNCTTTTTCTATNTTCTTTTTNCCTCCACTCTACNGGGGNNTCCCCCG
NGGGGCAAAANCCCNNNNCCNGGGGGNNNCNTNTTTTTTTGGGGGNCCCC
CCCCNGGGGGGGNNCCCNCTTTTTTTTTTCCCTTTNTNTGGGGGGTTTAA
ANGGGGNGNTTNNNGGGGNAGANATTACCNANCCCCCCCCCCCGGNNNCN
NANTTCNCCGCGANTNCCGGNGNGTCTTCCCCCCTTTCCCTTGNGGNTTT
AAAGGGNGCCNCCTNNCTTTCCGNNTTTTTTNNGCNNGGGGAAAAAAAAA
AAAATTTNNCCCCCTGGNTNCCCCCAATTTNANNNCCCCCGNCCCCCCCN
AAANGGTTTTNNNNAAANAAANAAAAANTTTTNCTGGNGGGGGGCNAAAA
AAGNCGGGGGGGGNTCCCCCCCCCGGNNCCCCCTGTGGGGGTAATTTTTC
AAANGGGNNAACCCCCTCNTNTACCCCCNNTTGTTNTCTGGGGGGGGNNC
CCCCCCNCCNCTCCNGAAGAAAGGNGGGATANNGTTCNTCCCTCNACNTA
NAAAAAANN
[0000]
TABLE 15
shows the protein sequence for part of Human
uncoupling protein homolog (UCPH) mRNA
(SEQ ID NO: 13).
ZYDSLZGELGTGPPLE
[0082] It will be understood by those of skill in the art that numerous and various modifications can be made without departing from the spirit of the present invention. Therefore, it should be clearly understood that the forms of the present invention are illustrative only and are not intended to limit the scope of the present invention. | A microarray and method of screening for rheumatoid arthritis (RA) in a mammal is disclosed. The method comprises contacting a sample from the mammal to an immobilized polypeptide or fragment thereof homologous to at least a portion of an RA marker protein, and detecting binding of an antibody from the sample to the immobilized polypeptide or fragment thereof. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a bistable semiconductor laser diode device. The bistable semiconductor laser diode device is used, for example, for an optical communication system in a local area network (LAN).
2. Description of the Related Arts
In general, a bistable semiconductor laser is constituted by a laminated structure of an N-side electrode, an N-type layer, an active layer, a P-type layer, and a P-side electrode. This laminated structure is horizontally divided into two regions, that is, the gain region and the saturable absorption region. The gain region has a laminated structure of an N-side electrode, an N-type layer, an active layer, a P-type layer, and a P-side electrode. The saturable absorption region has a laminated structure of an N-side electrode, an N-type layer, an active layer, and a P-type layer, but does not have a P-side electrode. In the gain region, electric current passing between the N-side and P-side electrodes causes a stimulated emission in the active layer so that a light gain is attained, while, in the saturable absorption region, no electric current passes through the N-type layer, the active layer, and the P-type layer so that no light gain is attained.
As to the characteristic of the carrier concentration in the active layer versus the gain, in the range where the carrier concentration in the active layer is low, the gain assumes a negative gain value revealing the absorption state, while in the range where the carrier concentration in the active layer is high, the gain assumes a positive value revealing the stimulated emission state to cause a laser oscillation so that the light amplification function is achieved.
In the saturable absorption region, as the intensity of the light increases, the degree of the absorption decreases, and the gain approaches from a negative value to the saturated value close to zero. However, the gain does not assume a positive value, since the saturable absorption region does not have any pumping mechanism.
The bistable semiconductor laser device has a hysteresis characteristic, and it is possible to carry out a resetting operation of the device either by electrical means or by optical means. It has been proposed that, as one of the optical resetting means, the bistable semiconductor laser device is brought to the beat oscillation state by using neighboring frequencies to attain a resetting.
For example, a reference can be made to K. Inoue and K. Oe; "Optically Triggered Off-Switching in a Bistable Laser Diode Using a Two-Electrode DFB-LD", Electronics Letters Vol. 24, No. 9, Apr. 28, 1988. In this optical resetting method, when two frequencies are very close to each other, the total light output is changed with the beat frequency of the two frequencies. If the light output becomes lower than a predetermined value, the carrier pumping in the saturable absorption region will be decreased to reduce the carrier concentration and to increase the light absorption. If the degree of the light absorption becomes higher than a predetermined value, it will become impossible to maintain the laser oscillation to cause the resetting of the device.
However, the above-mentioned prior art electrical or optical resetting method has problems that, in the case of the electrical resetting, the use of an electrical signal for control will cause electrical noises which disturb the neighboring circuits and, particularly in integrated circuit devices, will cause cross-talk between electrical wirings, and, in the case of the optical resetting using the beat frequency, there is a difficult requirement to make the motion of the carriers follow the period of the beat oscillation which requires the control of the wavelength of the irradiation light with quite a high resolution such as a wavelength difference of the order of 0.1 angstrom.
Also, the above-mentioned prior art optical resetting method has a problem that the frequency beat cannot be satisfactorily attained when a reset light is injected into the active layer of the laser along an axis different from the lasing light axis and accordingly the resetting cannot be attained.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved bistable semiconductor laser diode device in which the optical resetting of the device is carried out over a very broad range of the wavelength of an injection light without severe requirements for the precision of the wavelength.
It is another object of the present invention to provide an improved bistable semiconductor laser diode device in which the optical resetting of the device is carried out in accordance with the light wavelength versus light intensity characteristic and the choice of the irradiation light axis.
It is another object of the present invention to carry out both the setting and the resetting of a bistable semiconductor laser diode device by a single wavelength of light and a relatively low intensity of light.
It is another object of the present invention to provide an improved light signal inverter using a bistable semiconductor laser diode device with the optical resetting.
In accordance with the present invention, there is provided a bistable semiconductor laser diode device having reset light irradiation means for irradiating a reset light to stop the delivery of a lasing light from the laser, in which the laser includes an active layer comprising a gain region in which a stimulated emission occurs to attain an optical gain, and a saturable absorption region in which no stimulated emission occurs so as not to attain optical gain at a lasing wavelength, a resetting of the laser being carried out by irradiating onto the gain region of the laser a light having a wavelength by means of which the irradiated light is able to be amplified by a stimulated emission to reduce carriers in the gain region of the laser.
Also, there is provided a bistable semiconductor laser diode device comprising a bistable semiconductor laser, set light irradiation means for irradiating a set light causing a lasing light to be delivered from the laser, and reset light irradiation means for irradiating a reset light to stop the delivery of the lasing light from the laser due to a reduction of carriers by amplification of light by stimulated emission; in which the bistable semiconductor laser includes an active layer consisting of a gain region having a portion to which carriers are supplied from outside, and a saturable absorption region not having portions to which carriers are supplied from outside, clad layers formed on both sides of the active layer and having a refractive index smaller than that of the active layer, and a carrier supply portion arranged on the clad layers in correspondence with the portion to which the carriers are supplied. The reset light irradiation means is arranged to irradiate the reset light selectively onto a predetermined region of the active layer along a direction having a predetermined relationship with the lasing light axis of the laser; and the reset light has a wavelength and a border value (threshold) of light intensity which satisfy a predetermined condition concerning the gain or the absorption in the gain region or the saturable absorption region, and a predetermined relationship with regard to the border value (threshold) of set light intensity having the same wavelength as the wavelength of the reset light.
Also, there is provided a bistable semiconductor laser comprising a gain region having a portion to which carriers are supplied from outside and a saturable absorption region not having a portion to which carriers are supplied from outside, in which the setting or resetting of the bistable semiconductor laser is carried out by irradiating onto gain region of the laser a light having a wavelength around the border of a settable wavelength range and a resettable wavelength range to set or reset the bistable semiconductor laser, and the resetting of the bistable semiconductor laser is carried out by a reduction of carriers by amplification of light by stimulated emission.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a cross-sectional view of a prior art bistable semiconductor laser;
FIG. 2 is a diagram showing the carrier concentration versus gain characteristic of the bistable semiconductor laser;
FIG. 3 is a diagram showing the light intensity versus gain change in the saturable absorption region in the bistable semiconductor laser;
FIG. 4 is a diagram showing the light resetting operation for the bistable semiconductor laser;
FIG. 5 is a diagram showing the oscillation with beat frequency of the total light output of the bistable semiconductor laser;
FIG. 6 is a diagram showing the gain change in the saturable absorption region in the bistable semiconductor laser;
FIG. 7 is a cross-sectional view of a bistable semiconductor laser, illustrating the basis of the present invention, in the case where the axis of the reset light irradiation is the same as the light axis of the laser;
FIG. 8 is a cross-sectional view of a bistable semiconductor laser, illustrating the basis of the present invention, in the case where the axis of the reset light irradiation is different from the light axis of the laser;
FIGS. 9, 10, and 11 show the structure of a bistable semiconductor laser, according to an embodiment of the present invention where FIG. 9 shows a cross-sectional view, FIG. 10 shows a plan view, and FIG. 11 shows a perspective view;
FIGS. 12 and 13 show the structure of a bistable semiconductor laser, according to an embodiment of the present invention, where FIG. 12 shows a cross-sectional view and FIG. 13 shows plan view;
FIGS. 14A and 14B are diagrams for illustrating the basis of the operation of the bistable semiconductor laser of the present invention;
FIG. 15 is a diagram illustrating the characteristic of operation of the bistable semiconductor laser of the present invention;
FIGS. 16A and 16B are also diagrams for illustrating the basis of the operation of the bistable semiconductor laser of the present invention; .
FIGS. 17A and 17B are diagrams showing the wavelength versus irradiated light intensity characteristic of the bistable semiconductor laser of the present invention;
FIG. 18 is a diagram showing the wavelength versus light intensity characteristic of the bistable semiconductor laser according to an embodiment of the present invention;
FIG. 19 is a diagram showing the wavelength versus light intensity characteristic of the bistable semiconductor laser according to an embodiment of the present invention;
FIGS. 20A, 20B and 20C show example of the types of the bistable semiconductor laser device of the present invention;
FIG. 21 shows an example of actual operations of the bistable semiconductor laser device according to an embodiment of the present invention in the "same axis" manner;
FIG. 22 shows an example of the actual light signal waveform;
FIG. 23 is a diagram showing the operation of the resetting by inputting light in a bistable semiconductor laser device according to an embodiment of the present invention;
FIG. 24 shows an arrangement of the light signal inverter in accordance with an application of the laser device of the present invention;
FIG. 25 shows an operation of the light signal inverter in accordance with an application of the laser device of the present invention; and
The composite of FIGS. 26A and 26B shows an example of the characteristic of the optical set and the optical reset operations of the device according to an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
(Preliminary Explanation)
Before describing the preferred embodiment, prior art bistable semiconductor laser devices will be explained with reference to FIGS. 1 to 6. In general, the structure of a bistable semiconductor laser is, as shown in FIG. 1, a laminated structure of an N-side electrode, an N-type layer, an active layer, a P-type layer, and a P-side electrode. This laminated structure is horizontally divided into two regions, that is the gain region and the saturable absorption region. The gain region has a laminated structure of an N-side electrode, an N-type layer, an active layer, a P-type layer, and a P-side electrode. The saturable absorption region has a laminated structure of an N-side electrode, an N-type layer, an active layer, and a P-type layer, but does not have a P-side electrode. In the gain region, electric current passing between the N-side and P-side electrodes causes a population inversion in the active layer so that a light gain is attained, while, in the saturable absorption region, no electric current passes through the N-type layer, the active layer, and the P-type layer and thus no light gain is attained in the EL (non-lasing) state.
As to the characteristic of the carrier concentration in the active layer versus the gain of the device of FIG. 1, as shown in FIG. 2, in the range (B) where the carrier concentration in the active layer is low, the gain assumes a negative gain value revealing the absorption state, while in the range (A) where the carrier concentration in the active layer is high, the gain assumes a positive value revealing the stimulated emission state to cause a laser oscillation so that the light amplification function is achieved.
In the saturable absorption region of the device of FIG. 1, as shown in FIG. 3, as the intensity of the light increases, the degree of the absorption decreases and the gain approaches from a negative value to the saturated value close to zero. However, the gain does not assume a positive value at the wavelength of the light.
The bistable semiconductor laser diode device has a hysteresis characteristic, as shown in FIG. 4, and it is possible to carry out a resetting operation of the device either by electrical means or by optical means. It has been proposed that, as one of the optical resetting methods, the bistable semiconductor laser diode device is brought to the beat oscillation state by using neighboring frequencies to attain a resetting. In the optical resetting method, as shown in FIG. 5, when two frequencies are very close to each other, the total light output is changed with the beat frequency of the two frequencies. If the light output becomes lower than a predetermined value, the carrier pumping in the saturable absorption region will be decreased to reduce the carrier concentration to increase the light absorption. If the degree of the light absorption becomes higher than a predetermined value, it will become impossible to maintain the laser oscillation to cause the resetting of the laser.
(Basis and Examples of the Laser Device of the Present Invention)
The basis of the bistable semiconductor laser diode device of the present invention will be explained with reference to FIGS. 7 and 8. In FIG. 7, light having a wavelength at which the active layer has a gain coefficient, is irradiated onto the active layer of the laser and the number of carriers in the gain region is reduced, so that the resetting of the laser diode device is carried out.
In the laser diode device of FIG. 7, the axis of the irradiation light is the same as the axis of the laser light output from the laser diode device ("same axis" case).
In the case of FIG. 8, the axis of the irradiation light is different from the axis of the output laser light from the laser device ("different axis" case).
A bistable semiconductor laser diode device according to an embodiment of the present invention is shown in FIGS. 9, 10, and 11, where FIG. 9 is a cross-sectional view, FIG. 10 a plan view, and FIG. 11 a perspective view. This device is of the "same axis" type.
The bistable semiconductor laser diode device of FIG. 9 is constituted by the gain regions No. 1 and No. 2, and a saturable absorption region. The device has a laminated structure of electrode 11, substrate 12, clad layer 13, active layer 14, clad layer 15, cap layer 16, and electrodes 171 and 172.
The device has also a semi insulation layer 18 and protection layer 19. The substrate 12 is of N-type InP, the clad layer 13 N-type InP, the active layer 14 P-type InGaAs, the clad layer 15 P-type InP, the cap layer 16 P + -type InGaAsP, the semi insulation layer 18 InP, and the protection layer 19 SiO 2 .
A bistable semiconductor laser diode device according to another embodiment of the present invention is shown in FIGS. 12 and 13, where FIG. 12 is a cross-sectional view, and FIG. 13 a plan view. This device is of the "different axis" type.
The bistable semiconductor laser device of FIG. 12 is constituted by the gain region and a saturable absorption region. The device has a laminated structure of electrode 11, substrate 12, clad layer 13, active layer 14, clad layer 15, cap layers 161, 162, 163, and 164, and electrodes 171, 172, 173, and 174.
Openings 15a, 15b, and 15c are formed in the upper electrode and the cap layer. The light irradiation for resetting is irradiated toward the active layer 14 through these openings 15a, 15b, and 15c.
(Wavelength versus Gain Characteristic)
The wavelength versus gain characteristic of the gain region and the saturable absorption region of the device of the present invention is shown in FIGS. 14A, 14B and 15.
In the non-lasing state, the wavelength versus gain characteristic of the gain region and the saturable absorption region are as shown in the left part of FIG. 14A. In the non-lasing state, the gain region can attain a positive gain, but the saturable absorption region cannot attain positive gains but only negative gains, constituting an absorption state.
In the lasing state, the wavelength versus gain characteristics of the gain region and the saturable absorption region are as shown in FIG. 14B and FIG. 15. The upper curve represents the gain spectrum in the gain region, and the lower curve represents the gain spectrum in the saturable absorption region. The gap wavelength λ g , the laser wavelength λ l , and specific values λ s1 and λ s2 of wavelength are indicated. The λ s1 is defined as the wavelength at which the gain coefficient of gain region is zero, and the λ s2 is defined as the wavelength at which the gain coefficient of the saturable absorption region is zero.
The first condition of the device with the reset light axis of the different axis type by the operation of only the gain region covers the range from λ s1 to λ g . The second condition of the device with the reset light axis of the same axis type covers the range from λ l to λ g . The third condition of the device with the reset light axis of the different axis type by the operation of both the gain region and the saturable absorption region covers the range from λ l to λ g . The fourth condition of the device with the reset light axis of the different axis type by the operation of only the saturable absorption region covers the range from λ s2 to λ g .
(Light Intensities Required for Setting and Resetting)
The wavelength dependence of the injected light intensity required for the setting of the device is represented by the solid line curve of FIG. 16A. The wavelength dependence of the injected light intensity required for the resetting of the device is added by the broken line curve as a reference.
The wavelength dependence of the irradiated light intensity required for the resetting of the device is represented by the solid line curve of FIG. 16B.
In the light intensity characteristic shown in FIG. 16A concerning the solid rset line and the broken set line, since two values cannot exist for each wavelength value, only the lower value of the solid line value and the broken line value can exist for each wavelength value. This situation will be further explained with reference to FIG. 17.
(Border Lines of Settable and Resettable Ranges)
The determination of the border lines (threshold) of light intensity of settable and resettable ranges in the operation of the device of the present invention is illustrated in Case-1, Case-2, and Case-3 of FIGS. 17A, 17B and 17C, respectively, in each of which the abscissa represents wavelength and the ordinate represents light intensity.
In Case-1 of FIG. 17A, the broken line represents the border value (threshold) of settable light intensity, the range above the broken line having hatchings represents the settable range, and the solid line represents the resetting line.
In Case-2 of FIG. 17B, the solid line represents the border value of resettable light intensity, the range above the solid line having hatchings represents the resettable range, and the broken line represents the setting line.
In Case-3 of FIG. 17C, the broken line represents the setting characteristic, the solid line represents the resetting characteristic, and the sequence of the thickened solid line segments and the thickened broken line segments represents the resultant border line.
(Use of Light Having Wavelength About the Borders of Settable Wavelength Range and Resettable Wavelength Range)
In a bistable semiconductor laser diode device according to an embodiment of the present invention, it is possible to use a light having a wavelength about the borders which is of the settable wavelength range and the resettable wavelength range. The characteristic of the operation of this device is shown in FIG. 18. The points of the wavelength at the borders of the settable wavelength range and the resettable wavelength range are indicated as "a", "b", and "c" in FIG. 18.
The light having a wavelength about a point such as "a", "b", or "c" is used for setting or resetting the bistable semiconductor diode laser device.
It is possible to use the operation characteristic shown in FIG. 19. In the operation characteristic of FIG. 19, the wavelength of the light for setting or resetting is selected as a wavelength in the border range where the difference between the resonance wavelength for a non-lasing state of the laser and the resonance wavelength for a lasing state of the laser is 1 angstrom or less.
(Examples of Types of Device, Actual Operation of the Device, etc.)
Examples of the types of the bistable semiconductor laser device of the present invention are shown in FIGS. 20A, 20B and 20C. As a first case, a bistable laser device operable in the "same axis" manner is illustrated. As a second case (Case-2, FIG. 20B), a bistable laser device operable in the "different axis" manner is illustrated. As a third case, a bistable laser device with the electrical setting and the optical resetting and operable in the "same axis" manner is illustrated.
An example of actual operations of the bistable semiconductor laser diode device according to an embodiment of the present invention in the "same axis" manner is shown in the composite of FIGS. 21A and 21B. In FIGS. 21A and 21B, I 1 is the current, as a bias current, of one of the gain regions 1 and 2 in FIG. 11. The optical resetting of the device is carried out over 1 angstrom or 8 angstroms.
An example of the respective, actual light signal waveforms for the set light, the reset light, and the light output are shown in FIG. 22. The wavelength of the lasing light output is 1.307 μm and the respective wavelengths of the set and reset lights are 1.3044 μm and 1.3154 μm.
A diagram showing the operation of the resetting by light inputting in a bistable semiconductor laser diode device according to an embodiment of the present invention is shown in FIG. 23.
An arrangement of the light signal inverter in accordance with an application of the laser diode device of the present invention is illustrated in FIG. 24.
An operation of the light signal inverter in accordance with an application of the laser diode device of the present invention is illustrated in FIG. 25.
An example of the characteristic of the optical set and the optical reset operation of the device according to an embodiment of the present invention is shown in the composite of FIGS. 26A and 26B.
The case (1) where two kinds of pulses having different light intensities and the same pulse-width are used is shown in FIG. 26A. The case (2) where two kinds of pulses having the same light intensity and different pulse-widths are used is shown in FIG. 26B. In the case (1), the pulse-width of the set/reset light is 30 ns, the light intensity of the set light is 50 μw, and the light intensity of the reset light is 250 μw. In the case (2), the light intensity of the set/reset light is 350 μw, the pulse-width of the set light is 10 ns, and the pulse-width of the reset light is 50 ns. | A bistable semiconductor laser device has reset light irradiation means for irradiating a reset light for stopping the delivery of a lasing light from the laser. The laser comprises an active layer comprising a gain region in which stimulated emission occurs to attain a optical gain and a saturable absorption region in which no optical gain is attained at the lasing wavelength, resetting of the laser being carried out by irradiating onto the gain region of the laser a light having a wavelength in accordance with which the irradiated light is amplified by stimulated emission thereby to reduce carriers in the gain region of the laser. | 6 |
This is a national stage application of PCT/EP93/02511, filed Sep. 16, 1993.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention comprises a material for electric contacts based on silver-tin oxide
2. Description of the Prior Art
Contact materials based on silver-tin oxide have begun to replace the hitherto preferred silver-cadmium oxide materials because the former are environment friendlier and generally have a longer life span. Their thermal behavior is, however, unsatisfactory, since tin oxide, when subjected to continuous current, has a tendency to produce poorly conductive slag layers on the contact surface, influenced by electric arc. In order to overcome this disadvantage, it is known that admixtures, added in powder form to the powder metallurgically produced material, bring about a temperature reduction at the contact. Suitable admixtures in this sense have been mentioned in the patent literature, especially tungsten- and molybdenum-oxide and molybdenum carbide (DE-A-29 33 338, DE-A-31 02 067, DE-A-32 32 627). Further suitable admixtures such as bismuth- and germanium-oxides have been mentioned (DE-A-31 02 067 and DE-A-32 32 627). These admixtures help wet tin oxide particles so that when the contact area melts locally under the action of electric arc, tin oxide remains suspended in fine particles. Apart from this favorable thermal behavior under continuous current, theses admixtures have also unfavorable side effects. The already somewhat unsatisfactory plastic deformation behavior, i. e. brittleness, of silver-tin oxide contact materials, which can be improved, for example, by annealing the tin oxide powder (DE-A-29 52 128), is worsened by these admixtures, since they promote embrittlement. This is particularly true for bismuth and molybdenum oxide. A further disadvantage, especially of the tungsten and molybdenum compounds, is the fact that they tend to transfer material, especially during switching operations under AC1-loads (DIN 57660, Part 102), resulting in accelerated burning off and therefore reduced life span.
According to the teaching of WO 89/09478, a contact material with low welding tendency and minimal contact temperature under continuous current can be obtained by creating a structure containing regions with little or no metal oxides, alternating with regions containing the majority of metal oxides, finely dispersed. For this purpose a powdered compound, among other means, is commercially available, containing the predominant portion of tin oxides and the other oxides and/or carbides as well as a portion of the silver. This compound powder is combined with the remaining silver powder, and with the smaller remaining portion of metal oxides, mixed, condensed, sintered and transformed. In this manner a useful material is obtained but through a relatively costly process. Mentioned metal oxides are tungsten, molybdenum, bismuth, vanadium and copper.
From the paper by Christine Bourda et al. "Properties and effects of doping agents in AGSNO2contact materials", published in Proc. 16th Int. Conference on Electrical Contacts 7.-Sep. 12, 1992 in Loughborough, it is known that many admixtures made up of oxides react with silver or tin oxide; for example it was found that in a contact material produced from silver powder, tin oxide powder and molybdenum oxide powder or antimony oxide powder, at temperatures reached during electric arcing, silver and molybdenum oxide can combine into silver molybdate Ag 2 MoO 4 , and silver and antimony oxide can combine into silver antimonate AgSbO 3 . As to these admixtures, the bibliographical reference indicates that, according to results of tests, they do not influence the wetability of tin oxide and silver, so that they are not expected to improve the temperature behavior of contacts under continuous current.
In the older but not pre-published German patent application P 42 19 333.8, a material for electric contacts had already been proposed on the basis of silver-tin oxide which is obtained through mixing of a powder of silver or of a principally silver containing alloy with a tin oxide powder, whose powder particles are doped with up to 5 weight % of an oxide or carbide of molybdenum, tungsten, bismuth, antimony, germanium, vanadium, copper or indium, condensing the mixture, sintering and transforming it. The doped tin oxide powder is a compound powder which can be obtained through mixing tin oxide powder with the powdered doping agent, annealing the mixture, so that the doping agent diffuses into the tin oxide powder particles, and segregating the surplus of the doping agent from the tin oxide powder. A further process for obtaining doped tin oxide powder is made known in P 42 19 333.8. A solution of a salt of tin and of a salt of the metal or metals, whose oxides or carbides make up the doping agent, is sprayed into a hot oxidizing atmosphere in which the salts are to be decomposed so that a fine-grained compound powder precipitates whose particles contain tin oxide and the doping agent.
SUMMARY OF THE INVENTION
The purpose of the present invention is to create a material of the kind described at the beginning which, through use of admixtures exhibits an equally favorable thermal behavior as the already known materials do, but which is more ductile and has a longer life time when subjected to the AC1 switching load case. This task is solved by a material with characteristics described in claim 1. A particularly suitable process for producing such a material is the subject of claim 9. Favorable further developments of the invention are subject of dependent claims.
In the powder metallurgical production of a contact material on the basis of silver-tin oxide, the invention additionally utilizes a powder containing one or more chemical compounds of silver, oxygen and a metal from subgroups II to VI and/or antimony, bismuth, germanium, gallium and indium, especially silver-tungsten-oxygen compounds, silver-molybdenum-oxygen compounds, silver-antimony-oxygen compounds and silver-germanium-oxygen compounds. Although silver-antimonate and silver-molybdate belong to this class of compounds which are known to form in a silver-tin-oxide-molybdenum-oxide and/or a silver-tin-oxide-antimony-oxide material and to have no favorable influence on the wetability of tin oxide (see Christine Bourda's paper referenced above), one has achieved with the contact material according to the invention, a significantly lower temperature increase on the contacts under continuous current as compared with known contact materials with comparable weight composition. It is suspected that the reason for this can be found in the contact material not being produced in the usual manner by mixing and sintering silver powder, tin oxide powder and additional metal oxide powders, but, by starting out with a powder which contains, instead of a pure metal oxide such as, e.g., MoO 3 , a compound of type silver-metal-oxygen such as Ag 2 MoO 4 , especially when this compound is completely or partially combined with tin oxide powder particles, forming a compound powder in whose particles tin oxide and the silver-metal-oxygen compound are combined; this compound powder is then mixed with silver powder and sintered into a contact material. Significant advantages are achieved in the powder metallurgical production of the contact material according to the invention, by mixing silver powder with a powder consisting mainly of tin oxide and one or more compounds of type silver-oxygen-metal. Surprisingly, it turned out that with the contact material according to the invention a certain lowering of the contact temperature under given conditions could be achieved with a significantly smaller portion of the chosen admixtures than hitherto possible with known technology. First experience with the contact materials according to the invention shows that a certain reduction of the contact temperature can be achieved, according to the invention, with only 1/2 to 1/10 of the admixture quantity necessary to achieve the same temperature reduction with hitherto known technology. This is also true for the example of molybdenum oxide whose share can be drastically reduced when replaced by silver-molybdate, especially when combined with tin oxide particles.
This also results in a less brittle, i.e. more ductile contact material. A further advantage is the fact that because of the lower share of non-conductive admixture, the electric resistance of the contact material is additionally lowered contributing additionally to a lower contact temperature.
A further advantage of the invention is the fact that because of the lower share of admixture, the life span of contact pieces made from the contact material is increased, especially under AC1test conditions. The utilization of the powder according to the invention yields a lower burning off compared with conventional silver-tin oxide contact materials using pure metal oxide admixtures such as tungsten oxide, molybdenum oxide or bismuth oxide.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The tin oxide particles are preferably coated with a layer of silver-metal-oxygen compounds. They effectively promote wetting of tin oxide particles with the liquid phase generated by arc. A tin oxide powder modified in this manner can be made advantageously by mixing tin oxide powder with powdered admixture and annealing the mixture so that tin oxide powder particles are wetted by the admixture whereby a part of the admixture diffuses into the surface of the tin oxide particles, possibly forming a mixed oxide there.
In order to safeguard sufficiently against fusing of contact pieces, as required of silver-tin oxide materials, the material contains 5 to 20 weight %, preferably 8 to 14 weight % tin oxide, and, in order for tin oxide to remain in suspension when melted under the influence of electric arc, as desired, tin oxide should contain a minimum of 0.1 weight % admixtures, but not more than 2.5 weight %, and best not more than 1 weight %.
A particularly preferred admixture is silver-molybdate, because of its very favorable effect on thermal behavior.
Annealing the mixture of tin oxide and the selected admixture is best carried out under an oxygen containing atmosphere, preferably air, at a temperature of between 500 deg. C. and 800 deg. C., the best temperature being just above the melting point of the admixture, so that the admixture is liquefied and can wet the surfaces of the tin oxide particles. The admixture is thus deposited only where its favorable wetting effect is desirable, and can therefore be utilized without waste. Considering the small quantities with which it is used, the tin oxide particles do not stick together; but should this occur on rare occasions, then the material can be ground down.
Tin oxide and admixture can be combined not only through annealing but also through deposition of the admixture on tin oxide particles through application of chemical and physical separation processes.
The teaching contained in this patent can be applied to contact materials based on silver with zinc oxides. In these materials admixtures have so far not been used in practice. One rather tries to reduce contact temperatures in switching equipment through design measures. Through application of an admixture in the zinc-oxide powder according to the invention, a lowering of the the contact temperature is possible with this type of material also.
EXAMPLES
Example 1
With 100 parts by weight tin oxide powder with particle size <7 mm according to FSSS (FSSS=Fisher Sub-Sieve Sizer) and 0.5 parts by weight di-silver-mono-molybdate Ag 2 MoO 4 of similar or equal particle size, a powder mixture is produced by dry mixing. This powder mixture is placed in shallow ceramic dishes and annealed in air at 600 deg. C. for the duration of 1 hour, thereby wetting the tin oxide powder with Ag 2 MoO 4 . 12 parts by weight of the annealed mixture are mixed with 85 parts by weight silver powder with approximate particle size of 20 mm (FSSS value). The mixture is cold-isostatically pressed into a block under 200 MPa pressure, and subsequently sintered in air at 700 deg. C. for 2 hours. The sintered block is forward extruded into a 5 mm thick string. The string is then flattened through hot rolling thereby producing a solderable silver backing, then, through cold rolling, given the final thickness. From this strip contact platelets can be formed, as required, through shearing, stamping or saw cutting.
Example 2
A mixture is produced by dry mixing using 100 parts by weight tin oxide powder with particle size <7 mm (acc. to FSSS) and 1 part by weight silver-tetra-tungstate Ag 8 W 4 O 16 of similar or equal particle size. This powder mixture is placed in flat ceramic dishes and annealed in air for approximately 1 hour at 700 deg. C., thereby wetting the tin oxide powder with AG 8 W 4 O 16 . 10 parts by weight of the annealed mixture are mixed with 90 parts by weight silver powder with a particle size of approx. 20 mm (acc. to FSSS). The mixture is cold-isostatically pressed into cylindrical blocks under 200 MPa pressure and sintered in air for the duration of 2 hours at 700 deg. C.
The sintered block is encased in silver, inserted hot into a backward extrusion press (DE-OS 34 26 240). This process yields flat strips which have a solderable and weldable silver surface on one side. The final desired thickness is obtained through cold rolling. From this band contact platelet can be made, as required, through shearing, stamping or saw cutting.
Example 3
Example 1is modified in that 119.5 parts by weight tin oxide powder with particle size smaller than 7 mm and 0.5 parts by weight Ag 2 MoO 4 with a medium particle size of 40 mm are mixed and annealed at 600 deg. C. In this process Ag 2 MoO 4 is spread to the tin oxide particles. The remainder of the procedure is the same as in example 1.
Contact pieces produced in this manner are tested for life span according to test category AC1in a switching equipment having power output of 37 kW. After 200,000 switching operations the life time test was interrupted for a check on the temperature rise of the contact pieces under continuous current. It could be shown that the temperature rise with 70 to 90 deg. K in the average was not higher than for a conventionally produced material of composition Ag88/SnO 2 11.6/MoO 3 0.4 containing approximately 10 times as much molybdenum-oxide.
The three examples can be modified in that tin oxide is replaced by zinc-oxide. | A material for electric contacts based on silver-tin oxide is obtained by mixing a powder of silver or an alloy mainly containing silver with a powder consisting mainly of tin oxide and 0.01 to 10 wt. % (in relation to the quantity of tin oxide) of an additive consisting of one or more compounds containing silver, oxygen and a metal from sub-groups II to VI of the periodic system and/or antimony, bismuth, germanium, indium and gallium, compacting the mixture and sintering it. The tin oxide may be replaced by zinc oxide. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. Ser. No. 12/715,016, filed Mar. 1, 2010; which is a continuation of U.S. Ser. No. 10/737,497, filed Dec. 16, 2003 and issued as U.S. Pat. No. 7,670,364; which is a continuation of U.S. Ser. No. 09/794,648, filed Feb. 27, 2001 and issued as U.S. Pat. No. 6,663,660; which is a continuation of U.S. Ser. No. 09/418,277, filed Oct. 14, 1999 and issued as U.S. Pat. No. 6,203,558; which is a continuation of U.S. Ser. No. 08/916,554, filed Aug. 22, 1997 and issued as U.S. Pat. No. 5,968,069; which is a Continuation-in part application based on U.S. Ser. No. 08/807,791, filed Feb. 28, 1997 and issued as U.S. Pat. No. 6,077,273, U.S. Ser. No. 08/701,979, filed Aug. 23, 1996 and issued as U.S. Pat. No. 6,395,008, U.S. Ser. No. 08/697,453, filed Aug. 23, 1996 abandoned, and U.S. Ser. No. 08/702,150, filed Aug. 23, 1996 and issued as U.S. Pat. No. 6,007,543; all of which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
This invention relates to an assembly and method for delivering and deploying an inflation expandable stent, particularly within a lumen of a body vessel. More specifically, this invention relates to stent securement devices most notably positioned between the balloon and the inner shaft of the catheter.
BACKGROUND OF THE INVENTION
Stents and stent delivery assemblies are utilized in a number of medical procedures and situations, and as such their structure and function are well-known. A stent is a general cylindrical prosthesis introduced via a catheter into a lumen of a body vessel in a configuration having a generally reduced diameter and then expanded to the diameter of the vessel. In its expanded configuration, the stent supports and reinforces the vessel walls while maintaining the vessel in an open, unobstructed condition.
Both self-expanding and inflation expandable stents are well-known and widely available. Self-expanding stents must be maintained under positive external pressure in order to maintain their reduced diameter configuration during delivery of the stent to its deployment site. Inflation expandable stents (also known as balloon expandable stents) are crimped to their reduced diameter about the delivery catheter, positioned at the deployment site, and then expanded to the vessel by diameter by fluid inflation of the balloon positioned between the stent and the delivery catheter. The present invention is particularly concerned with enhanced stent securement and safer stent loading in the delivery and deployment of balloon expandable stents.
In angioplasty procedure, there may be restenosis of the artery, which either necessitates another angioplasty procedure, a surgical bi-pass procedure, or some method of repairing or strengthening the area. To prevent restenosis and strengthen the area, a physician can implant an intravascular prosthesis for maintaining vascular patency, i.e. a stent, inside the artery at the lesion. The stent is expanded to a larger diameter for placement in the vasculature, often by the balloon portion of the catheter. Stents delivered to a restricted coronary artery, expanded to a larger diameter as by a balloon catheter, and left in place in the artery at the site of a dilated lesion are shown in U.S. Pat. No. 4,740,207 to Kreamer; U.S. Pat. No. 5,007,926 to Derbyshire; U.S. Pat. No. 4,733,665 to Palmaz; U.S. Pat. No. 5,026,377 to Burton et al; U.S. Pat. No. 5,158,548 to Lau et al; U.S. Pat. No. 5,242,399 to Lau et al; U.S. Pat. No. 5,344,426 to Lau et al; U.S. Pat. No. 5,415,664 to Pinchuck; U.S. Pat. No. 5,453,090 to Martinez et al; U.S. Pat. No. 4,950,227 to Savin; U.S. Pat. No. 5,403,341 to Solar; U.S. Pat. No. 5,108,416 to Ryan et al; and European Patent Application No. 707837A1 to Scheiban, all of which are incorporated herein by reference. A stent particularly preferred for use with this invention is described in PCT Application No. 96/03092-A1, published 8 Feb. 1996, the content of which is incorporated herein by reference.
In advancing a balloon expandable stent through a body vessel to the deployment site, there are a number of important considerations. The stent must be able to securely maintain its axial position on the delivery catheter. The stent, particularly its distal and proximal ends, are sometimes protected to prevent distortion of the stent, and minimize trauma to the vessel walls. Balloon expandable stent delivery and deployment assemblies are known which utilize restraining means that overlay the stent during delivery. U.S. Pat. No. 4,950,227 to Savin et al, relates to a balloon expandable stent delivery system in which a sleeve overlaps the distal or proximal margin (or both) of the stent during delivery. During inflation of the stent at the deployment site, the stent margins are freed of the protective sleeve(s) and the sleeves then collapse toward the delivery catheter for removal. A number of balloon expandable stent delivery and deployment assemblies do not use overlaying restraining members, such as the Savin sleeves, to position the stent for delivery. European Patent Application No. EP 055 3960A1 to Lau et al, uses an elastic sheath interspaced between the balloon and the stent. The sheath is said to act as a barrier to protect the balloon from the stent, allow uniform stent expansion, decrease balloon deflation time, prevent undesirable balloon flattening upon deflation and provide a friction substrate for the stent. The Lau sheath can be positioned on the inside or outside of the balloon. U.S. Pat. No. 5,409,495 to Osborne, similarly uses an elastic sleeve or sheath surrounding and in contact with the balloon for controlling the balloon radial expansion. In addition, Osborne is said to use restraining bands or a pair of balloons to achieve controllable stent expansion characteristics. U.S. Pat. No. 5,403,341 to Solar, relates to stent delivery and deployment assembly which uses a retaining sheath positioned about opposite ends of the compressed state. The retaining sheaths of Solar are adapted to tear under pressure as the stent is radially expanded, thus releasing the steno for engagement with the sheaths. U.S. Pat. No. 5,108,416 to Ryan et al. describes a stent introducer system which uses one or two flexible end caps and annular socket surrounding the balloon to position the stent during introduction to the deployment site. The content of all of these patents is incorporated herein by reference.
In positioning a balloon expandable stent on the delivery catheter over the fluid expandable balloon, the stent must be smoothly and evenly crimped to closely conform to the overall profile of the catheter and the unexpanded balloon. It has been noted that, due to physical properties of the material used in manufacturing the stent (typically a shaped memory metal, such as stainless steel or Nitinol™) there is a certain amount of “recoil” of the stent despite the most careful and firm crimping. That is the stent evidences a tendency to slightly open up from the fully crimped position and once the crimping force has been released. For example, in the typical stent delivery and deployment assembly, if the stent has been fully crimped to a diameter of approximately 0.0035″, the stent has been observed to open up or recoil to approximately 0.0037″. This phenomenon has been characterized as “recoil crimping”. Due to recoil crimping to this slightly enlarged diameter, it can be understood that the stent tends to evidence a certain amount of looseness from its desired close adherence to the overall profile of the underlying catheter and balloon. That is, the stent tends to have a perceptible relatively slack fit in its mounted and crimped position. During delivery, the stent can thus tend to slip and dislocate from its desired position on the catheter or even become separate from the catheter, requiring further intervention by the physician.
According to the present invention, a securement device is secured over the inner catheter beneath the balloon to compensate for the undesired looseness or slack that due to recoil crimping and to aid in securing the stent to the balloon, as well as protecting the balloon material from being sandwiched between the stent and any metal or protruding item which may be mounted on the inner shaft/guide wire lumen, for delivery of the stent. The securement devices secure the stent during tracking and delivery and provide a good friction fit to the stent and insure good contact between the stent and underlying balloon and catheter, instead of merely crimping the stent onto the balloon and the underlying catheter and relying on the bulk of the flaccid balloon to hold the stent on.
The art referred to and/or described above is not intended to constitute an admission that any patent, publication or other information referred to herein is “prior art” with respect to this invention. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 C.F.R. §1.56(a) exists.
SUMMARY OF THE INVENTION
This invention concerns a catheter apparatus suitable for performing angioplasty and for delivery of stents to body cavities. In general, stents are prosthetic devices which can be positioned within a body cavity, for example, a blood vessel or in some other difficultly accessible place of the body of a living human or animal. The stent prosthesis is formed of a generally tubular body, the diameter of which can be decreased or increased. Stents are particularly useful for permanently widening a vessel which is either in a narrowed state, or internally supporting a vessel damaged by an aneurysm. Such stents are typically introduced into the body cavity by use of a catheter. The catheter is usually of the balloon catheter type in which the balloon is utilized to expand the stent, which is positioned over the balloon for delivery, to place it in a selected location in the body cavity. The present invention is particularly directed to improved arrangements for releasably attaching and securing the stent to the catheter to facilitate delivery thereof, specifically having a securement device within the balloon. The below identified embodiments all disclose improved means for securing the stent to the catheter during the delivery procedure.
In certain embodiments the stent is held in place on the catheter by means of an enlarged mounting body carried within the balloon by the catheter shaft to which the stent and balloon are fitted. The stent is fitted over the balloon, as by crimping. According to the invention in some embodiments, the enlarged body is axially movable on the inner shaft of the catheter so that it can be retracted from the stent mounting area to provide a small profile for performing angioplasty. The catheter can then be withdrawn; the enlarged body can be moved into the stent mounting area; the stent can be mounted and the catheter can be re-inserted to implant the stent. In other embodiments, the enlarged body can be arranged to be reducible and enlargeable in size rather than being movable. Alternatively, the movable mounting body may be carried outside the balloon. A catheter of this type makes possible a method in which, before stent loading with the associated mounting body arranged to provide reduced diameter in the balloon region, the catheter may be used to dilate a lesion or the like. The catheter may be withdrawn and the mounting body may then be selectively manipulated to provide an enlarged diameter in the stent mounting region and a stent may be loaded onto the catheter. The catheter may be re-inserted to implant the stent. The catheter may be withdrawn or left in situ and the mounting body may be manipulated to provide reduced diameter again and the catheter may be used for any post-dilation desired. Also, the catheter may be used multiple times in the procedure for dilation and stent implantation.
Another embodiment of the present invention is also an assembly for delivery and deployment of an inflation expandable stent within a vessel. The assembly comprises a catheter, an expandable tube component mounted on the catheter, an expandable balloon mounted on the catheter and encompassing the tube component, and a stent mounted on the balloon. The catheter has proximal and distal ends. The stent is inflation expandable from a delivery diameter to a deployment diameter. The delivery diameter is reduced from the deployment diameter for conforming the stent to the catheter. The stent, in its delivery diameter, is coaxially mounted on the catheter near the catheter distal end. The expandable balloon is coaxially mounted on the catheter axially within the stent. The balloon is designed and adapted for expansion of the stent from the delivery diameter to the deployment diameter upon application of fluid deployment pressure to the balloon. The expandable tube component is coaxially mounted on the catheter, axially within the expandable balloon. The tube components is designed and adapted for fluid expansion to provide a securement pressure to the stent in the delivery diameter to maintain the stent in position on the catheter during delivery to the deployment site. The expandable tube component is sized and constructed to be fluid expandable to no more than the delivery diameter. The tube component is essentially equal in length to the stent and the stent is positioned on the assembly essentially coextensive with the tube component.
In another embodiment, this invention is a method for delivering and deploying a stent using an assembly as just described. A catheter is provided having proximal and distal ends. An expandable balloon is coaxially mounted on the catheter. An expandable tube component is coaxially mounted on the catheter, axially within the expandable balloon. The balloon and the tube component are each in an unexpanded condition. A stent is provided which is expandable from a delivery diameter to a deployment diameter. The stent, in a diameter greater than the delivery diameter, is mounted on the balloon. The stent is collapsed to the delivery diameter to conform to an overall profile of the catheter, the tube component and the balloon. The tube component is inflated to provide to the stent a securement pressure, to retain the stent on the assembly in the delivery diameter. The assembly is delivered to a deployment site. The balloon is inflated to expand the stent to its deployment diameter.
An alternative embodiment of present invention is also an assembly for delivery and deployment of an inflation expandable stent within a vessel. The assembly comprises a catheter, an expandable balloon mounted on the catheter, a corrugated tubing mounted on the catheter beneath or within the balloon, and a stent mounted on the balloon. The catheter has proximal and distal ends. The stent is inflation expandable from a delivery diameter to a deployment diameter. The delivery diameter is reduced from the deployment diameter for conforming the stent to the catheter. The stent, in its delivery diameter, is coaxially mounted on the catheter near the catheter distal end. The expandable balloon is coaxially mounted on the catheter axially within the stent. The balloon is designed and adapted for expansion of the stent from the delivery diameter to the deployment diameter upon application of fluid deployment pressure to the balloon. The corrugated tubing is mounted and adhered coaxially onto the catheter and is situated between the balloon and the catheter itself. When the stent is crimped and loaded onto the balloon, the balloon is situated therefore between the stent and the corrugated tubing. The tubing is preferably essentially equal to the length of the stent and the stent is positioned on the assembly essentially co-extensive with the tube component. The tubing on the catheter effectively holds the stent in place, takes up the slack due to recoil and protects the balloon material from being damaged during crimping.
Still another embodiment of the present invention comprises an assembly for delivery and deployment of an inflation expandable stent. The assembly comprises a catheter having proximal and distal ends. An annular collar or the like is coaxially located on the catheter distal end. A fluid expandable balloon is coaxially mounted over the collar at the catheter distal end. The balloon is expandable from a contracted to an expanded state. A stent is coaxially mounted on the balloon. The stent is inflation expandable from a reduced to an enlarged condition, the reduced condition conforming the stent to the balloon, collar and catheter in the preferred embodiment. The stent has at least an end portion overlying the balloon. At least one cup is coaxially mounted on the catheter distal end. The cup has a first end portion which may overlie the stent end portion. The cup and collar are cooperatively constructed and arranged to retain the stent end portion on the catheter in the stent reduced condition when the balloon is in the contracted state. The balloon and catheter are cooperatively constructed and arranged to cause expansion of the balloon from the contracted to the expanded state to cause enlargement of the stent, including the stent end portion, from the reduced to the enlarged condition, and thereby release the stent end portion from the cup end portion. The cup may be axially spaced from the collar but preferably they are relatively close together. The second end portion of the cup may be fixed to the catheter. The cup may overlie at least a portion of the collar. The collar can be shaped as a single member with the catheter, that is integral with it or the collar may be a separate body mounted axially and positioned on the catheter. The collar may be a mounting ring or cylinder axially positioned between stent end portions under the stent and balloon. The collar may be a sheath under the stent and balloon.
A further embodiment is also directed to improved arrangements for releasably attaching the stent to the catheter to facilitate delivery thereof. The stent is held in place on the catheter by means of an enlarged body carried by the catheter shaft within the balloon to which the stent and balloon are fitted, as by crimping in combination with one or more sleeves releasably overlying an end portion or portions of a stent and balloon.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is an isometric view, a portion of which is enlarged and in longitudinal section, of a balloon catheter having a mounting body in a retracted position;
FIG. 2 is an even more enlarged view in longitudinal cross-section of the distal end portion of the catheter of FIG. 1 ;
FIG. 3 is similar to FIG. 2 but showing the mounting body advanced to receive a stent mounted on the balloon;
FIG. 4 is an enlarged cross-sectional view of the distal end portion of the catheter of FIG. 1 similar to that of enlarged view FIG. 3 but showing the balloon in an expanded condition along with the expanded stent;
FIG. 5 is a schematic showing of a preferred mounting body carried by the catheter shaft within the balloon, the body being spirally cut to improve flexibility;
FIG. 6 is a schematic showing in cross-section of another embodiment of the invention with a mounting body positioned to receive a stent but with a stent not yet mounted;
FIG. 7 is a schematic showing of another embodiment of the invention;
FIG. 8 is a schematic showing of a means for conveniently crimping the stent on the embodiment shown in FIG. 5 ;
FIG. 9 is a schematic showing of yet another embodiment of the invention;
FIG. 10 is a showing of another embodiment of a mounting body according to the invention;
FIG. 11 is a schematic of an enlargeable mounting body which is not axially movable;
FIG. 12 is a schematic of an alternate enlargeable mounting arrangement which is not axially movable;
FIGS. 13 and 14 are schematic showings of yet another embodiment in which the axially movable mounting body is carried outside the balloon;
FIGS. 15 and 16 are schematic showings of still yet another embodiment of the invention, and
FIGS. 17 and 18 are modified versions of the embodiment shown in FIG. 11 .
FIGS. 19-21 are modified versions of the securement means of the present invention.
FIG. 22 is a side profile section showing a balloon expandable stent delivery and deployment assembly, with the stent crimped to delivery diameter onto the balloon, the underlying inflating component and the catheter and with the inflating tube component inflated to securement pressure.
FIG. 23 is a side profile section, similar to FIG. 22 , with the balloon and the stent fully inflated to deployment diameter.
FIG. 24 is a side profile section showing an alternative embodiment of a balloon expandable stent delivery and deployment assembly, having a tube component formed in several sections.
FIGS. 25 , 26 and 27 are cross-sectional views taken along lines 4 - 4 , 5 - 5 and 6 - 6 of FIG. 24 , respectively.
FIG. 28 is a side profile section showing a balloon expandable stent delivery and deployment assembly, with the stent crimped to delivery diameter onto the balloon, the underlying tube component and the catheter.
FIG. 29 is a side profile section, similar to FIG. 28 , with the balloon and the stent fully inflated to deployment diameter.
FIG. 30 is a perspective view of the corrugated tubing of the present invention.
FIGS. 31-33 are side profile sections showing alternative embodiments of balloon expandable stent delivery and deployment assemblies, having the tubing component formed in a plurality of sections.
FIGS. 34-35 are side profile sections showing alternative embodiments of the balloon expandable stent delivery and deployment assemblies, the tube component inflatable to add securement pressure.
FIG. 36 is a side profile section showing a balloon expandable stent delivery and deployment assembly, with the stent crimped to delivery diameter onto the balloon, the underlying tube component and the catheter, and also having containment sleeves covering the ends of the stent.
FIG. 37 is a side profile section showing a balloon expandable stent delivery and deployment assembly, with the stent crimped to delivery diameter onto the balloon, the underlying tube component and the catheter, and also having a pull-back wire attached to the tube component.
FIG. 38 is a longitudinal cross-section of a stent delivery and deployment assembly of this invention showing a catheter with a collar mounted at the catheter distal end, an uninflated balloon mounted on the catheter over the collar, an unexpanded stent mounted on the balloon abutting the collar and a cup overlying the stent proximal end portion.
FIG. 39 is a longitudinal cross-section of another stent delivery and deployment assembly of this invention showing a catheter with a collar mounted as a mounting ring at the catheter distal end, an uninflated balloon mounted on the catheter over the mounting ring, an unexpanded stent mounted on the balloon overlying the mounting ring and a cup overlying the stent proximal end portion; note that the collar is positioned closer to the cup than in FIG. 38 .
FIG. 40 is a longitudinal profile in partial cross-section of an assembly similar to that of FIG. 38 , with a bulge formed under the uninflated balloon at the catheter distal end.
FIG. 41 is a longitudinal profile in partial cross-section of the assembly shown in FIG. 38 with the balloon inflated and the stent expanded, showing the cup end portion flared to release the stent.
FIG. 42 is a longitudinal profile, similar to FIG. 41 , showing the cup end portion rolled proximally to release the stent.
FIG. 43 is a longitudinal profile of yet another stent delivery and deployment assembly of this invention, with the balloon mounted on the catheter, which has a collar formed as a tapered single enlarged piece on the catheter, an unexpanded stent mounted on the unexpanded balloon abutting the collar and a cylindrical sleeve overlying the stent proximal end portion.
FIG. 44 is a longitudinal profile of the assembly of FIG. 43 with the balloon inflated and the stent expanded, showing the sleeve moved proximally to release the stent.
FIG. 45 is a side profile of still another stent delivery and deployment assembly of this invention with the uninflated balloon mounted on the catheter which has two collars formed integrally with the catheter, an unexpanded stent mounted on the balloon abutting the collar and a cylindrical cup overlying the stent proximal end portion and the underlying collar.
FIG. 46 is a longitudinal profile of another stent delivery and deployment assembly of this invention with the uninflated balloon mounted on the catheter, an unexpanded stent mounted on the balloon, mounting a cylinder on the catheter and a pair of cups overlying the stent ends.
FIG. 47 is an isometric view, a portion of which is enlarged and in longitudinal section, of a balloon catheter having a stent fixed to the catheter over the balloon;
FIG. 48 is an even more enlarged view in longitudinal cross-section of the distal end portion of the catheter of FIG. 47 ;
FIG. 49 is a schematic showing of one form of retraction of the releasable sleeve upon expansion of the balloon;
FIG. 50 is a schematic showing of another form of retraction of the releasable sleeve upon expansion of the balloon;
FIG. 51 is yet another form of retraction of the releasable sleeve upon expansion of the balloon;
FIG. 52 is a schematic showing of yet another form of retraction of the releasable sleeve upon expansion of the balloon;
FIG. 53 is a schematic showing of a modified shape for the releasable sleeve;
FIG. 54 is a schematic showing in cross-section of another embodiment of the invention with a stent not yet mounted;
FIG. 55 is a schematic showing of another embodiment of the invention; and
FIG. 56 is a schematic showing of yet another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to stent securement devices, most notably positioned between the balloon and the inner shaft of the catheter. Individual elements of the below disclosed embodiments are generally interchangeable if desired. Referring to FIGS. 1-4 an angioplasty and stent delivery catheter system generally indicated at 10 includes a balloon catheter 12 having a balloon 14 on a distal end portion generally indicated at 16 . FIG. 1 shows a proximal portion of the catheter at 12 a and a distal portion 12 b in enlarged view. FIGS. 2 and 3 show the distal end portion 16 in an even more enlarged view. The illustrative catheter 12 is of the type known as a rapid exchange or single operator catheter. However, other types of catheters may be used, such as over the wire and fixed wire types. The balloon 14 is fixed to the catheter 12 by standard means. The balloon is shown in its contracted state in. A stent 18 is fixed about the balloon by crimping thereto. The stent has a larger expanded diameter which is obtained when the balloon is expanded in the known manner. In FIGS. 1 and 2 catheter is shown prepared for performing angioplasty and in FIG. 3 it is prepared for stent implantation.
In FIGS. 1 and 2 , an axially movable mounting body 30 is shown in a position proximal to the end portion 16 of the catheter where a stent may be mounted. The catheter includes at its proximal end a manifold, generally designated 13 , as is known in the art. The manifold includes an inflation port 15 as is known in the art. A wire 31 is attached to body 30 to enable remote (from the proximal catheter end) advancement and retraction of it axially on inner lumen 26 over which it slides. In the retracted position shown in FIGS. 1 and 2 , the catheter has a low profile for performing angioplasty.
This position is a refracted position and is selected by operation of a pull wire 31 . The retracted position of the mounting body may vary. To maximize the low profile of the distal end 16 of the catheter, the retracted position may be within the outer member 24 .
After such a procedure, the balloon is deflated, the catheter is withdrawn and the mounting body is advanced by means of wire 31 to the stent mounting position shown in FIG. 3 . A stent 18 may then be fixed about the deflated balloon by crimping it thereto. The stent has a larger expanded diameter which is obtained when the balloon is again expanded in the known manner. That is, the stent is released from the catheter upon expansion of the balloon as shown in FIG. 4 to be placed in a vessel at the desired location. When the balloon is then again deflated, removal of the balloon and catheter may be accomplished, leaving the stent in place. Exemplary dimensions for the inner 26 is a diameter of ½ mm and for body 30 a diameter of ¾ mm.
As is known in the art the balloon is either bonded at its ends by adhesive 20 and 22 , respectively to the outer member 24 of the catheter and to the inner member 26 of the catheter in the manner as shown, or is made one-piece with the outer member as is known in the art. The catheter balloon may be inflated by fluid (gas or liquid) from an inflation port extending from a lumen 28 (seen in FIGS. 2 and 3 ) contained in the catheter shaft and opening into the balloon as shown, or by other known arrangements, depending on the design of the catheter. The details and mechanics of balloon inflation and specific overall catheter construction will vary according to the particular design involved in any given instance, and are known in the art per se. Such details are only shown schematically herein. All variations are acceptable for use with this invention.
Any balloon expandable stent may be used with this invention. Many are known in the art including plastic and metal stents. Some are more well known such as the stainless steel stent shown in U.S. Pat. No. 4,735,665; the wire stent shown in U.S. Pat. No. 4,950,227; another metal stent shown in European Patent Application EPO 707 837 A1 and that shown in U.S. Pat. No. 5,445,646, or U.S. Pat. No. 5,242,451. All of these patents are incorporated herein by reference. Also, shape memory metal stents may be used. As already indicated the stent of PCT Application 960 3092 A1 is particularly preferred.
The stent is typically for example about 16 mm long, while the balloon may be 20 mm long for example. These dimensions, however, are merely representative for illustrative purposes only and are not meant to be limiting. The stent is positioned over the balloon portion of the dilatation catheter and gently crimped onto the balloon either by hand or with a tool such as a pliers or the like to be mounted for delivery as shown in FIG. 3 . The crimping may be readily accomplished by the physician during the procedure.
In accordance with this invention, mounting body 30 , best seen in FIGS. 2 and 3 , is included inside balloon 14 to provide a cushion and/or substrate of enlarged diameter relative to the stent to support and hold the stent and secure it during crimping and the delivery procedure. The mounting body may be axially movable proximally or distally from the position shown in FIG. 3 , proximally being preferred.
In the embodiment shown in FIGS. 1-3 , mounting body 30 is cylindrical in form and takes the shape of a sleeve axially and slidably carried on inner lumen 26 , providing an enlarged area or portion for receiving the balloon and stent when the latter is crimped to the balloon. Marker band 34 may also be included on inner 26 as shown. Any radiopaque material such as gold is useful for this purpose. A stop member 36 of generally conical shape or any other shape may also be included on the marker band 34 as shown to provide additional resistance to stent movement during delivery and to protect the leading edge of the stent during delivery. Polyethylene or the like is suitable for the stop member. Other marker arrangements and stop arrangements may be used as well.
Although, the material of the mounting body may be hard, it is preferably of any deformable thermoplastic material, preferably an elastomer material and more preferably of a relatively resilient elastomer material, e.g., lower durometer silicone. A preferred deformable thermoplastic material is high density polyethylene (HDPE). A preferred lower durometer silicone is in the form of tubing. The deformation of the resilient material of the mounting body when the stent/balloon is crimped to it causes a radial outward force on the stent/balloon increasing the friction therebetween despite any recoil of the stent.
During stent delivery, the balloon catheter is advanced through and positioned in a patient's vasculature so that the stent is adjacent to the portion of the vessel where treatment is to take place. The balloon is inflated to expand the stent to an enlarged diameter. When the stent has reached the desired diameter, the balloon is deflated so that the catheter may be removed leaving the stent in place.
Another embodiment of the invention is shown in FIG. 5 . In this embodiment mounting body 30 is a spiral cut elastomer or other suitable material, such as a rigid or flexible plastic, to provide separation for flexibility in that portion of the catheter, allowing more easy movement or tracking around bends. The spiral cut may be only partly through the mounting body or may be all the way through as shown in FIG. 5 . Also, while stop member 36 is shown at the distal end portion of the catheter in this embodiment, no stop member may be used.
Another similar version is shown in FIG. 6 which includes a cylindrical mounting body 30 made up of a plurality of separate adjacent rings 30 a held together by wire 31 which extends therethrough as shown with stops 29 to secure the rings together. Rings 30 a may be individual bodies carried on the sheath or bodies cut from a cylinder to partially separate them or fully separate them. Suitable arrangements may be made to wire 31 at each end of the body 30 to hold the rings together, as shown.
The embodiment shown in FIG. 7 includes another feature based on the geometry of the mounting body for further securing the stent upon crimping. This feature is referred to herein as “interlocking” That is, the stent may be interlocked to the mount so that the stent cannot slide proximally or distally on the balloon unless it is deformed, such as by expansion. This can be seen by perusing the structure shown in FIG. 7 which includes the inner 26 having a two-piece mounting body made up of spaced mounting bodies 30 a and 30 b . These bodies are connected to each other by connection means 33 which may be a separate or integral cylindrical body of lesser diameter or may be one or two or more relatively rigid wire members as shown. The spacing between bodies 30 a and 30 b allows portions of the stent 18 and balloon 14 to be depressed or inserted between the bodies upon crimping of the stent thus forming an interlock against sliding of the stent axially or longitudinally before the stent is released.
The interlock formation or crimping is readily accomplished by any suitable means such as a two-piece die 40 shown in FIG. 8 or the like.
FIG. 9 demonstrates that more than a two-piece mounting body arrangement may be used if desired. In this embodiment, the mounting body is comprised of three spaced interconnected bodies 30 a , 30 b and 30 c on the inner 26 . Preferably in the embodiments of FIGS. 7 and 9 , the mounting bodies will be ring-like in shape or cylindrical in shape although other configurations will be readily apparent to those familiar with this art.
Referring now to FIG. 10 , another embodiment of a movable mounting body 30 is shown in the form of a rigid coil of plastic, metal or the like having a control wire 31 , preferably integral therewith. When in the metal form, the coil may be coated with a polymer such as polyethylene or PTFE or enclosed in a polymeric sheath of similar material. The coil may be slidably received on the inner 26 similar in arrangement to that shown in the preceding Figures.
As already indicated, an alternate arrangement may be used in which the mounting body, instead of being movable, is designed to be enlargeable and reducible or collapsible, while remaining in a fixed position in the stent mounting area of the catheter. FIGS. 11 and 12 are directed to such an arrangement.
In FIG. 11 , an inner balloon 50 of smaller diameter than outer balloon 14 is mounted on the inner 26 . Balloon 50 may have a separate inflation conduit 52 inside inner 26 , preferably including a valving arrangement 54 . Valve 54 may be a one-way valve allowing only inflation of balloon 50 if desired. However, inner 26 may serve as the inflation conduit as well. In addition to fully inflating the balloon, inner balloon 50 may also be partially inflated.
FIG. 19 shows a modification to FIG. 11 in which two inner balloons 50 a and 50 b are included. FIG. 20 shows a modification in which two inflation valves 54 a and 54 b are included.
FIG. 21 shows a full arrangement of inner balloon 50 in which a syringe 120 is inserted into the distal end of the liner 26 of the catheter. The syringe has at its ends blocks 122 and 124 to enable local pressurization of inner 26 to inflate balloon 50 .
FIGS. 17 and 18 show an inner balloon 50 similar to the arrangement of FIG. 11 but the balloon 50 in FIG. 17 has a narrow center portion and wide ends to provide a mounting shape similar to that of FIG. 7 . In FIG. 17 , balloon 50 is inflated and balloon 14 is partially inflated. In FIG. 18 , balloon 50 is inflated and balloon 14 is uninflated ready for stent loading. Balloon material is preferably a polyethylene or urethane elastomer such as Tecoflex or Tecothane from Thermedics.
Referring to FIG. 12 , an alternate embodiment is shown in which the proximal portion of the inner 26 is axially movable while the distal portion 26 b is fixed with respect to the catheter. In between portion 26 a and portion 26 b is a coil spring 60 inside a flexible sheath 62 of PTFE or the like. Portion 26 b of the inner is attached to balloon 14 at the very distal end portion of the catheter. Portion 26 a is movable axially within the outer 22 . Thus, if 26 a is pushed in the distal direction and held to compress coil 60 , the coil will enlarge in diameter to provide an enlarged mounting area for a stent. Twisting the inner to twist the coil will enhance enlargement. Alternatively, coil spring 60 may be replaced by a braided element.
Also, by providing different pitch over the length of the coil it can be made to enlarge more in some regions than in others. For example, if the coil windings are closer together in the center portions than in the end portions, when the coil undergoes compressing, the two end portions will enlarge in diameter more than the center portion to provide a mount similar to that of FIG. 7 .
Referring now to FIGS. 13 and 14 , another embodiment is shown which is alternative to the earlier described embodiments which are inside the balloon on the catheter. In this embodiment a sheath 80 is carried on the outside of the catheter. Sheath 80 is elastomeric and is axially movable from a stent mounting position as shown in FIG. 14 to a position remote from the stent mounting position, such as the retracted position as shown in FIG. 13 . In the position shown in FIG. 13 , balloon 14 may be inflated and deflated. In the position shown in FIG. 14 , balloon 14 will be deflated for low profile. Sheath 80 when over the balloon as in FIG. 14 acts to increase the profile of the catheter to facilitate crimping a stent thereto during deployment of the stent, sheath 80 will expand with balloon 14 to facilitate inflation and during deflation the elastomer sheath will return to its original dimension. An elastomer material which is presently preferred is Tecothane, a trade name for a thermoplastic polyurethane available from Thermedics, Inc., of Woburn, Mass. It may be about 0.003 inches thick, for example.
With respect to FIGS. 15 and 16 , a further embodiment of the invention is shown in which inner 26 carries a mounting body 30 , the distal end 100 of which is secured or fixably attached to inner 26 , as by any suitable adhesive. The remainder of body 30 is slidable over inner 26 as by the application of compression in the distal direction at the proximal end 102 . This may be accomplished by push wire 104 which extends to the proximal end of the catheter for remote manipulation as is known in the art.
Mounting body 30 is accordion folded with more widely spaced folds at the end portions 106 , than at the central portion 108 . Thus, as can be seen in FIG. 15 , a relatively low profile is provided without compression for normal angioplasty use. When a stent is to be mounted (not shown), compression by means of push wire 104 will result in a configuration of enlarged diameter of body 30 as shown in FIG. 16 to provide a mount similar to that of FIG. 7 in general configuration. If the spring is uniform over the body, it will enlarge uniformly, similar to the inner balloon of FIG. 11 . The Figures are schematic in form but the concept can be readily appreciated.
As an alternative to a folded construction, the body may be of braided construction to achieve the same operation.
Also, this form of body 30 may be inserted into a two piece inner 26 similar to the arrangement shown in FIG. 12 . In all of these arrangements, the accordion folded body material may be of any suitable polymer, such as polyethylene. For example, tubing having a wall thickness of about 0.002 inches may be used. The accordion folds or pleats may be readily formed in such tubing by means of a pressure mold containing spaced blades placed in a heated chamber.
FIGS. 22-27 show embodiments wherein the inner securement device comprises an inner balloon beneath the outer catheter balloon, similar to above. FIGS. 22 and 23 illustrate a side profile section showing an inflation expandable stent delivery and deployment assembly generally designated 110 . Assembly 110 includes a catheter comprised of inner shafts 112 and 113 and an outer shaft 115 of the coaxial type, an inflation expandable balloon 114 , an inflation tube component 116 such as an inner balloon and inflation expandable stent 118 . Any conventional type of catheter may be used, such as a catheter of the type generally used for PTA or PTCA angioplasty procedures, for prostate therapy, and TTS endoscopic catheters for gastrointestinal use. However, coaxial types as shown are most preferred. The particular catheter 112 shown is formed of a biocompatible and hydrophilic compatible material, such as a lubricous polyimide or polyethylene. Other suitable materials for the catheter 112 include nylons, urethanes, and polypropylene materials compatible with coatings such as silicone and/or hydrophilic coatings. In addition to hydrophilic compatible materials, any biocompatible material may be used. For example, polyethylene or polypropylene can be coated with a hydrophilic material to render them hydrophilic compatible suitable catheters for use according to the present invention include a number of catheters available from SciMed Life Systems, Inc., Maple Grove, Minn., the assignee of the present invention, such as BANDI™, COBRA™, VIVA™, and VIVA PRIMO™ catheters.
Inflatable tube component 116 is fixed at its distal and proximal end to inner shaft 112 and at its proximal end to inner shaft 113 at a position to be encompassed within the distal and proximal ends of the outer balloon 114 . According to art-recognized convention, the length L-B of the balloon 114 is defined as the length of the body portion of the balloon 114 , excluding the terminal cone sections 120 . As seen in FIG. 23 , the body portion of the balloon 114 is generally cylindrical when in its deployed or inflated condition. Tube component 116 is illustrated as having terminal sections 122 which are more relatively vertical than the cone sections 120 illustrated for the balloon 114 . However, it is to be understood that, according to the present invention, either of the terminal sections 120 , 122 may be relatively cone shaped, relatively vertical or of any other configuration known to those of skill in this art. A preferred length L-T of the tube component 116 is illustrated in FIGS. 22 and 23 as substantially equal to the length L-B of balloon 114 , and substantially equal to the length L-S of stent 118 . However, according to the present invention, stent 118 should be supported by the underlying tube component 116 for a length sufficient to permit accomplishment of the stated purpose of the tube component 116 , when inflated, to provide-securement pressure for stent 118 to maintain stent 118 in position with assembly 110 during delivery. It is also within the present invention for tube component 116 to be slightly shorter than stent 118 , for example, the distal end 119 of stent 118 may extend distally beyond the distal end 121 of tube component 116 (not shown), so that the distal end 119 of stent 121 can be crimped over the distal end 121 of tube component 116 to prevent the distal end 119 of stent 118 from catching and tending to further open as it is maneuvered within a body vessel. As has been explained above, tube component 116 is designed and constructed to be inflatable to no more than is necessary to compensate for recoil crimping of stent 118 and to closely accommodate (or even slightly over-stress) the delivery diameter of stent 118 , taking into consideration the thickness of the intervening uninflated balloon 114 . Tube component 116 is inflated through the opening(s) 117 of inner shaft 112 . Typically, tube component 116 will have a wall thickness of about 0.0002-0.0007 inch and will be inflatable to no more than about 0.035.-0.045 inches.
Inflating tube component 116 may be formed of either compliant or non-compliant balloon materials. Compliant materials include low pressure, relatively soft or flexible polymeric materials, such as thermoplastic polymers, thermoplastic elastomers, polyethylene (high density, low density, intermediate density, linear low density), various co-polymers and blends of polyethylene, ionomers, polyesters, polyurethanes, polycarbonates, polyamides, poly-vinyl chloride, acrylonitrile-butadiene-styrene copolymers, polyether-polyester copolymers, and polyetherpolyamide copolymers. Suitable materials include a copolymer polyolefin material available from E.I. DuPont de Nemours and Co. (Wilmington, Del.), under the trade name Surlyn™ Ionomer and a polyether block amide available under the trade name PEBAX. Non-compliant materials include relatively rigid of stiff high pressure polymeric materials, such as thermoplastic polymers and thermoset polymeric materials, poly(ethylene terephthalate) (commonly referred to as PET), polyimide, thermoplastic polyimide, polyamides, polyesters, polycarbonates, polyphenylene sulfides, polypropylene and rigid polyurethanes.
A balloon 114 for use according to the present invention may be any conventional balloon for catheter delivery, such as a balloon of the type generally used for PTA and PTCA procedures. Typically, balloon 114 is fixed at its distal end to inner shaft 112 near the catheter-distal end and at its proximal end to outer shaft 115 . Balloon 114 is larger in diameter than tube component 116 , because balloon 114 must be able to expand to a larger diameter than tube component 116 . Balloon 114 is inflatable through an inflation conduit 123 , i.e., the space between coaxial inner shaft 113 and outer shaft 115 of the catheter. The distal and proximal ends of balloon 114 are shown in FIGS. 22 and 23 positioned exterior to the distal and proximal ends of tube component 116 , respectively, and of a length L-B generally equal to the length L-T of the tube component 116 . To be compatible with tube component 116 illustrated in FIGS. 22 and 23 and described above, balloon 114 is inflatable at deployment to about the diameter of the body vessel in which the stent 118 is to be deployed. Balloon 114 may be formed of a compliant or non-compliant material, of the types of compliant materials described herein above, such as polyethylene or any standard balloon material. Balloon 114 typically has a wall thickness of about 0.0007-0.004 inch for example.
A stent for use according to the present invention may be any conventional type of balloon expandable stent, including stents of the type used for PTA and PTCA angioplasty procedures, for prostate therapy, and TTS endoscopic catheters for gastrointestinal use. Suitable stent material is biocompatible stainless steel in the form of sheet metal, tube component wire or Nitinol. A preferred stent is described in PCT Application No. 960 3072 A1, published 8 Feb. 1996, the content of which is incorporated herein by reference. All such stents are well known in this art generally and additional examples are described in U.S. Pat. No. 5,507,768 to Lau et al; in U.S. Pat. No. 5,458,615 to Klemm et al; in U.S. Pat. No. 5,226,889 to Sheiban; in U.S. Pat. No. 4,875,480 to Imbert; in U.S. Pat. No. 4,848,343 to Wallsten et al, and in U.S. Pat. No. 4,733,665 to Palmaz. Stent 18 as shown in FIGS. 22 and 23 is positioned on balloon 114 , the underlying inflatable tube component 116 and the distal end of the catheter. The length L-S of stent 118 is shown as essentially equal or slightly smaller than the length L-T of tube component 116 and is positioned on assembly 110 to be co-extensive with tube component 116 . In this position, stent 118 is shown in FIG. 22 crimped to its delivery diameter D 1 , which is about 0.035-0.045 inch for example.
As discussed above, despite the most careful and firm crimping of stent 118 to closely conform to the overall profile of the catheter unexpanded balloon 114 and underlying inflatable tube component 116 , there is a certain amount of “recoil” of stent 118 or a tendency of stent 118 to slightly open from a desired hypothetical minimum crimped diameter. The actual minimum diameter achievable for fully crimped stent 118 on assembly 110 is referred to as the stent 118 delivery diameter D 1 . This tendency of stent 118 to open or recoil slightly when crimped on assembly 10 has been characterized as “recoil crimping”. In FIG. 22 , inflatable tube component 116 is shown inflated to a diameter which is generally sufficient to compensate for any slack or looseness between crimped stent 118 and the overall profile of the catheter, the unexpanded balloon 114 and the underlying inflatable tube component 116 due to recoil crimping.
FIG. 23 illustrates a side profile section showing a stent delivery and deployment assembly 110 of this invention with balloon 114 fluid inflated to its fully expanded position. As a result of the fluid inflation of the balloon 114 , stent 118 has also been fully expanded to its deployment diameter D 2 in which it can be deployed against the walls of a body vessel in which it is situated.
Tube component 116 may have a shape other than the cylindrical shape described and illustrated with regard to the embodiment shown in FIGS. 22 and 23 . Further, the tube component may be comprised of more than one separately inflatable pouch. For example, as illustrated with regard to FIG. 24 , the tube component of an alternative stent delivery and deployment assembly generally designated 130 can be comprised of three separately inflatable pouches 136 , 138 , 140 . The pouches 136 , 138 , 140 are each separately inflatable through their respective inflation conduits 137 , 139 141 , and each of the pouches 136 , 138 , 140 can be inflatable to a different extent. The conduits are formed in the wall of shaft 132 as can be seen in FIGS. 25-27 . The stent delivery and deployment assembly 130 of FIG. 24 is also comprised of a catheter having inner shaft 132 and outer shaft 135 , a balloon 134 , with its balloon inflation conduit 139 and the balloon terminal cone sections 144 , and a stent 142 . As has been explained above with reference to FIGS. 22 and 23 , stent 142 is crimped to closely conform to the overall profile of the catheter the unexpanded balloon 134 and the underlying inflatable pouches 136 , 138 , 140 . Even with the most careful and firm crimping, there is a certain amount of “recoil” of the stent 142 or a tendency of stent 142 to slightly open from a desired hypothetical minimum diameter. In FIG. 24 , the first 136 and third 140 pouches are inflated to a slightly larger size than the second pouch 138 . As discussed above, the inflation of the pouches 136 , 138 , 140 to this configuration is generally sufficient to compensate for any slack or looseness between the crimped stent 142 and the overall profile of the catheter, the unexpanded balloon 134 and the underlying inflatable pouches 136 , 138 , 140 due to recoil crimping. Once pouches 136 , 138 140 have been inflated to the configuration shown in FIG. 24 , stent 142 is firmly secured against axial movement with regard to assembly 130 . The distal 146 and proximal 148 ends of stent 142 are protected from any possible unwanted contact with vessel walls during maneuvering, which helps to protect the vessel walls from abrasion and also helps to protect the ends 146 , 148 of stent 142 from distortion. Additionally, stent 142 may be of a length such that it fits over pouch 140 and pouch 136 as well as over pouch 138 .
The method of using the stent delivery and deployment assembly 110 of this invention, as shown in FIGS. 22 and 23 , is described as follows. The assembly 110 is constructed as described above. Stent 118 is compressed or crimped onto balloon 114 , inflatable tube component 116 and the catheter to a delivery diameter D 1 . This crimping can be done manually or with the aid of tooling specially designed for the purpose either by the physician or the manufacturer. In the crimped position, stent we closely conforms to the overall profile of balloon 114 , inflatable tube component 116 and the catheter except for the slight slack or looseness due to recoil crimping. Tube component 116 is fluid inflated to the extent necessary to compensate for this slack or looseness due to recoil crimping. The pressure of force required to inflate tube component 116 to this extent is also referred to as securement pressure, i.e., the force or pressure needed to secure stent 118 in this position. It is to be noted that, since tube component 116 is designed and constructed to be capable of fully expanding to no more than the size necessary to compensate for recoil crimping, there is no possibility of stent 118 expanding or beginning to open to a larger diameter. Thus, there is no hazard of stent 118 moving out of its position on the catheter during delivery or of becoming separated from the catheter within a body vessel. The catheter distal end is delivered by standard techniques to the deployment site within the body vessel of interest. At this point, stent 118 is positioned as required by the physician and balloon 114 is fluid inflated by standard technique to expand stent 121 to its deployment diameter D 2 . During this expansion, stent 118 is expanded to fill the body vessel. Following deployment of stent 118 , balloon 114 and optionally, tube component 116 are deflated and the assembly 110 is retracted proximally and withdrawn from the body. If required by the procedure, the site of entry to the body is appropriately closed.
The method of using the stent delivery and deployment assembly 130 of this invention, as shown in FIG. 24 , is similarly described. The assembly 130 is constructed as described above. Stent 142 is compressed or crimped to closely conform to the overall profile of balloon 134 , inflatable pouches 136 , 138 , 140 and the catheter except for the slight slack or looseness due to recoil crimping. Pouches 136 , 138 , 140 are each fluid inflated to the profile shown in FIG. 24 through separate fluid inflation conduits (not shown) to securement pressure to compensate for this slack or looseness and to secure stent 142 in this position. The overall configuration of pouches 136 , 138 140 further serves to position stent 142 against axial dislocation during delivery. The catheter is delivered by standard techniques to the deployment site within the body vessel of interest. At this point, stent 142 is positioned as required by the physician and balloon 134 is fluid inflated by standard technique to expand and deploy stent 142 . Following deployment of stent 142 , balloon 134 and, optionally, pouches 136 , 138 140 are deflated and the assembly 130 is retracted proximally and withdrawn from the body. If required by the procedure, the site of entry to the body is appropriately closed.
The inflation tube component provided by this invention maximizes stent securement force by optimizing the frictional force between the inflating tube component, the balloon wall and the internal diameter of the stent in its reduced crimped delivery diameter. The inflation tube component is more flexible than a solid sheath under the expandable balloon, and thus the entire assembly has greater flexibility. This invention has particular advantages for assemblies in which the stent is provided for use as pre-crimped to the balloon and underlying catheter, by increasing the shelf life of the pre-crimped assembly. The features and principles described for this invention are suitable for use with fixed wire, over-the-wire and single operator exchange assemblies.
FIGS. 28-37 disclose still further embodiments of the securement device. FIGS. 28 and 29 illustrate a side profile section showing an inflation expandable stent delivery and deployment assembly, generally designated 210 . Assembly 210 includes a catheter comprised of inner shaft 212 and outer shaft 213 of the coaxial type and an optional retractable delivery shaft 211 (typically called a guide catheter, shown refracted in FIG. 29 , an inflation expandable balloon 214 , a corrugated/ribbed stent securement device 216 , optional marker bands 217 and an inflation expandable stent 218 . Any conventional type of catheter may be used, such as a catheter of the type generally used for PTA or PTCA angioplasty procedures, for prostate therapy, and TTS endoscopic catheters for gastrointestinal use. However, coaxial types as show are most preferred. The particular catheters 212 and 213 shown are formed of a biocompatible and hydrophilic compatible material, such as a lubricous polyimide or poly ethylene. Other suitable materials for the catheters 212 and 213 include nylons, urethanes, and polypropylene materials compatible with coatings such as silicone and/or hydrophilic coatings. In addition to hydrophilic compatible materials, any biocompatible material may be used. For example, polyethylene or polypropylene can be coated with a hydrophilic material to render them hydrophilic compatible. Suitable catheters for use according to the present invention include a number of catheters available from SciMed Life Systems, Inc., Maple Grove, Minn., the assignee of the present invention, such as BANDIT™, COBRA™, VIVA™, VIVA PRIMOT™, MAXXUM™, MAXXUM ENERGY™ and RANGER™ catheters.
Securement device 216 is fixed at its distal and/or proximal ends to inner shaft 212 at a position to be encompassed within the distal and proximal ends of the outer balloon 214 . According to art-recognized convention, the length L-B of the balloon 214 is defined as the length of the body portion of the balloon 214 , excluding the terminal cone sections 220 . As seen in FIG. 29 , the body portion of the balloon 214 is generally cylindrical when in its deployed or inflated condition. Securement device/tube component 216 is illustrated as having terminal sections 221 , 222 . It is to be understood that, according to the present invention, either of the terminal sections 220 , 222 may be relatively cone shaped, relatively vertical, relatively flat or of any other configuration known to those of skill in this art. A preferred length L-T of the tubing 216 is illustrated in FIGS. 28 and 29 as substantially equal to the length L-B of balloon 214 , and substantially equal to the length L-S of stent 218 . However, according to the present invention, stent 218 should be supported by the underlying tube component 216 for a length sufficient to permit accomplishment of the stated purpose of the tube component 216 , to provide a superior securement and protective surface for stent 218 to maintain stent 218 in position with assembly 210 and to protect the balloon material during loading/crimping. It is also within the present invention for the tube component 216 to be slightly shorter than stent 218 , for example, the distal end 219 of stent 218 may extend distally beyond the distal end 222 of tube component 216 (not shown), so that the distal end 219 of stent 218 can be crimped over the distal end 222 of tube component 216 to prevent the distal end 219 of stent 218 from catching and tending to snag or further open as it is maneuvered within a body vessel. As has been explained above, tube component 216 is designed and constricted to have enough flexibility and have enough volume to no more than is necessary to compensate for recoil crimping of stent 218 and to closely accommodate (or even slightly over stress) the delivery diameter of stent 218 , taking into consideration the thickness of the intervening uninflated balloon 214 . Typically, the tube component 216 will have a consistent frequency of ribs, but may also vary by having intermittent groups of ribs along the tubing.
The balloon and the crimped stent slightly conform to the undulations of the tube component for greater securement, but this conformation is not illustrated.
Tube component 216 may be formed from a thermoplastic material, preferably a low modulus polymer, such as Surlyn™, Pebax and urethane. The device such as polypropylene, low density polyethylene (LDPE), high density polyethylene (HDPE), ethylene vinyl acetate (EVA), nylon, polyester and polyethylene terephthalate (“PET”), may be prepared through free blowing in a mold or inside a coil. Tubing is extruded with relatively thin walls and then free-blown in a mold, coil or other fixture to form the ribs/corrugation.
A balloon 214 for use according to the present invention may be any conventional balloon for catheter delivery, such as a balloon of the type generally used for PTA and PTCA procedures. Typically, balloon 214 is fixed at its distal end to inner shaft 212 near the catheter distal end and at its proximal end to inner shaft 212 , near the distal end of the outer shaft 213 . Balloon 214 . is inflatable through an inflation conduit 223 , i.e., the space between coaxial inner shaft 213 and outer shaft 213 of the catheter. The distal and proximal ends of balloon 214 are shown in FIGS. 28 and 29 positioned exterior to the distal and proximal ends of tube component 216 , respectively, and of a length L-B generally equal to the length L-T of the tube component 216 . To be compatible with the tube component 216 illustrated in FIGS. 28 and 29 and described above, balloon 214 is inflatable at deployment to about the diameter of the body vessel in which the stent 218 is to be deployed. Balloon 214 may be formed of a compliant or non-compliant material, such as polyethylene or any standard balloon material. Compliant materials include low pressure, relatively soft or flexible polymeric materials, such as thermoplastic polymers, thermoplastic elastomers, polyethylene (high density, low density, intermediate density, linear low density), various co-polymers and blends of polyethylene, ionomers, polyesters, polyurethanes, polycarbonates, polyamides, poly-vinyl chloride, acrylonitrile-butadiene-styrene copolymers, polyether-polyester, copolymers, and polyetherpolyamide copolymers. Suitable materials include a copolymer polyolefin material available from E.I. DuPont de Nemours and Co. (Wilmington, Del.), under the trade name Surlyn™ Ionomer and a polyether block amide available under the trade name PEBAX™. Non-compliant materials include relatively rigid stiff high pressure polymeric materials, such as thermoplastic polymers and thermoset polymeric materials, poly(ethylene terephthalate) (commonly referred to as PET), polyimide, thermoplastic polyimide, polyamides, polyesters, polycarbonates, polyphenylene sulfides, polypropylene and rigid polyurethanes, or combinations thereof. The balloon 214 typically has a wall thickness of about 0.0007-0.004 inch for example.
A stent for use according to the present invention may be any conventional type of balloon expandable stent, including stents of the type used for PTA and PTCA angioplasty procedures, for prostate therapy, and TTS endoscopic catheters for gastrointestinal use. Suitable stent material is biocompatible stainless steel in the form of sheet metal, tube component wire or Nitinol. A preferred stent is described in PCT Application No. 960 3072 A1, published 8 Feb. 1996, the content of which is incorporated herein by reference. All such stents are well known in this art generally and additional examples are described in U.S. Pat. No. 5,507,768 to Lau et al; in U.S. Pat. No. 5,458,615 to Klemm et al; in U.S. Pat. No. 5,226,899 to Sheiban; in U.S. Pat. No. 4,875,480 to Imbert; in U.S. Pat. No. 4,848,343 to Wallsten et al; and in U.S. Pat. No. 4,733,665 to Palmaz. Stent 218 as shown in FIGS. 28 and 29 is positioned on balloon 214 , which is over the underlying tube component 216 , at the distal end of the catheter. The length L-S of stent 218 is shown as essentially equal or slightly smaller than the length L-T of tube component 216 and is positioned on assembly 210 to be coextensive with tube component 216 . In this position, stent 218 is shown in FIG. 28 crimped to its delivery diameter D 1 , which is about 0.035-0.45 inch for example.
As discussed above, despite the most careful and firm crimping of stent 218 to closely conform to the overall profile of the catheter unexpanded balloon 214 and underlying tube component 216 , there is a certain amount of “recoil” of stent 218 or a tendency of stent 218 to slightly open from a desired hypothetical minimum crimped diameter. The actual minimum diameter achievable for fully crimped stent 218 on assembly 210 is referred to as stent 218 delivery diameter D 1 . This tendency of stent 218 to open or recoil slightly when crimped on assembly 210 has been characterized as “recoil crimping”. In FIG. 28 , tube component 216 is shown inflated to a diameter which is generally sufficient to compensate for any slack or looseness between crimped stent 218 and the overall profile of the catheter, the unexpanded balloon 214 and the underlying tube component 216 due to recoil crimping.
FIG. 29 illustrates a side profile section showing a stent delivery and deployment assembly 210 of this invention with balloon 214 fluid inflated to its fully expanded position. As a result of the fluid inflation of the balloon 214 , stent 218 has also been fully expanded to its deployment diameter D 2 in which it can be deployed against the walls of a body vessel in which it is situated.
FIG. 30 illustrates the preferred configuration of the tube component 216 . The tube component has a plurality of ribs 230 and is configured in a corrugated or accordion fashion. The ends of the tube component 216 , 222 and 221 , are substantially rib-free so as to provide a flat surface to receive an adhesive and thereby bond to the inner shaft 212 . Preferable adhesives include cyanoacrylates such as Loctite 4061/4011 or urethanes, such as H.B. Fuller 3507/3506. The tube component may also be heat bonded to the inner shaft. The ribs may vary in frequency and spacing.
Tube component 216 may have different configurations in other embodiments, as shown in FIGS. 31-33 . The tube component 216 may be comprised of more than one piece of corrugated tubing ( FIG. 31 ), a smaller single piece ( FIG. 32 ) or one single piece of tubing sectioned into a plurality of ribbed sections, wherein the tubing is adhered to the inner shaft 212 in more than two locations ( FIG. 33 ).
FIG. 31 shows two pieces of tubing component 216 a , 216 b . Both pieces are adhered to inner shaft 212 at adhesion points 232 . FIG. 32 discloses an embodiment which comprises one smaller piece of tube component 216 which is adhered to inner shaft 212 at adhesion points 232 . FIG. 33 discloses an embodiment which comprises one tube component 216 which has interrupted ribbed sections 234 adhered to the inner shaft 212 .
FIGS. 34 and 35 illustrate an alternative embodiment in which the tubing component is inflatable to increase the securement pressure on the inside of balloon 214 when the stent is crimped onto the balloon so as to negate additional recoiling. The full expansion of the tube component 216 should only be slightly greater than the diameter of the inside of the balloon 214 when the stent 218 is fully crimped onto the balloon 214 .
In FIG. 34 , the inflating fluid comes through the guide wire lumen 212 under pressure from the proximal end or the distal end of the guide wire lumen 212 , preferably via a syringe, and fills the tubing component 216 through a one-way valve 247 (preferably resisting up to about 4 atm) in the inner catheter 212 .
In FIG. 35 , the tubing component 216 is inflated via an additional lumen 242 which extends from the proximal end of the catheter along the guide wire lumen 240 , much the same as any inflating lumen incorporated to inflate a balloon.
In an alternative embodiment, as shown in FIG. 36 , socks or sleeves 251 may be incorporated to stretch over the ends of the stent to prevent snagging and to secure the stent onto the balloon. Such sleeves are demonstrated in U.S. application Ser. No. 08/702,149, filed Aug. 23, 1996, and Ser. No. 08/701,979, filed Aug. 23, 1996, which are incorporated in their entirety herein by reference.
In still another embodiment, as shown in FIG. 37 , the tubing component 216 is slidable axially along the inner shaft 212 and is connected to a retracting wire 250 such that the tubing component may be retracted into the outer shaft 213 after the balloon has been inflated to reduce the profile of the balloon 214 when the catheter is removed. The tubing component, since it is not adhered to the inner shaft 212 in this embodiment, should fit tightly enough on the inner shaft to stay in place, but not too tightly so that it may be retracted by pulling on the retracting wire 250 .
The method of using the stent delivery and deployment assembly 210 of this invention, as shown in FIGS. 1 and 2 , is described as follows. The assembly 210 is constructed as described above. Stent 218 is compressed or crimped onto balloon 214 , tube component 216 and the catheter to a delivery diameter D 1 . This crimping can be done manually or with the aid of tooling specifically designed for the purpose either by the physician or the manufacturer. In the crimped position, stent 218 closely conforms to the overall profile of balloon 214 , tube component 216 and the catheter except for the slight slack or looseness due to recoil crimping. Tube component 216 is flexible enough to slightly collapse during crimping and rebound to the extent necessary to compensate for the slack or looseness due to recoil crimping, thus securing the stent. As a result, the stent does not move out of its position on the catheter during delivery or become separated from the catheter within a body vessel. The catheter distal end is delivered by standard techniques to the deployment site within the body vessel of interest. At this point, stent 218 is positioned as required by the physician and balloon 214 is fluid inflated by standard technique to expand stent 218 to its deployment diameter D 2 . During this expansion, stent 218 is expanded to fill the body vessel. Following deployment of stent 218 , balloon 214 is deflated and the assembly is retracted proximally and withdrawn from the body. If required by the procedure, the site of entry to the body is appropriately closed.
The tube component provided by this invention increases stent securement force by increasing the frictional force between the tube component, the balloon wall and the internal diameter of the stent in its reduced crimped delivery diameter. The tube component is more flexible than a solid sheath under the expandable balloon, and thus the entire assembly has greater flexibility. This invention has particular advantages for assemblies in which the stent is provided for use as pre-crimped to the balloon and underlying catheter, by increasing the shelf life of the pre-crimped assembly. The tube component also protects the balloon material during crimping by acting as a buffer between the balloon material and whatever may be mounted on the inner shaft, such as marker bands 217 . The features and principles described for this invention are suitable for use with fixed wire, over-the-wire and single operator exchange assemblies.
FIGS. 38-46 disclose alternative embodiments of the securement device. FIG. 38 shows a stent delivery and deployment assembly generally designated 310 . A catheter 312 has a collar 314 coaxially mounted at the catheter distal end portion 316 . An uninflated balloon 318 is coaxially mounted on catheter 312 over collar 314 . An unexpanded stent 320 is coaxially mounted on the balloon 318 abutting but not overlying collar 314 . A cup 322 coaxially overlies the stent proximal end portion 324 . Cup 322 may be elastomeric or rigid, preferably elastomeric. Cup 322 is over-expanded over the stent 320 , so that recoil of the cup 322 is sufficient to secure stent 320 in place and prevent it from being pulled off of the assembly 310 distally or proximally as assembly 310 is delivered to a deployment site in a body vessel. Cup 322 also protects the proximal end of stent 324 from inadvertently catching on anatomical structures or other things during maneuvering within the body or during loading and other handling. The ends of the stent may axially protrude and should be protected during maneuvering of stent 320 to keep stent 18 on assembly 310 in its contracted configuration and to maintain the structural integrity of stent 320 . Collar 314 abuts the stent distal end 326 without underlying stent 320 . The position of cup 322 overlying stent 320 and containing stent 320 against collar 314 increases the securement force maintaining stent 320 in its axial and radial position on catheter 12 . FIG. 40 is similar to FIG. 38 , showing a bulge 28 beneath the uninflated balloon 318 at catheter distal end 316 .
Any of the various types of known stents may be used in the delivery system of this invention, even self-expanding stents which are partly balloon-expandable may be used, the balloon initiating release of the stent and/or finally seating the stent after self-expansion. However, ordinary balloon expandable stents are preferred and aforenoted.
FIG. 39 shows another stent delivery and deployment assembly generally designated 330 . A catheter 332 has a collar coaxially mounted as a mounting ring 334 on the catheter. An uninflated balloon 338 is coaxially mounted on catheter 332 over mounting ring 334 . An unexpanded stent 340 is coaxially mounted on balloon 338 overlying the mounting ring 34 . A cup 342 overlies the stent proximal end portion 344 to secure the stent 340 in place and prevent it from being pulled off of assembly 330 distally or proximally, as assembly 330 is delivered to a deployment site in a body vessel. Cup 342 also protects the proximal end of stent 40 from inadvertently catching on anatomical structures during maneuvering within the body. The position of cup 342 overlying stent 340 together with the closer positioning of mounting ring 334 as compared to FIG. 38 increases the securement force maintaining stent 340 in its axial and radial position on catheter 332 . The closer the mounting ring 334 is positioned to cup 342 the more securely the stent is held in place and interlocked between this cup and ring. When used in conjunction with mounting ring 334 , cup 342 will also prevent the stent proximal segment 344 from opening up, i.e., increasing its diameter, and will keep the stent 340 locked onto the mounting ring 334 . This will prevent stent 340 from moving on the catheter distally as well as proximally. This cup does not have to be an elastomer, but may be sufficiently rigid to prevent the stent 340 from expanding.
Cups 322 , 342 of FIGS. 38-40 release stents 320 , 340 when balloons 318 , 338 are inflated during deployment. Cups 322 , 342 can, for example, flare radially outward as illustrated with reference to FIG. 41 , roll axially away from stents 320 , 340 as illustrated with reference to FIG. 42 , or slide axially away from stents 320 , 340 as illustrated with reference to FIGS. 43 and 44 . Also, the cups may be formed with axial areas of weakness which split on balloon inflation, as described in the aforenoted Savin patent.
FIG. 41 shows an assembly generally designated 310 as shown in FIGS. 38 and 36 with balloon 318 inflated and stent 320 expanded, showing the cup 322 end portion flared to release stent 320 . As noted above, cup 322 may be elastomeric or rigid. The dimension L is short enough and the material of cup 322 is sufficiently elastic so that cup 322 flares out and is no longer in contact with stent 320 when balloon 318 is inflated and the stent 320 expanded for deployment.
FIG. 42 shows an assembly generally designated 310 , as shown in FIGS. 38 and 36 , with balloon 318 inflated and stent 320 expanded, showing cup 322 end portion rolled proximally to release the stent 320 . As noted above, the cup 322 may be elastomeric to facilitate rolling. The cup may also accordion or bunch up on itself to release the stent.
FIGS. 43 and 44 show yet another stent delivery and deployment assembly generally designated 350 . The catheter 352 has a coaxial collar 354 formed integrally with catheter 352 at the catheter distal end 356 . A balloon 358 is coaxially mounted on catheter 352 , overlying collar 354 . In FIG. 43 , balloon 358 is coaxially mounted on catheter 352 , overlying collar 354 . In FIG. 43 , balloon 358 is shown as uninflated, with an unexpanded stent 360 mounted on balloon 358 abutting collar 354 , and a cylindrical cup in the form of sleeve 362 overlying the stent proximal end portion 364 . FIG. 44 shows the assembly 350 of FIG. 43 with balloon 358 inflated and stent 360 released and expanded. Sleeve 362 is designed, constructed and adapted so that, as balloon 358 and stent 360 are enlarged, the sleeve portion 366 gathers or moves proximally to release stent 360 . The increasing angle of the balloon 358 cone (the tapered end sections of balloon 358 ) during inflation push sleeve 362 axially away from stent 360 . This can be done by shaping sleeve 362 with preformed accordion pleats 368 . Sleeve 362 may also be formed so that the portion detaining (that is, abutting or overlying) stent 360 is of thicker or more rigid material than the portion of sleeve 362 axially distant from stent 360 . Materials which may be used to provide the foregoing function are silicones, urethanes and the like as well as other elastomers, for example. A rigid sleeve carried on the catheter for sliding movement may also be used. Sleeves may be included at the proximal and distal end of the stent.
FIG. 45 shows still another stent delivery and deployment assembly generally designated 370 . A catheter 372 has two collars 374 formed integrally with catheter 372 and spaced from each other on the catheter distal end portion. A balloon 378 is coaxially mounted on the catheter 372 , overlying the collars 374 . The balloon 378 is shown as uninflated with an unexpanded stent 380 mounted on balloon 378 abutting both of the collars 374 . It can be seen that the distance between the collars 374 is to be chosen to closely accommodate stent 380 in its fully contracted position about the balloon 378 and underlying catheter 372 . A cup 382 overlies the stent proximal end portion 384 and the underlying proximal collar 374 . Cup 382 will deploy during balloon 378 inflation in the manner described above with reference to FIGS. 41-44 .
FIG. 46 shows even another stent delivery and deployment assembly generally designated 390 . The uninflated balloon 398 is shown coaxially mounted on a catheter 392 at the catheter distal end portion. An unexpanded stent 400 is coaxially mounted on balloon 398 . A pair of cups 402 overlap the ends of the stent 400 ends. A mounting cylinder 404 is carried by the catheter shaft 392 .
The Figure also illustrates cups at both ends of the stent, an arrangement which may be used in all the foregoing embodiments.
The cups or sleeves used in the various embodiments of this invention can be of elastomeric or rigid material to contain one or both ends of the stent. In preferred embodiments of this invention the cups are used in conjunction with one or more stent collars positioned under the balloon. The collar may be formed as a ring, to abut the end of the stent, to lie under the stent and the intervening balloon, or as a cylinder, to lie under essentially the entire length of the stent and the intervening balloon. The stent detainment according to the present invention offers increased stent securement, particularly on pre-mounted delivery systems. The cups and sleeves illustrated in the various embodiments of this invention can be secured to the catheter, as by adhesive or thermal bonding, or they may be sliding cups or sleeves. When the cups are freely sliding on the catheter, they should always be used directly over a collar so that there is a friction fit between the cup and the stent.
A method for delivering and deploying a stent using an assembly according to the present invention is described as follows: A catheter is provided as described above with reference to any of FIGS. 38-40 , 43 and 45 . At least one collar is coaxially mounted at the catheter distal end. As discussed above, the collar may be a separate element affixed to the catheter or the collar and catheter may be formed together as a single element. The collar may be positioned abutting an end of the stent. The collar may be a mounting ring, may be positioned under the stent or underlying the balloon. The collar may be a cylinder essentially coextensive in length with the stent and underlying the balloon. A fluid expandable balloon is coaxially mounted over the collar on the catheter distal end. A stent is provided which is inflation expandable from a reduced to an enlarged condition. The stent, in its reduced condition, is coaxially mounted on the balloon so that at least an end portion of the stent overlies the balloon. A cup is provided which has first and second end portions. The cup is in an expanded form and also has a retracted form. The expanded cup is coaxially mounted on the catheter at the distal end portion so that the cup first end portion detains the stent end portion. The cup first end portion detains the stent end portion by overlying the stent end portion, or by closely accommodating the stent against the collar without overlying the stent end portion. The cup is then contracted about the catheter and the stent end portion to fix the stent to the catheter. The cup and collar cooperate to retain the stent on the catheter in its reduced condition. The assembly is then maneuvered by the physician through a body vessel by methods known per se to reach a pre-selected deployment site. The surgeon can determine when the assembly has reached the deployment site by means which are themselves known per se. For example, the assembly may be provided with radiopaque marking bands at either end of the stent, or the cups or the collars or both may be made of radiopaque material. Once the surgeon determines that the stent has been correctly positioned at the desired site, the balloon is inflated to expand the stent to its enlarged condition. Inflation of the balloon expands the stent and the stent is released from the cup or cups. As has been discussed above, the cups may deploy to release the stent in a number of ways, dependent on the construction and materials of the cup or cups. The cup may flare or enlarge radially following the increasing angle of the balloon cones. The cup may roll axially away from the stent. The portion of the cup axially distant from the stent may accordion back on itself. The cup may slide axially. The cup may accordion or buckle. If the cup is not fixed to the catheter, but is freely slidable on the catheter, the cup may slide axially away from the stent. After deployment of the stent, the balloon, according to previously known procedures, is deflated and the assembly is withdrawn proximally from the body vessel. Any incision made to allow access from the assembly is appropriately closed.
FIGS. 47-56 illustrated alternative embodiments of securement devices. Referring to FIGS. 47 and 48 a stent delivery system generally indicated at 410 includes a balloon catheter 412 having a balloon 414 on a distal end portion generally indicated at 416 . FIG. 47 shows a proximal portion of the catheter at 412 a and a distal portion 412 b in enlarged view. FIG. 48 shows the distal end portion 416 in an even more enlarged view. The illustrative catheter 412 is of the type known as an over the wire catheter. However, other types of catheters may be used, such as rapid exchange/single operator exchange and fixed wire types. The balloon 414 is fixed to the catheter 412 by standard means. The balloon is shown in its contracted state in FIGS. 47 and 48 . A stent 418 is fixed about the balloon by crimping it thereto. The stent has a larger expanded diameter which is obtained when the balloon is expanded in the known manner. That is, the stent is released from the catheter upon expansion of the balloon when placed in a vessel. When the balloon is then deflated, removal of the balloon and catheter may be accomplished while leaving the stent in place.
As is known in the art the balloon is either bonded at its ends by adhesive 420 and 422 , respectively to the outer member 424 of the catheter and to the inner member 426 of the catheter in the manner as shown, or is made one-piece with the outer member as is known in the art. The catheter balloon may be inflated by fluid (gas or liquid) from an inflation port extending from a lumen 428 contained in the catheter shaft and opening into the balloon as shown, or by other known arrangements, depending on the design of the catheter. The details and mechanics of balloon inflation and specific overall catheter construction will vary according to the particular design involved in any given instance, and are known in the art per se. All variations are acceptable for use with this invention.
Any balloon expandable stent may be used with this invention. Many are known in the art including plastic and metal stents. Some are more well known such as the stainless steel stent shown in U.S. Pat. No. 4,735,665; the wire stent shown in U.S. Pat. No. 4,950,227; another metal stent shown in European Patent Application No. EPO 707 837 A1 and that shown in U.S. Pat. No. 5,445,646. All of these patents are incorporated herein by reference. Also, shape memory metal stents may be used. As already indicated the stent of PCT Application 960 3092 A1 is particularly preferred.
The stent is typically about 16 mm long, while the balloon may be 20 mm long. These dimensions, however, are merely representative for illustrative purposes only and are not meant to be limiting. The stent is positioned over the balloon portion of the dilatation catheter and gently crimped onto the balloon either by hand or with a tool such as a pliers or the like to be mounted for delivery as shown in FIGS. 47 and 48 . The crimping may be accomplished by either the manufacturer or the physician.
In accordance with one embodiment of this invention, a mounting bodies 430 , seen in FIGS. 47 and 48 are included inside balloon 414 to provide a cushion and/or substrate of enlarged diameter relative to the shaft to support and hold the stent and secure it during crimping and the delivery procedure. The mounting bodies are preferably located in the body portion of the balloon.
In the embodiment shown, mounting bodies 430 are ring-like in form and are mounted on inner lumen 426 , providing an enlarged area or portion for receiving the balloon and stent when the latter is crimped. Marker bands 432 and 434 may also be included on inner 426 as shown. Any radiopaque material such as gold is useful for this purpose. Although, the material of the mounting bodies may be hard, it is preferably of any thermoplastic elastomer having elastic or deformable properties, more preferably of a relatively resilient elastomer material, e.g., silicone, preferably a lower durometer silicone, or polyurethane, such as Tecothane 1055D. A deformable thermoplastic material such as high density polyethylene (HDPE) may be used. Any deformation of resilient material of the mounting body when the stent/balloon is crimped to it causes a radial outward force on the stent/balloon increasing the friction therebetween despite a recoil of the stent.
The stent is also fixed in position by two overlying retaining sleeves 436 and 438 . Sleeves 436 and 438 are formed of polyurethane, preferably Tecothane 1055D, and are axially fixed on catheter 412 by adhesive plugs 440 and 442 of urethane adhesive. The plugs of adhesive may be tapered to the catheter as shown to facilitate movement of the catheter in a vessel. The sleeves overlap the marginal end portions of stent 418 as shown.
A lubricating solution such as silicone fluid may be used between balloon 414 and sleeves 436 and 438 and thereon to facilitate release of stent 418 from the sleeves.
During delivery, the balloon catheter is advanced through and positioned in a patient's vasculature so that the stent is adjacent to the portion of the vessel where treatment is to take place. The balloon is inflated to expand the stent to an enlarged diameter. At this time, expansion of the balloon causes the end margin of the sleeves to slide axially from over the stent thereby releasing the ends of the stent from the catheter. Various forms of retraction of sleeves 436 and 438 are shown in FIGS. 49-52 . These figures illustrate the configuration of the sleeves 436 and 438 in their retracted state after the balloon 414 has been fully expanded. Only the distal sleeve 438 is shown. FIG. 49 illustrates the preferably refraction configuration. To promote easier retraction sleeves are coated with silicone. The sleeves are preferably adhered to the outer shaft 424 and the inner shaft 426 at point 440 , 442 , but may be adhered further up the waste 441 of the balloon. The refraction configurations may be controlled by either pre-creasing the sleeves or adhering the sleeve to a point further up on the waist of the balloon. The sleeves have a tendency of folding at a pre-fold crease or at the point of adherence. A preferred cone angle of 45.degree, for the balloon is shown in FIG. 52 , which shows an expanded balloon 414 and retracted sleeves 436 , 438 . When the stent has reached the desired diameter, the balloon is deflated so that the catheter may be removed leaving the stent in place.
A modified 439 sleeve configuration is shown in FIG. 53 in stepped form 43 having a large diameter at 444 in one section 446 and a small diameter 445 in a second section 450 .
FIGS. 54-56 show alternative embodiments of the invention. Specifically, alternative positioning and number of mounting bodies 430 . These figures show an unexpanded balloon having the mounted bodies 430 within the balloon. They are meant to illustrate essentially the same structure as shown in FIG. 448 differing only in the number and positioning of the mounted bodies 430 . In the embodiment shown in FIG. 54 , the ring-like mounting body 430 is singular. Another similar version is shown in FIG. 55 which includes three ring-like mounting bodies 430 . The embodiment shown in FIG. 56 includes four ring-like mounting bodies 430 .
It should be understood that the various elements and materials of all embodiments could be utilized in each of the other embodiments, if desired.
The above Examples and disclosure are intended to be illustrative and not exhaustive. These examples and description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the attached claims. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims attached hereto. | Medical devices and methods for making and using medical devices are disclosed. An example medical device may include an elongate shaft including a first tubular member and a second tubular member. A balloon may be coupled to the shaft. A first member may be coupled to the first tubular member and positioned within the balloon. A second member may be coupled to the first tubular member and positioned within the balloon. A medical implant may be coupled to the shaft and positioned adjacent to the balloon. | 0 |
TECHNICAL FIELD
[0001] This invention relates to blood pressure measurements, and more particularly to a blood pressure cuff that may be easily installed around the arm and released.
BACKGROUND OF THE INVENTION
[0002] Hypertension in adults is regarded as a significant health risk since the symptoms of the disease are not apparent to the individual. The presence of the disease in the individual may therefore remain hidden until a catastrophic health event, such as a heart attack, or a stroke occurs. Fortunately, initial diagnosis of the condition is easily accomplished by a simple blood pressure measurement. Consequently, automatic blood pressure monitoring stations have become widely available to the general public that allow blood pressure measurements to be self-administered. An example of one such system is the VITA-STAT™ blood pressure monitoring station manufactured by Spacelabs Medical, Inc. of Redmond, Wash., which is shown in U.S. Pat. No. D-371,844 to Sadritabrizi, et al. Briefly, the VITA-STAT™ station consists of a kiosk, in which a test subject can be accommodated in a sitting position. The test subject then places an upper arm into a blood pressure cuff apparatus that constricts the flow of blood in an artery to obtain blood pressure measurements at systole and diastole. A processor accepts and processes blood pressure signals obtained from the cuff apparatus during the examination, and subsequently displays the processed information to the test subject on a monitoring device.
[0003] A significant difficulty encountered in self-administered blood pressure measurements is the application of the blood pressure cuff to the test subject. The flat, flexible cuff commonly associated with the sphygmomanometer is particularly unsuited for use in automatic blood pressure monitoring stations, since the application of the flexible cuff around the arm of the test subject is difficult to accomplish without assistance. Moreover, once properly positioned, it must be secured into place by hooks, elastic bands, or specialized fasteners such as VELCRO™. As a consequence, a number of automatic cuff devices have been developed for use with automatic blood pressure monitoring stations. An example of a self-installing cuff apparatus is described in U.S. Pat. No. 4,109,646 to Keller, which uses a motor-driven rotating drum to continuously wrap a blood pressure band onto a limb of a test subject that is placed within the drum. Removal of the blood pressure band from the test subject is accomplished by reversing the motor. A similar technique is described in U.S. Pat. No. 4,206,765 to Huber, which uses a motor driven tensioning drum to tension the blood pressure band around the limb of a test subject. A slip clutch is provided to prevent over tensioning of the blood pressure band during the application of the band to the test subject. U.S. Pat. No. 3,935,984 to Lichowsky, et al., uses a mechanical cable wrapped around the blood pressure band to snug the band tightly about the arm of the test subject. Release of the test subject's arm is similarly accomplished by reversing the direction of the motor.
[0004] A significant shortcoming of these prior art devices is that they rely on a blood pressure band tensioning means that requires a blood pressure band tensioning drive motor and mechanism, which adds to the cost and complexity of the blood pressure monitoring station. Further, since the tensioning means is motor driven, some means must be provided to allow the test subject to release the blood pressure cuff in the event of a power failure, or to protect the test subject from over-tensioning the band due to system malfunctions. The release mechanisms employed in prior art devices have not, in general, adequately addressed these abnormal operating conditions. Additionally, a particular shortcoming present in the prior art devices is that there is no provision for a release mechanism that allows the band tension and the pneumatic pressure in the band to be released simultaneously through a user actuated release.
[0005] The self-installing cuff used with the VITA-STAT™ blood pressure monitoring station mentioned previously does not rely on a motor driven tensioning means to snug the blood pressure band about the arm. Instead, the arm is tightly confined within a fixedly mounted cylindrical housing that retains the inflatable blood pressure band. The use of a cylindrical, non-resilient member to retain the inflatable band also has some drawbacks. A limit on the maximum cylinder diameter exists because the blood pressure band must achieve adequate snugness prior to inflation. Since the cylinder diameter is generally sized according to median estimates of upper arm diameter, some individuals may find that the cylindrical cuff apparatus simply cannot accommodate them. In other cases, some individuals may damage the flexible blood pressure band inside the cylinder by unsuccessfully attempting to insert their upper arms into the cylinder, which may render the blood pressure cuff apparatus unusable, or cause it to yield inaccurate measurements. Still other individuals may misalign the upper arm with the cylindrical housing so that a successful inflation of the blood pressure band is impeded, resulting in an erroneous blood pressure reading. Finally, some individuals may find the insertion of the arm into a closed cylindrical member that subjects the arm to a constriction too psychologically intimidating to use.
[0006] A further drawback present in all prior art cuff devices is that they lack an ergonomic adjustment feature. Typically, automatic blood pressure devices, such as the VITA-STAT™ blood pressure monitoring station, accommodate the test subject in a seated position while undergoing a blood pressure test. Since the orientation of the cuff assembly cannot be adjusted, the test subject must make suitable adjustments in body position to properly align the arm in the cuff assembly prior to inflation of the internal band, and maintain the arm in the aligned position until the blood pressure evaluation is complete. As a consequence, individuals whose bodily dimensions significantly differ from median estimates cannot be accommodated by the blood pressure cuff in a comfortable manner.
[0007] Accordingly, there is a need in the art for a cuff assembly that does not use a motor driven band tensioning devices to tension the band prior to inflation, and that provides a cuff release capability to a greater degree than present in prior art devices. Further, there is also a need in the art for a cuff apparatus that does not rely on a confining cylindrical member to retain the inflatable band. Finally, the cuff assembly should provide an ergonomic adjustment capability that will permit the proper alignment of the blood pressure cuff with the arm to be conveniently attained during a blood pressure measurement, which, at the same time, enhances the comfort of the test subject.
[0008] Other advantages of the invention will become apparent based upon the description of the invention provided below when read with reference to the drawing figures.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a method and apparatus for obtaining blood pressure measurements employing a user releasable and adjustable blood pressure cuff. In one aspect of the invention, the blood pressure cuff apparatus consists of a first cuff member connected to a mounting surface and rotatable about a first axis of rotation substantially perpendicular to the mounting surface. The first cuff member is connected to a second cuff member that is rotatable about a second axis of rotation that is substantially perpendicular to the first. A blood pressure cuff comprised of a loop adapted to receive the arm of a test subject is connected to the second cuff member. In another aspect of the invention, the elongated flexible band has a first end and a second end. The first end is connected to the second member of the cuff housing, and the second end is connected to a cuff retainer. The cuff retainer is releasibly latchable from the second member so that the elongated flexible band forms a loop to snugly fit the arm of the test subject with a first circumferential length when the cuff retainer is latched. When the cuff retainer is unlatched, the elongated flexible band forms a loop with a second circumferential length, which allows the arm of the test subject to be easily withdrawn.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a frontal isometric view of one embodiment of the user releasable and adjustable automatic cuff apparatus.
[0011] [0011]FIG. 2 is a frontal isometric view the embodiment of the user releasable and adjustable automatic cuff apparatus shown in FIG. 1 with the release mechanism shown in the open position.
[0012] [0012]FIG. 3 is a rear isometric view the embodiment of the user releasable and adjustable automatic cuff apparatus shown in FIG. 1.
[0013] [0013]FIG. 4 is a rear isometric view the embodiment of the user releasable and adjustable automatic cuff apparatus shown in FIG. 1 with the release mechanism shown in the open position and the inner housing removed to show internal details.
[0014] [0014]FIG. 5 is an isometric view of the embodiment of the user releasable and adjustable automatic cuff apparatus in FIG. 1 shown receiving an upper arm for a blood pressure determination.
[0015] [0015]FIG. 6 is a rear isometric view of an alternative embodiment of the user releasable and adjustable automatic cuff apparatus.
[0016] [0016]FIG. 7 is a frontal isometric view of an alternative embodiment of the user releasable and adjustable automatic cuff apparatus.
[0017] In the drawings, like reference numbers identify similar elements or steps. For ease in identifying the discussion of any particular element, the most significant digit in a reference number refers to the Figure number in which the element is first introduced (e.g., element 24 is first introduced and discussed with respect to FIG. 2).
DETAILED DESCRIPTION OF THE INVENTION
[0018] For purposes of the following description, the terms “upper”, “lower”, “front” and “back” and relative terms of similar reference shall refer to the orientation of the invention a shown in FIGS. 1 through 7, except where expressly specified to the contrary. Specific dimensions and other physical characteristics related to different embodiments are not to be considered as limiting unless the claims expressly state otherwise.
[0019] [0019]FIG. 1 illustrates an embodiment of the user releasable and adjustable blood pressure cuff according to the invention. The blood pressure cuff 10 includes an elongated flexible band 11 with inner and outer surface layers. The band 11 also has a plurality of air-impermeable compartments (not shown) between the inner and outer surface layers that can be connected to a pressurization source to allow the band 11 to be inflated prior to a blood pressure measurement. The elongated flexible band 11 is preferably formed of layers of a durable woven fabric such as nylon, and the air impermeable compartments located between the inner and outer layers are preferably retained in position by stitching. Alternatively, other structures could be used to form the band 11 , such as fabricating the band 11 from rubber-impregnated fabrics, or from entirely non-woven resilient materials such as elastomers. The band 11 may also be fabricated as a single structure, with the air impermeable compartments formed within the band.
[0020] Still referring to FIG. 1, the blood pressure cuff 10 further includes an outer housing 13 , and an inner housing 14 that are rotationally connected to allow ergonomic adjustment to the test subject. A swivel plate 15 , which is rotationally connected to the inner housing 14 , provides additional rotational flexibility. The rotational relationship between the outer cuff housing 13 , the inner cuff housing 14 and the swivel plate 15 will subsequently be described in greater detail in connection with other figures. The outer cuff housing 13 is a box like structure having top and bottom sides, and having a back side, which is preferably open. The back side of the outer cuff housing 13 is adapted to receive an inner cuff housing 14 , so that inner cuff housing 14 can be at least partially recessed within the outer cuff housing 13 . The inner cuff housing 14 is similarly a boxlike structure with top and bottom sides, an open front side (not shown) and a back side. When inner cuff housing 14 is recessed within outer cuff housing 13 , an enclosure is formed which contains internal elements of the apparatus, that will be discussed more fully in connection with a subsequent figure.
[0021] With reference now to FIG. 2, a first end of the band 11 is attached to the outer cuff housing 13 by metal retainer strips 23 which are held in place by screws. The other end of the band 11 is similarly attached by metal retainer strips 46 (as best seen in FIG. 4) to the cuff retainer 12 , to form the loop 19 . Although the retainer strips 23 and 46 securely hold the ends of the band to the outer cuff housing 13 and the cuff retainer 12 by clamping means, other means for attaching the band 11 to the outer cuff housing 13 and to the cuff retainer 12 are possible.
[0022] Still referring to FIGS. 1 and 2, the cuff retainer 12 is located on the top side of the outer cuff housing 13 and is held in a position adjoining outer housing 13 by a latching mechanism (not shown). When the cuff retainer 12 is latched to the top side of the outer cuff housing 13 , the loop 19 has a minimum circumferential length so that the band 11 forms a snug fit about the arm of the test subject. As shown in FIG. 2, where the elongated flexible band 11 has been partially cut away, the cuff retainer 12 is free to translate away from the top of the outer cuff housing 13 when the cuff retainer 12 is released. As a result, the circumferential length of the loop 19 increases when the cuff retainer 12 is in the released state, which allows the test subject additional freedom of movement during withdrawal of the limb.
[0023] Referring now to FIGS. 2 and 4, where the cuff retainer 12 is shown in the unlatched state, the cuff retainer is supported by a pair of support rods 22 securely attached to the under side of cuff retainer 12 . The support rods 22 slide through access holes 27 and through linear bearings 40 to restrict the cuff retainer 12 to vertical movement relative to the outer cuff housing 13 . The cuff retainer 12 further includes a release knob 17 , which allows manual release of the cuff retainer 12 from a latched condition when actuated. The release mechanism will be described in more detail in connection with subsequent figures.
[0024] Although the support rods 22 as shown in FIG. 2 are securely attached to the cuff retainer 12 , other support rod configurations are possible. For example, the cuff retainer 12 may be supported by a single support rod, which has a longitudinal surface groove that engages a key in the outer cuff housing 13 to prevent rotation of the cuff retainer 12 relative to the outer cuff housing 13 when the cuff retainer 12 is released. Alternatively, more than two support rods may also be used. Still another configuration may be obtained when the support rods are securely attached to the outer cuff housing, with the cuff retainer 12 sliding along the stationary support rods when the cuff retainer is released.
[0025] Turning now to FIG. 3, the rotational relationship between the outer cuff housing 13 and the inner cuff housing 14 and the swivel plate 15 will now be discussed. With the inner cuff housing 14 recessed into the outer cuff housing 13 , the inner cuff housing 14 and the outer cuff housing 13 are preferably connected by a pair of pivot screws 31 which are inserted through the top and bottom sides of the outer cuff housing 13 to engage threads in adjacent holes in the inner cuff housing 14 . Rotational movement between the outer cuff housing 13 and inner cuff housing 14 about an axis 33 that projects through the centerline of the pivot screws 31 is thus attained. Since the rotational axis 33 is shown at an intermediate position along the length of the outer cuff housing 13 , a clearance bevel 35 is formed in the outer cuff housing 13 to permit rotation of the outer cuff housing 13 about the axis 33 . The back side of the inner cuff housing 14 is connected to swivel base 15 by a screw 32 (not shown). The swivel plate 15 is a thin, flat member with attachment holes 35 to permit secure attachment to a fixed support. An access hole 30 is provided in the swivel base 15 to allow routing of electrical wiring and pneumatic tubing from an external monitoring device (not shown) into the interior of the enclosure formed by the outer cuff housing 13 and inner cuff housing 14 . The screw 32 permits rotational movement of the inner cuff housing 14 relative to the swivel plate 15 about an axis 34 , which is substantially perpendicular to the axis 33 . Accordingly, rotational motion of the blood pressure cuff 10 about the mutually perpendicular axes 33 and 34 provides the blood pressure cuff 10 with an ergonomic adjustment feature that allows the blood pressure cuff 10 to be conveniently adjusted to the test subject's body position when the upper arm of the test subject is inserted into the loop 19 .
[0026] Although the present embodiment preferably uses pivot screws 31 and a swivel plate 15 to attain rotational movement about the mutually perpendicular axes 33 and 34 , other equally feasible means are available for establishing these rotational relationships. For example, a hinge pin could be substituted for the pivot screws 31 to allow rotation of the outer cuff housing 13 about axis 33 . Rotation of the inner cuff housing about axis 34 may also be obtained when the screw 32 is also used to in mount the blood pressure cuff 10 to a fixed support, thus eliminating the swivel plate 15 .
[0027] Internal components of the blood pressure apparatus 10 will now be described with reference to FIG. 4. In order to view these internal components, FIG. 4 shows the blood pressure apparatus 10 with the inner cuff housing 14 and swivel plate 15 removed, and also shows the cuff retainer 12 in the unlatched state for clarity. FIG. 4 shows pneumatic pressure relief components located within the blood pressure cuff 10 which allow pressurized air contained within the band 11 to be exhausted to the surroundings when the cuff retainer 12 is moved from the latched state to the released state. An electrical switch 26 , located within the housing 39 is connected by a wire 44 to an electrically actuated valve 41 , which is, in turn, connected to a source of electrical energy through wire 46 . When the cuff retainer 12 is moved from the latched state to the released state, the electrical switch 26 located in the housing 39 is moved to a relaxed state, which causes the electrically actuated valve 41 to open. Pressurized air held within the band 11 is thus released from the band 11 through the flexible tube 42 , where it is exhausted to the surroundings through the valve 41 . Actuation of the switch 26 may additionally be used to provide an indication to the monitoring station that the band 11 is snug about the arm of the test subject, and flexible band is ready to be inflated.
[0028] Alternative approaches may be used to release pressurized air within the band 11 when the cuff retainer 12 is unlatched. For example, a mechanical valve which is opened by a mechanical linkage attached to cuff retainer 12 may be substituted for the electrical components described above, thus eliminating the need for a source of electrical energy. Further, where electrical components are used, alternative circuit designs are possible. For example, the electrical switch 26 may be of the normally closed, or normally open type. Similarly, the electrically actuated valve 41 may be in the open state when electrical energy is applied, or when it is removed, depending on the configuration of the electric circuit.
[0029] Still referring to FIG. 4, the latching mechanism will now be described. Attached to cuff retainer 12 is a latching mechanism 45 with a spring-loaded pawl 47 . When the cuff retainer 12 is moved to the latched position (as shown in FIG. 1), the pawl 47 engages an aperture 25 to latch the cuff retainer 12 securely to the outer cuff housing 13 . When the pawl 47 is engaged with the aperture 25 , the latching mechanism 45 is concealed within a recess 24 (best seen in FIG. 2) in the linear bearing assembly 40 . When the latching mechanism 45 is concealed in the recess 24 , the latching mechanism 45 also engages and actuates the electrical switch 26 .
[0030] Alternatives to the mechanical latching mechanism 45 are available, and may be substituted for the mechanical device shown. For example, an electrically actuated latching device, such as a spring-loaded solenoid latch, may replace the mechanical latching mechanism 45 . Still other means, such as pneumatic latching mechanisms, may also be used.
[0031] FIGS. 5 ( a ) and ( b ) illustrate the operation of the blood pressure cuff 10 during a blood pressure measurement. As shown in FIG. 5( a ), an upper arm 50 of a test subject is inserted into the circumferential loop formed by the band 11 , while the remainder of the arm rests on a supporting surface 52 . The cuff retainer 12 is also shown in the released state, with the support rods 22 fully extended from the outer cuff housing 13 . When the cuff retainer 12 is in the released state, the circumferential length of the loop 19 formed by the band 11 is increased by approximately a length 51 , which affords the test subject additional freedom of movement within the loop 19 . In preparation for the blood pressure determination, the test subject may adjust the orientation of the band 11 through manual manipulations about the two independent axes of rotation 33 and 34 to accommodate his body position. Before a measurement can be made, the cuff retainer 12 must be moved to the latched condition, as shown in FIG. 5( b ). At this point, the band 11 is held snugly about the upper arm 50 , and the electrical switch 26 (not shown in FIG. 5) has been actuated by the latching mechanism 45 (also not shown in FIG. 5) causing the electrically actuated valve 41 to close. Upon commencement of the blood pressure measurement, the band 11 is inflated by a pneumatic source, which causes constriction of the blood flow in an artery within the upper arm 50 . When the flow is fully constricted, air is bled from the band 11 at a controlled rate, whereupon systolic and diastolic determinations are made by conventional means. At the conclusion of the measurement, the test subject actuates the release knob 17 to allow the cuff retainer 12 to move to the released state. Since the electrical switch 26 is moved to the deactivated state when the cuff retainer 12 is released, the electrical switch 26 causes the electrically actuated valve 41 (not shown in FIG. 5) to depressurize the band 11 . If it is desired to terminate the blood pressure evaluation prior to completion, the test subject may actuate the release knob 17 at any time to simultaneously release the cuff retainer 12 and depressurize the band 11 .
[0032] [0032]FIG. 6 illustrates an alternative embodiment of the invention. In this embodiment, the cuff retainer 12 is allowed to translate along guide surfaces 51 in a direction 52 when cuff retainer 12 is in the released state in order to permit the test subject to remove his arm. The released state affords the test subject additional freedom of movement by increasing the circumferential length of the loop by a length 53 . As in the previous embodiment, release of the cuff retainer 12 will simultaneously deactivate an electrical switch (not shown in FIG. 6), or other similar means, to depressurize the band 11 .
[0033] [0033]FIG. 7 illustrates still another alternative embodiment of the invention. In this embodiment, the cuff retainer 12 coincides with the top surface of outer cuff housing 13 . Actuation of release knob 17 allows a slidable member 71 to translate along guide surfaces 72 in a direction 73 in order to increase the circumferential length of the loop by a length 74 . As in the previous embodiments, actuation of the release knob 17 will simultaneously deactivate an electrical switch (not shown in FIG. 7), or other similar means, to depressurize the band 11 .
[0034] The above description of illustrated embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed. While specific embodiments of, and examples of, the invention are described in the foregoing for illustrative purposes, various equivalent modifications are possible within the scope the invention, as those skilled in the relevant art will recognize. Moreover, the various embodiments described above can be combined to provide further embodiments. Accordingly, the invention is not limited by the disclosure, but instead the scope of the invention is to be determined entirely by the following claims. | The present invention is directed to a method and apparatus for obtaining blood pressure measurements employing a user releasable and adjustable blood pressure cuff. In one aspect of the invention, the blood pressure cuff apparatus consists of a first cuff member connected to a mounting surface and rotatable about a first axis of rotation substantially perpendicular to the mounting surface. The first cuff member is connected to a second cuff member that is rotatable about a second axis of rotation that is substantially perpendicular to the first. A blood pressure cuff comprised of a loop adapted to receive the arm of a test subject is connected to the second cuff member. In another aspect of the invention, the elongated flexible band has a first end and a second end. The first end is connected to the second member of the cuff housing, and the second end is connected to a cuff retainer. The cuff retainer is releasibly latchable from the second member so that the elongated flexible band forms a loop to snugly fit the arm of the test subject with a first circumferential length when the cuff retainer is latched. When the cuff retainer is unlatched, the elongated flexible band forms a loop with a second circumferential length, which allows the arm of the test subject to be easily withdrawn. | 0 |
This application is a division of Ser. No. 09/066,725 filed Apr. 23,1998, Pat. No. 6,081,956.
FIELD OF THE INVENTION
The present invention is in the field of input devices for personal computers and has particular application to pointer devices such as computer mouse devices and trackballs, and teaches methods and apparatus for cleansing the internal rollers and associated elements of such devices.
BACKGROUND OF THE INVENTION
Input devices used for personal computers such as pointer devices for cursor control, such as mouse and trackball devices, have traditionally been the most commonly used input devices for controlling cursor movement on a computer screen. A computer mouse is a device that a user can move across a pad thereby controlling cursor movement and cursor-related functions on a computer screen via a calibrated ball that rolls across the surface of a pad as the mouse is caused to move. Coded signals sent by a computer mouse are decoded with the aid of software in the computer, and the signals received are often and interfaced with the appropriate features within an application being used.
A computer mouse or trackball is typically physically enabled via a ball and two internal rollers. The rollers are held against the ball by springs or other tension devices. The ball inside a mouse is designed for rolling on a desk or mouse-pad as a user operates the device. As the ball rolls on a surface, calibrated contact-rollers that interface to the ball move in conjunction with the ball thus enabling cursor movement. Typically one roller is set at right angles to another with one providing input for x-direction movement and the other for y-direction movement. A trackball operates much in the same way as a conventional mouse accept that instead of moving the input device across a mouse pad, the device is stationary and a user manipulates the ball directly to provide the same type of input as would be the case with a mouse.
One problem with the ball-roller system of a mouse is that the internal rollers of the mouse or track ball inevitably become contaminated with lint, dirt, grime, hair, and other types of particulate matter present in the environment. When the ball and roller system of a mouse or track ball becomes contaminated, the efficiency of the device related to cursor movement begins to degrade.
Cleaning the internal rollers of a mouse or track ball is often a tedious and monotonous process. This process involves removing the rubber ball from the bottom of the mouse (from the top with a track ball) and manually scraping the rollers with a knife or other device. Often heavy lint must be tweezed out from rollers and tension devices with a pair of tweezers or other such implement. Manual cleaning operations may take considerable time depending on the type of contamination. If one is not careful during the cleaning process, rollers may be damaged by scratching or gouging. In some cases, new device components may be required to replace components such as rollers damaged during scraping. More often it is necessary to purchase and install a new pointer device to achieve expected functionality.
What is clearly needed is method and apparatus for cleaning the rollers of a mouse or track ball that eliminates the need for manual operations such as scraping, tweezing, swabbing, and the like.
SUMMARY OF THE INVENTION
In a preferred embodiment of the present invention a hand-held cleaning apparatus for a computer pointing device having a rollable ball of a standard size and internal rollers adapted to provide directional input is provided, comprising a housing adapted to a user's hand; a rotatable shaft connected to a rotary drive within the housing; and a cleaning ball having an abradant surface mounted to the rotatable shaft outside the housing. An on-off switch is typically provided for activation and de-activation. The rotary drive may be a variable speed drive including a user-input for varying the speed. There may be in addition an air pump connected to openings through the surface of the abradant ball, providing ingress of air to sweep matter abraded from the rollers from within the pointer device.
In an aspect of the invention a ball having an abradant surface is provided, the ball adapted for mounting to a rotary shaft of a hand-held rotary tool. The abradant surface can take many forms, such a brush-like bristles on the ball surface.
In another aspect an apparatus adapted for cleaning rollers for a computer pointing device having a rollable ball of a standard size and internal rollers adapted to provide directional input is provided, the apparatus comprising a housing having an upper surface with an upper opening; a rotatable shaft connected to a rotary drive within the housing and directed through the upper opening; a cleaning ball having an abradant surface mounted to the rotatable shaft outside the housing; and a user operable input adapted for activating the rotary drive. In this aspect the housing may be adapted to stand on a supporting surface, or may be a part of another housing, such as for a computer or video display. Also in this aspect the cleaning ball may be presented at a position such that a pointer device having the rollable ball of standard size removed, presented to the apparatus such that the cleaning ball engages the rollers of the pointer device, has a surface of the pointer device contacting the upper surface of the housing. In this case the user-operable input may be implemented on the upper surface of the housing, such that the contact of the surface of the pointer device with the upper surface of the housing operates the input device and activates the rotary drive. There may also be a variable-speed rotary drive, and there may be an air pump to provide for removal of abraded material.
Methods for practicing the invention are disclosed and claimed below as well. In the various aspects of the invention taught in enabling detail below, apparatus and methods are provided to meet a long-standing need, which is to keep mouse and trackball devices clean and operating properly.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is an underside view of a typical mouse illustrating the ball and roller system architecture.
FIG. 2 is an elevation view of a hand-held mouse-cleaning system according to an embodiment of the present invention.
FIG. 3 is an elevation view of the hand-held cleaning system of FIG. 2 positioned for a cleaning operation according to an embodiment of the present invention.
FIG. 4 is an illustrative view of a mouse-cleaning system according to another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is an underside view of a typical mouse illustrating the ball and roller system architecture. A typical computer mouse 9 is viewed from underneath showing various standard components. Trackballs have a similar structure. A removable cover plate 11 physically holds a mouse ball 15 in a spherical cavity. When mouse ball 15 is inserted into mouse 9 with cover plate 11 snapped firmly into place, mouse ball 15 makes contact with a plurality of calibrated rollers. In this example, there are two rollers 13 a and 13 b for providing directional input. In a typical mouse at least one tension device such as spring 17 is used to effect 100% physical contact between mouse ball 15 and the rollers. In some cases a third spring-loaded idler roller is provided to urge the ball into the directional input rollers.
The constant physical contact between mouse ball 15 and rollers 13 a and 13 b enables smooth and accurate directional input during operation as long as the system is clean. Smooth and accurate cursor movement is essential to successful cursor manipulation, object manipulation in drawing applications and for other purposes. As previously described in the background section, contamination of the form of lint, dust, food particles and the like eventually corrupts the ball-roller system and degrades the performance of the device.
A track ball is essentially a mouse device with the ball-roller system on the upper surface instead of the lower. Instead of rolling across a surface as with a conventional mouse, a track ball is stationary with cursor movement effected by physically manipulating the ball directly. The ball-roller system is basically identical with both types of pointer devices with an exception that a ball used with a track ball is notably larger than a mouse ball.
An object of the present invention is to provide a cleaning system and method that can be used to clean the ball-roller systems of a conventional mouse or a conventional track ball. The system of the present invention may be adapted, in various embodiments, to effectively clean any accessible ball-roller system such as may be found in a computer pointer device. More detail regarding the method and apparatus of the present invention is provided below.
FIG. 2 is an elevation view of a hand-held mouse-cleaning tool 19 according to an embodiment of the present invention. Tool 19 is provided as a simple tool for cleaning a ball-roller system of a mouse such as mouse 9 of FIG. 1 . Tool 19 comprises a cleaning ball 21 , a rotary shaft 25 , and an easy-grip handle further comprising a switch housing 31 , a center section 27 , and an end cap 29 .
Cleaning ball 21 is mounted to rotary shaft 25 via a mounting flange 23 . The mounting method used to mount ball 21 to flange 23 may vary. In a preferred embodiment, ball 21 is easily removable such as by unscrewing or unsnapping. In one embodiment of the invention, the mount is spring loaded (not shown) so that ball 21 may be removed by pushing ball 21 toward shaft 25 and than twisting one half turn thereby releasing it from flange 23 . There are many quick release schemes known in the art and available for attaching ball 21 to shaft 25 .
Rotary shaft 25 is mounted to a small electric motor (not shown) housed within the handle. Such motors are well-known in the art for providing rotary power. Power to hand unit 19 is effected via an on/off switch 33 located in a convenient position on switch housing 31 . In a preferred embodiment, hand unit 19 is powered via batteries (not shown), however, power may also be supplied via plug-in cord (not shown).
Cleaning ball 21 in a preferred embodiment is made of a light weight, semi-pliable material such as molded rubber. Ball 21 is hollow in it's interior to add flexibility, and for another innovative reason that will be further explained below. The components making up the handle of hand unit 19 namely switch housing 31 , center section 27 , and end cap 29 are manufactured in a preferred embodiment of a lightweight polymer material. Other lightweight materials known in the art may also be used. Center section 27 may be affixed to switch housing 31 and end cap 29 via threaded ends that can be screwed together as with flashlights and other hollowed cylindrical products. In this embodiment, center section 27 is the predominant section of the handle and has a finger grip area (marked by depressions formed therein) to facilitate a user's grip.
The inside area of the handle houses various components necessary to unit 19 such as an electric motor, wiring, switching apparatus, circuitry, and batteries. The aforementioned components are all common and known in the art to be used for enabling function of a rotary type hand tool, therefore, much detail will not be provided in this regard. The operation of tool 19 is similar to that of a variable speed dremel tool used in metal grinding operations. When a user activates switch 33 , rotary shaft 25 and mounted cleaning ball 21 spin in accordance with the speed of the motor used. The speed and direction of spin may vary according to user desire. For example, selections may be available in switch 33 for varying the speed of unit 19 and reversing the direction of spin. However, one speed in one direction is typically sufficient for the purpose of the present invention.
Cleaning ball 21 has an outer surface specifically adapted for providing the cleaning function of the ball. In a broad sense this surface is “abradant” as defined in Funk and Wagnall's New International Dictionary of the English Language, published by Publisher's International Press, Newark, N.J., USA, © 1984. The definition of the verb is: “To rub or wear off by friction. To scrape away.”
In a preferred embodiment, this special surface comprises a plurality of sweeper extensions 35 protruding from the outer surface area of ball 21 . Sweeper extensions 35 act to remove dust and other particulate matter from contact-rollers, such as rollers 13 a - 13 c , by sweeping them clean during the spinning operation of ball 21 . The diameter of cleaning ball 21 is held smaller than the diameter of the standard ball used in the cavity, to an extent that only sweepers extensions 35 actually make contact with rollers 13 a and 13 b . The sweeper extensions thus abrade the rollers to aid in removal of unwanted material. In other embodiments the ball size may be larger, and the surface of the ball is made mildly abrasive.
It will be apparent to those with skill in the art that the standard ball for a mouse or trackball is necessarily smooth. In operation foreign matter caught between the ball and one of the rollers of a pointer device using rollers and a ball my be pressed onto the surface of a roller, and remain there in a manner that the smooth rolling action required for efficient operation is periodically interrupted.
The abradant surface provided can take many forms, such as simply an irregular surface, extensions much like brush bristles, tiny scrapers, and the like.
In the case of the sweeper extensions described as an example as element 35 , the angle of the extensions with the surface of ball 21 may be in one direction (pointing toward the direction of the spin), as is shown here, or may be multidirectional. Sweeper extensions 35 may be of the same material as ball 21 and may be formed during molding of ball 21 so as to be one piece with the ball. In other embodiments sweeper extensions 35 may be part of an overlay of material that adheres to ball 21 via adhesive or the like. Sweeper extensions 35 may be of many shapes as long as suitable contact with rollers is maintained. Sweepers 35 may also protrude at various angles as well as substantially 90 degrees from the surface of ball 21 without substantially affecting the cleaning operation.
In still another embodiment, a small air pump may be provided inside the handle of hand unit 19 and a line connected thereto may be provided through an inside diameter (ID) bore running through the longitudinal center of shaft 25 and into the hollowed inside of cleaning ball 21 . In this case, a plurality of small openings (not shown) are provided through the surface of ball 21 allowing dust and particulate matter to be suctioned through the openings and into the interior of ball 21 . The connecting passage may then carry the suctioned material to an exhaust vent through which it may be expelled. Such a vent may be conveniently located, perhaps on end cap 29 . In yet another embodiment, the suctioned particulate may be trapped in a removable screen or small bag. The air pump may be driven by the same motor used to drive the shaft that turns ball 21 , or by a separate drive unit.
FIG. 3 is an elevation view of tool 21 positioned for a cleaning operation according to an embodiment of the present invention. Before a user begins the cleaning operation, cover plate 11 and mouse ball 15 are removed from mouse 9 thereby exposing rollers 13 a and 13 b . By holding mouse 9 with one hand, and tool 19 with the other hand, a user may begin the cleaning operation. Because rollers 13 a and 13 b are mounted in a horizontal position with respect to mouse 9 , tool 19 should be presented at an angle as shown. The exact angle is not of great importance. A range from between 20 and 45 degrees from vertical should suffice. The inventor notes that presenting tool 19 such that the motion of ball 21 is essentially parallel to the centerlines of rollers 13 a and 13 b will not cause the rollers to turn and present all of the surface of the rollers for cleaning.
When tool 19 is activated, ball 21 will spin causing sweepers 35 to brush against rollers 13 a and 13 b , turning the rollers and cleaning them of any loose or embedded unwanted material. An electronic cleaning solution may also be used in conjunction with hand unit 19 . Such cleaning solutions formulated for electronic components are well known in the art. Such solutions may be applied to ball 21 , sprayed on rollers, or both in combination. In one embodiment, a cleaning solution may be stored in a reservoir in hand unit 19 and caused to spray a short burst via a delivery tube running along side of or through the center of rotary shaft 25 of FIG. 2 . There are many possibilities.
FIG. 4 is an illustrative view of a mouse-cleaning system according to another embodiment of the present invention wherein a cleaning unit 37 is provided in the form of a tabletop device that may, in some instances, be mounted to a solid surface for the purpose of providing stability to the unit. Unit 37 may simply set on a surface, be mounted to a surface, or perhaps, be provided as part of the structure of a computer. In the latter instance, unit 37 may be sold as an accessory that may be affixed to, or may be part of, for instance, a computer tower.
Unit 37 has an adjustable table 39 that may be adjusted up or down according to required parameters such as the height of a mouse-ball cavity. Much like the tool 19 of FIG. 2, a cleaning ball 41 is affixed to a rotary shaft 43 via screw, snap method, or the like. Unit 37 has an electric motor for providing spin to rotary shaft 43 and an air pump 53 for suctioning loose particulate matter as described above with reference to FIG. 3 .
An ID bore 47 is provided through the length of rotary shaft 43 and into the interior of cleaning ball 41 . A vacuum guard 45 is affixed to rotary shaft 43 so as to become an integral part of rotary shaft 43 . The function of vacuum guard 45 is to add vacuum capability to the outside surface area of ball 41 and to trap any material that might in-advertantly become stuck to ball 41 . A vacuum line 59 provides a suctioning passage for air pump 53 through rotary shaft 43 via an ID bore 47 . ID bore 47 extends into the inside area of cleaning ball 41 A plurality of small openings (not shown) may be provided through the shared wall of ID bore 47 and rotary shaft 43 at a location where vacuum guard 45 adjoins rotary shaft 43 for the purpose of providing suction power both to the inside of ball 41 , and to the out side area of ball 41 covered by vacuum guard 45 . In this way, particles suctioned into ball 41 through openings beneath sweepers as described with reference to FIG. 3, and particles trapped in vacuum guard 45 may be suctioned to exhaust. An exhaust vent and tube structure 61 is shown connected to air pump 53 for the aforementioned purpose. All of the added function described in this embodiment may also be utilized in a hand-held version of the mouse cleaner such as tool 19 of FIG. 2 .
As with tool 19 of FIG. 2, power to unit 37 may be supplied by a battery 51 or an AC/DC adapter 57 with a plug-in cord 55 . An on/off switch 42 shown wired to motor 49 provides power to unit 37 . As can be seen in this embodiment, rotary shaft 43 is mounted at an angle from vertical. Suitable clearance for this angled presentation is provided via a clearance cavity 44 . The reason for the angled presentation is the same as described with reference to FIG. 3 . An adjustment feature (not shown) regarding the angle of mount of shaft 43 may be provided so that a user may fine tune the presentation. The aforementioned adjustment feature may be of the form of a pivotal and lockable motor mount accessible to the user perhaps by removing a cover or the like. Such features are known in the art and easily provided.
It will be apparent to one with skill in the art that a desktop mouse-cleaning unit such as unit 37 may be mounted to a surface or made into part of the computer without departing from the spirit and scope of the present invention, such as by mounting the unit to a computer tower or the like. It will also be apparent to one with skill in the art that power to unit 37 may be effected via a variety of techniques known in the art. In one embodiment, power to unit 37 is effected via a user placing a mouse over cleaning ball 41 and against adjustable table 39 with sufficient force required to trigger a pressure sensitive switch. In this case, an on/off switch such as switch 42 would not be required.
In still another embodiment, a hand held unit such as tool 19 of FIG. 2 may be adapted to dock into a housing similar to the housing structure containing the components of unit 37 of FIG. 4 including an adjustable table. In this way the invention may function as a hand-held unit or a stationary desk-top unit. Additional cleaning balls as accessories are provided to facilitate a larger mouse-ball cavity such as those typically found in a track ball. The exact size of a cleaning balls will conform to industry standards. The spirit and scope of the present invention is limited only by the claims that follow. | A cleaning apparatus for computer pointer devices having a standard ball contacting input rollers has an abradant ball mounted to a rotary shaft in a manner that the abradant ball may be brought into contact with rollers of the pointer device with the standard ball removed, the position of the abradant ball such that rotating the shaft will rotate the abradant ball in a manner that the abradant ball will both abrade and turn the rollers. The cleaning apparatus may be a hand-held device, built into a free-standing housing, or into a housing as a part of another computer housing, such as a computer or display. In some cases there is a variable speed drive with user settable speed, and in some cases there is a vacuuming system for removing abraded matter from a pointer device while cleaning takes place. | 0 |
BACKGROUND OF THE INVENTION
This application relates to a device for removably connecting an object to a wrist strap. In a preferred embodiment the invention relates to an archery bowstring release aid that is attached to an archer's wrist by a quick release mechanism.
Archery release aids have been developed to assist archers in shooting modern archery bows. A release aid assists an archer when drawing the bowstring back and then further assists the archer when releasing the bowstring. Thus, release aids commonly provide some type of triggering device for smoothly releasing the bowstring. Examples of prior art archery release aids are shown in: U.S. Pat. No. 5,653,213, Aug. 5, 1997, to Linsmeyer for “Bow String Release with Trigger Having Multiple Bow String Securing Positions”; U.S. Pat. No. 5,653,214, Aug. 5, 1997, to Lunn for “Pivotal Bowstring Release Mechanism”; and U.S. Pat. No. 4,831,997, May 23, 1989, to Greene for “Wrist Strap.”
Release aids are generally attached to wrist straps to ensure that the archer does not accidentally drop the release aid which could result in harm to the archer or damage to the bow and further to ensure that the release aid is readily available in the event a shot presents itself Some release aids are attached to the archer's wrist via a wrist strap, e.g., a Velcro® or buckle wrist strap such as is shown in the aforementioned U.S. Pat. No. 4,831,997. Release aids are usually joined to wrist straps with a rope or straight-shaft mechanism. In some cases the mechanism can be adjusted to fit an archer's draw length, i.e., distance between the archer's wrist and fingers. However, prior art designs do not offer a means for readily detaching and reattaching the release aid to the wrist strap without removing the entire assembly from the wrist.
While release aids have been beneficial to the archer, there remains a need for improvement. Release aids, which are fixedly attached to a wrist strap when not in use, are problematic. For example, when the archer is not engaged in shooting, the release aid dangles from the wrist and interferes with non-shooting tasks. Dangling release aids tend to snag on clothes, backpacks, and other equipment and the free movement of the release aid tends to interfere with tasks requiring free hands. Although some release aid designs allow the release aid to fold out of the way, tuck away into a shirtsleeve, or pivot back and forth, such designs are somewhat cumbersome.
Fixedly attached release aids can also be an unwanted source of noise and missed shot opportunities. While wearing a release aid, it is difficult to install screw-in or rope tree-steps, climbing sticks, climbing and fixed position deer stands, etc., without clanking the free-swinging release aid against something.
Because of the problems described above, archers often remove their wrist straps and release aids from their wrists while en route to their hunting site. However, the time required to reattach the assembly to the wrist can result in missing a shot opportunity. To reduce the time required to reattach/detach a release aid to/from the wrist, Velcro® has been incorporated into wrist straps. Unfortunately, the loud, unnatural sound that comes from removing or attaching the release aid to the wrist with Velcro® can spook game, resulting in missed shot opportunities. A quiet alternative to Velcro® designs are buckle-type wrist straps, which are quiet when putting on, but take considerable time to attach and detach and, or course, have the disadvantage of the dangling release aid banging on equipment if not detached.
It would be desirable to have a system having a wrist strap with a quick release mechanism that would allow an archer to quickly, quietly, and easily attach and detach an archery release aid to/from a wrist. Accordingly, the present invention provides a release aid which can be readily attached and detached from an archer's wrist without removing the wrist strap, hence, there is no need to suffer a dangling release aid which hinders the archer or produces game spooking noise. Furthermore, the present invention provides a release aid, which can be quietly detached or reattached at any time with minimal effort whenever desired by the archer. Thus, the present invention avoids game spooking noise associated with Velcro wrist straps or time fumbling with buckles. The archer can perform a plethora of tasks without interference of the release aid by simply removing the release aid from the wrist strap. Then, for example, the archer may add or remove clothing, use any accessory while hunting such as binoculars, range finder, or rattling antlers used to lure deer to the hunter by simulating a fight, or simply put hands inside of pockets or muffler for warmth. Of course, the wrist strap may be attached before leaving the vehicle to reduce noise en route and at the hunting site where the release aid may be simply reattached to the wrist strap.
In addition to the above advantages, the release aid of the present invention is convenient and easy to use and is inexpensive to manufacture. Further understanding of the present invention will be had from the following description and claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
In accordance with the present invention a system for removably connecting an object to a wrist strap has:
a) a wrist strap; b) a first member attached to said wrist strap; c) a second member adapted to be attached to said object; and said first member and said second member being removably connected to each other by a quick connect/disconnect mechanism.
In a preferred embodiment, the present invention is a system for removably connecting an archery release aid to a wrist, said system having:
(a) a wrist strap; (b) a first member attached to said wrist strap; (c) a second member attached to said archery release aid; said first member and said second member being removably connected to each other by a quick connect/disconnect mechanism.
Preferably, the release aid is freely rotatably connected to the second member and the second member comprises a length adjustment element by which the length of the release aid along its longitudinal axis may be adjusted. Also preferably, a safety feature is built into the quick disconnect to prevent an unintentional disconnect of the release aid from the strap fitting. These features enable the archer to fine tune the fit of the release, have a torque free shot for better accuracy, and wear the wrist strap minus the release aid to perform any number of duties without sacrificing a potential shot. If a shot opportunity presents itself the archer can quickly, quietly, and easily reattach the release aid in a matter of seconds.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a perspective view of a preferred embodiment of the present invention in operative association with a wrist strap;
FIG. 2 is an exploded view, in perspective, of the preferred embodiment of FIG. 1 ;
FIG. 3 is a pull-apart Keytag commonly used as a key ring and incorporated into the design of the preferred embodiment of FIG. 1 as the quick connect/disconnect feature;
FIG. 4 is an elevational view of a pull-apart Keytag cut longitudinally along its axis;
FIG. 5 is an isometric view of the preferred embodiment of the present invention shown in FIGS. 1 and 2 from the wrist strap perspective;
FIG. 6 is an isometric view of the preferred embodiment of the present invention shown in FIGS. 1 and 2 from the release aid perspective showing apertures and surfaces not visible in FIG. 5 ;
FIG. 7 is a cross-sectional view, broken away and taken along the longitudinal axis of the preferred embodiment of the present invention shown in FIGS. 1 and 2 ;
FIG. 8 is a perspective view showing an alternative preferred embodiment of the present invention with a portion broken away; and
FIG. 9 is a perspective view of another alternative preferred embodiment of the present invention shown in detached configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the present invention relates broadly to devices for connecting an object to a wrist strap, in a preferred embodiment, the present invention relates to an archery release aid and the invention is specifically described herein as an archery release aid. It will be appreciated by those skilled in the art, however, that the invention is broadly useful to removably attach other devices to a wrist.
Now referring to FIGS. 1-2 , a preferred embodiment of a system of the present invention is shown and indicated generally by the numeral 130 . A first member comprises parts shown as optional attachment 1 for female socket 12 , female socket 12 , and a wrist strap GWS, which is well known in the art.
Also shown is a second member, which comprises body tube 16 , pushpin 18 , locknut 28 , adjustable screw 26 , release aid adapter 22 , male connector 10 , body tube 16 , setscrews 14 a and 14 b , pushpin 18 , adjustable screw 26 , lock nut 28 , cap screw 24 , and a release aid GRA which is well known in the art. Quick Connect/Disconnect System 130 can be used to secure two members together in a wide variety of applications where quick connect/disconnect of the two members is desirable. However, it has been found that Quick Connect/Disconnect System 130 is particularly suitable for securing a wrist strap GWS to an archery release aid. For the purposes of exemplification herein, Quick Connect/Disconnect System 130 includes wrist strap GWS and release aid GRA. Release aids such as GRA are known in the art and used to draw back and trigger the release of a bowstring in order to launch an arrow as smoothly as possible. The Quick Connect/Disconnect System 130 allows the release aid GRA to be detached from wrist strap GWS without removing the wrist strap GWS from the wrist. Primarily this will reduce noise while hunting as discussed in the Objects and Advantages section of this document and will free up the archer's hands for other tasks when the archer is not actually engaged in shooting.
Male connector 10 and female socket 12 are pull-apart keytag parts, which are readily commercially available. Such keytags parts are preferred in the present invention but it is to be understood that other quick connect/disconnect mechanisms can be used herein without departing from the spirit and scope of the present invention.
FIG. 3 is a pull-apart keytag. Female socket 12 can be attached to wrist strap GWS through aperture 20 of female socket 12 in a plurality of ways. As shown, male connector 10 consists of a plunger 33 that has an existing aperture 51 tapped to mate the thread pitch of pushpin 18 . The main body of male connector 10 consists of two shoulders 41 a and 41 b and a neck 52 . When press-fitted, surfaces 41 c and 41 d of shoulders 41 a and 41 b come in contact with the internal surface 19 a of cavity 19 of body tube 16 . Male connector 10 is further secured by setscrews 14 a and 14 b and tightened against surface 52 a of neck 52 . Ball bearings 32 a and 32 b fit into annular groove 35 of female socket 12 when male connector 10 is inserted through aperture 30 into cavity 12 a of female socket 12 .
FIG. 4 is a cross-sectional view of the internal components of the pull-apart keytag male connector 10 and female socket 12 . Female socket 12 has an annular groove 35 machined into surface 12 b of cavity 12 a to accept two ball bearings 32 a and 32 b on male connector 10 . Male connector 10 is comprised of a plunger 33 with a shaft 36 that has a bulb 34 on the end that restricts movement of two ball bearings 32 a and 32 b when said plunger 33 is not depressed. A spring 37 slides over said shaft 36 and sits above said bulb 34 and ball bearings 32 a and 32 b . Plunger 33 has a collar 39 that is larger in diameter than aperture 31 to keep the plunger from pulling out of male connector 10 . All parts fit into channel 38 of male connector 10 through aperture 31 .
Male connector 10 is inserted into cavity 12 a through aperture 30 of female socket 12 , mating surfaces 11 of male connector 10 and surface 13 of female socket 12 in order to secure the release aid GRA to wrist strap GWS.
Referring to FIGS. 5 , 6 , and 7 , system 130 can be assembled as follows:
Step 1. Female socket 12 is attached to wrist strap GWS. To do so, female socket 12 is attached to wrist strap GWS through existing hole 20 in female socket 12 by any number of means such as a bolt and locking nut optional attachment 1 .
Step 2. Male connector 10 is attached to body tube 16 . In order to do so, male connector 10 is press fit into cavity 19 through aperture 40 of body tube 16 . Screw setscrews 14 a and 14 b are threaded into threaded passages 42 a and 42 b , respectively, of body tube 16 until both setscrews are seated tightly against surface 52 a of neck 52 of male connector 10 . This offers additional assurance that male connector 10 will remain in cavity 19 of body tube 16 .
Step 3. Pushpin 18 is assembled to press fitted male connector 10 by inserting pushpin 18 through passage 50 of body tube 16 and pushpin 18 is screwed into threaded passage 51 of plunger 33 of male connector 10 .
Step 4. Surface head 26 a of adjustment screw 26 is assembled to the surface head 22 a of release aid adapter 22 by using cap screw 24 to secure assembly. To do so, cap screw 24 is inserted first through counter-bored passage 90 of release aid adapter 22 , through passage 80 and into threaded cavity 81 of adjustment screw 26 until the head of cap screw 24 is snug against surface 22 b of release aid adapter 22 and the heads of the two surfaces 22 a and 26 a ( FIGS. 4 a , 4 b ), respectively, are adjacent to one another. Cap screw 24 should be snug but not so tight that release aid adapter 22 does not rotate 360° around said cap screw 24 .
Step 5. Lock nut 28 is assembled to adjustment screw 26 by threading adjustment screw 26 through threaded passage 70 of locknut 28 . The position of locknut 28 along adjustment screw 26 is left to the archer to decide upon. The locknut's 28 placement determines the ultimate length that will result between the final wrist strap GWS assembly and release aid GRA.
Step 6. The above subassembly resulting from steps 4-5 is threaded into the body tube 16 subassembly from steps 2-3. To do this, adjustment screw 26 is threaded into mating cavity 17 through passage 60 of body tube 16 until surface 16 a of body tube 16 is adjacent to surface 29 of locknut 28 . To secure these parts, a wrench is used on flat head surfaces 28 a and 28 b of locknut 28 and hex head of adjustment screw 26 . Opposing pressure is applied to adjustment screw 26 in a counterclockwise direction while pressure is applied to locknut 28 in a clockwise direction in order to tighten surface 29 of locknut 28 against surface 16 a of body tube 16 . It should be noted that before tightening locknut 28 , the archer can fine-tune the length of this assembly by merely adjusting passage 60 of body tube 16 and passage 70 of locknut 28 all along the threads of adjustment screw 26 . Once the desired length is achieved locknut 28 can be tightened down in the above manner.
Step 7. Release aid adapter 22 is threaded into existing aperture 100 in release aid GRA by applying one wrench to surfaces 22 c and 22 d of release aid adapter 22 and another wrench to the hex head of adjustment screw 26 . Opposing pressure is applied in a clockwise direction to release aid adapter 22 and counterclockwise to adjustment screw 26 until the release aid GRA is firmly attached to the preferred embodiment 130 . Release aid adapter 22 and adjustable screw 26 are joined together by cap screw 24 . In a preferred embodiment, release aid adapter 22 includes a standard Archery Manufacturers and Merchants Organization (AMO) thread pitch for archery release accessories; however, other mating thread pitches are suitable.
FIG. 8 shows an alternative embodiment 110 of the present invention. System 110 uses the same Quick Connect/Disconnect System as preferred embodiment 130 . The length and torque free 360° swivel are realized through the use of a rope, which secures release aid GRA to body tube 16 . The rope goes through hole 114 a of modified release aid adapter 114 and both ends of the rope are threaded through hole 112 a of body tube cap 112 . Both ends of the rope are knotted together when the desired length between the release aid GRA and wrist strap GWS is determined. The knot then goes through passage 60 and into cavity 17 (which is not threaded in this embodiment) of body tube 16 . Body tube cap 112 mates to threads 16 b on the outside of body tube 16 . In this alternative embodiment A 110 , the modified release aid adapter 114 includes a standard Archery Manufacturers and Merchants Organization (AMO) thread pitch for archery release accessories; however, other mating thread pitches are suitable.
FIG. 9 is yet another alternative embodiment 120 of the present invention. Alternative embodiment 120 uses the same quick connect/disconnect system as preferred embodiment 130 . The length adjustment and torque free 360° swivel are realized through the use of a rope that secures the release aid GRA to body tube 16 . A rope goes through hole 114 a in modified release aid adapter 114 . The two ends of the rope are inserted into passage 60 and one end goes out passage 60 a and the other out passage 60 b . Knots are tied in the two ends of the rope at the desired length that are large enough not to pull back through passages 60 a and 60 b . In alternative embodiment 120 , the modified release aid adapter 114 includes a standard Archery Manufacturers and Merchants Organization (AMO) thread pitch for archery release accessories; however, other mating thread pitches are suitable.
In operation, all wrist strap type release aids currently on the market require the archer to physically remove the wrist strap in order to remove the release aid for any reason. The manner of using the Quick Connect/Disconnect System 130 is unique to all other wrist strap type archery release aids in that the release aid can quickly, quietly, and easily be detached from the wrist strap to free up the hands of the archer and reattached to the wrist-strap in seconds when needed. To disconnect the release aid GRA from the wrist strap GWS, the archer simply grasps body tube 16 with his/her free hand, slides pushpin 18 towards the wrist while simultaneously pulling body tube 16 and release aid GRA from the wrist. In so doing, plunger 33 depresses spring 37 , and moves bulb of shaft 34 down past ball bearings 32 a and 32 b allowing them to fall into channel 38 and disengage from annular groove 35 in female socket 12 . This leaves only the wrist strap GWS and female socket 12 attached to the archer's wrist. To reconnect the release aid GRA to the wrist strap GWS the archer simply slides pushpin 18 away from release aid GRA and simultaneously inserts male connector 10 into cavity 12 a through aperture 30 of female socket 12 , releases pushpin 18 , allowing bulb of shaft 34 to slide upwards pushing ball bearings 32 a and 32 b into annular groove 35 in female socket 12 thus reattaching release aid GRA to the wrist strap GWS.
Because the fit of a release aid is so crucial to proper form and smooth release when shooting a bow and arrow, a fine length adjustment feature is machined into preferred embodiment 130 . To adjust the preferred embodiment 130 , locknut 28 is loosened with a wrench applied to the two flat sides 28 a and 28 b of lock nut 28 and another on the hex head of adjustable screw 26 . Adjustable screw 26 is then simply screwed in or out until the perfect fit for the archer is achieved, and locknut 28 is tightened back down to secure the fit. Alternative embodiment 110 is connected/disconnected in the same manner as preferred embodiment 130 . However, to adjust the length, body tube cap 112 is removed by simply unscrewing body tube cap with the archer's fingers, the rope either shortened or lengthened, the knot retied and body tube cap 112 replaced and retightened. Alternative embodiment 120 is connected/disconnected in the same manner as preferred embodiment 130 . Again a rope is used as the length adjustment feature. Both ends of the rope coming from the release aid GRA are threaded through aperture 60 of body tube 16 and one end of the rope threaded through hole 60 a and the other end threaded through hole 60 b . A knot larger than hole 60 a and 60 b is then tied in the end of each rope to set the length.
A torque free 360° swivel feature for the release aid is achieved by inserting cap screw 24 into the counter-bored interior of release aid adapter 22 and threading it into adjustable screw 26 . The inside of release aid adapter 22 is smooth to allow the release aid adapter to rotate freely around the head of cap screw 24 once it is screwed into cavity 81 through aperture 60 of adjustable screw 26 . In alternative embodiments 110 , and 120 , the rope provides a torque free shot because it allows the release aid GRA to rotate to the correct position when the bowstring is pulled back.
From the description above, a number of advantages of the release aid of the present invention over the prior art become evident:
a) The release aid can be detached quickly, quietly, and easily without removing the wrist strap and any number of duties requiring the archer to have free hands can be performed. b) The release aid can be quickly and easily reattached—within seconds—to the archer's wrist with no noise and minimal movement. c) The release can be precisely fit to the archer using the fine adjustment screw, or in an alternative embodiment by adjusting the length of rope securing the release aid to the body tube. d) The release aid is completely torque free due to the 360° rotation of the release aid adapter.
Although the description above and detailed drawings of the preferred and alternative embodiments contain much specificity, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the Quick Connect/Disconnect System 130 could be modified in many ways to obtain the desired effect of removing the release aid from the wrist strap without departing from the spirit and scope of the present invention. Synthetic materials or different alloys could be used in manufacturing, the parts could be reduced or enlarged so as to adapt to larger or smaller archers, etc. Thus the scope of the invention should be limited only by the appended claims. | A quick connect/disconnect system for connecting and disconnecting an object, such as an archery release aid, to a wrist strap on a human wrist has a first member adapted to be attached to the wrist strap and a second member adapted to be attached to the object. The first and second members fit together coaxially and can be released by movement of a single lever. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a sheet feeding device for use in facsimile apparatus, and more particularly to a sheet feeding device capable of automatically selecting a sheet size in accordance with a received message, wherein the sheet feeding device includes a sheet supplier and a sheet discharging means.
2. Description of the Prior Art
To clearly explain the background of the invention, reference will be made to FIG. 2 in which facsimile apparatus in common use is shown:
Facsimile apparatus are provided with one or two cassettes in which recording sheets are stacked. The illustrated example is a two-stage type which has one cassette above another. Received messages are recorded on the sheet fed from the cassette, and the sheets bearing the message are discharged by means of a discharging means. The apparatus requires another discharging means which discharges an original from which a message is transmitted.
In FIG. 2 a facsimile apparatus is provided with cassettes 2, 3 and discharging trays 2a, 3a. The double-cassette apparatus can handle sheets of five or six sizes, such as A4, B4, B5, letter size, legal size, which are stacked in the two cassettes. For use, a required size is automatically selected from the two cassettes. In FIG. 2 the facsimile apparatus includes a transmitter 4, a receiver 5 and a developing section 6 in which the received message is developed.
The known facsimile apparatus has the following disadvantages:
When a long message is received, the single-cassette type of facsimile must record it on two pages. As a result, the received message is divided into two pages. This consumes sheets and the reader must turn pages. This is troublesome. If the cassette contains sheets of no corresponding size to a received message size such as A4 v. B4 size, the received message (B4 size) will be automatically contracted to the A4 size.
With the double-cassette the same difficulty as pointed out above arises. Additional disadvantage is that the size of the facsimile apparatus as a whole is increased because of the provision of double cassettes. Likewise, the provision of double discharging trays enlarges the size of the apparatus, which reflects in the production cost, and requires a larger installation site.
SUMMARY OF THE INVENTION
The sheet feeding device for use in facsimile apparatus of the present invention, which overcomes the above-discussed and numerous other disadvantages and deficiencies of the prior art, comprises a housing for accommodating different sizes of sheets, and a control means for selecting an appropriate sheet size to the size of a received message.
In a preferred embodiment, the roll sheet is housed in a pocket and the cut sheets are placed in a recess, the pocket and the recess being formed in a tray in such a manner as to be adjacent to each other in the feeding direction of sheet.
In a preferred embodiment, the sheet feeding device includes a sheet discharging means on an extension of the feeding path of a transmitting original, and a change-over means for selecting a first position for receiving the transmitting original or a second position for allowing the transmitting original to pass.
Thus, the invention described herein makes possible the objectives of (1) providing a sheet feeding device adapted for use in facsimile apparatus, the device being compact in size and requiring no large installation space, (2) providing a sheet feeding device capable of selecting sheet sizes between roll sheet and cut sheets in response to a received message size, and (3) providing a sheet feeding device enabling one of the roll sheet or the cut sheets to automatically replace with the other which runs out of stock.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings as follows:
FIG. 1 is a vertical cross-sectional view through a facsimile apparatus including a sheet feeding device according to the present invention;
FIG. 2 is a schematic view showing a prior art two-stage type facsimile apparatus;
FIG. 3 is a block diagram showing a control section of the sheet feeding device according to the present invention;
FIGS. 4a and 4b are diagrams showing the interrelations between a B4 size original and a legal size original; and
FIG. 5 is a perspective view on an enlarged scale showing a sheet feeding cassette.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1, 4 and 5, there is provided a facsimile apparatus having a main body 11 which comprises halved port 11a (upper) and 11b (lower). The main body 11 includes a transmitter section 12 and a receiver section 13. The following embodiments use paper for a sheet.
The transmitter section 12 is situated at a left-hand corner of the main body 11, and comprises a feeding path 18 including a plurality of rollers 16 and 17, the feeding path 18 for feeding an original from a platen 14 to a discharging tray 15, and a reading section 20 for optically reading the original received, a transmitter/receiver-side control section 21 for electrically converting a word signal read at the reading section 20 into an electrical signal and transmitting the signal to a recipient, and an operation panel 22 for sending a signal to operate the control section 21, which is disposed above the roll paper 9. Hereinafter, the receiver/transmitter-side control section 21 will be referred to as the control section.
The receiver section 13 has the same structure as that of an ordinary laser printer. In addition to the control section 21, which converts electrical signals into optical signals, this section 13 has an optical system 28, including a rotary reflector 27, for injecting the optical signals from the control section 21 onto a photosensitive drum 26 through a lens 25, a developing unit 29 for developing an electrostatic latent image on the photosensitive drum 26 into a visible toner image, a charger 30 for charging the photosensitive drum 26, a transfer charger 32 for transferring the toner image onto the paper fed from a supplier section 31, a fixing section 33 for fixing the toner image and the discharging tray 15 for receiving the image-bearing paper. The reference numeral 35 denotes a cleaning device for removing a developer remaining on the photosensitive drum 26, and the reference numeral 36 denotes a feed path leading from the paper supplier section 31.
The paper supplier section 31 will be described in greater detail:
The paper supplier section 31 includes an accommodation chamber 37 for housing a cassette 38 in which a roll paper 9 and cut sheets are stored. The cassette 38 is inserted into the accommodation chamber 37 through an opening 60 in the same manner as a drawer is. The cassette 38 has a recess 46 at one end in which cut sheets are stacked and a pocket 42 at the opposite end in which the roll paper 9 is placed. The reference numeral 45 denotes a raised plate.
The cassette 38 includes feed rollers 44 adjacent to the pocket 42. The feed rollers 44 are driven by power through a gear 43. The roll paper 9 is fed by the feed rollers 44 and cut by a cutter 70 disposed in the feed path 36, the cutter being operable in response to a signal from the control section 21.
There is disposed a pick-up roller 51 above the recess 46, and the cut paper placed in the recess 46 is fed to the feed rollers 44 under the guidance of a curved wall 50.
The control section 21 includes an original width detecting means 51a, an original length detecting means 52a, a roll paper width detecting means 53a, a cut paper size detecting means 54a, a central processing unit (CPU) 55a for judging whether the roll paper 9 or the cut paper should be used in response to a signal from these detecting means 51a to 54a, a driving section 56a for driving the feed rollers 44 and a driving section 57a for operating the cutter 70 both in response to a signal from the CPU 55a, and a driving section 58a for driving the pick-up roller 51.
The original width detecting means 51a detects the width of an original (message) sent from an outside transmitter 60 by a digital discriminating signal in the phase B.
In general the image data is transmitted as line picture units, and is stored in the page memory in line pictures. The original length detecting means 52a counts the memory lines in the page memory and determines the length of an original sent from the transmitter 60.
Referring to FIG. 3, the roll paper width detecting means 53a and the cut paper size detecting means 54a comprise optical sensors disposed in the recess 46 and the pocket 42.
Examples of the operation of the sheet feeding device will be described:
CASE (1)
In the case (1) as shown in FIG. 4a the received original (message) is B4 size, and the cassette accommodates a B4 roll paper 9 and A4 cut papers 10. The facsimile apparatus recognizes the width of the original by a digital signal issued in accordance with the original width, transmitted subsequently to a call signal from the transmitter. The control section 21 selects the B4 roll paper 9 in response to the signal indicating that the receiving original is B4 size, and drives the feed rollers 44.
The length of the received original (message) is recognized by counting the lines stored in the page memory, in response to which the cutter 70 is driven to cut the roll paper 9 to an appropriate length. If the received original is found A4 size, the A4 cut paper is selected and fed out by the pick-up roller 51. In this way the receiving data is printed on the A4 cut paper 10.
To print the data on the paper, the photosensitive drum 26 is subjected to exposure by the optical system 28 in response to a character signal so that an electrostatic latent image is formed on the photosensitive drum 26, and the latent image is developed into a visible toner image by the developing unit 29. Then the toner image is transferred onto the paper and fixed at the fixing section 33. The printed paper is led to the discharging tray 15.
CASE (2)
This is a case where a legal size (14 inches) original (message) is longitudinally received. Suppose that the cassette 38 accommodates a letter-size roll paper 9a (8.5 inches) and a letter-size cut paper 10a. The message is received on the letter-size roll paper 9a. If the roll paper 9a runs out of stock, the letter-size cut paper 10a replaces for it.
As is evident from the foregoing description, the present invention has many advantages as follows:
The paper sizes are selected between the roll paper and the cut paper in accordance with a received message. In addition, if either roll paper or cut paper runs out of stock, the other automatically replaces for it to receive the message. The roll paper and the stacked cut papers are accommodated in the cassette in a flat posture, thereby contributing to the compact size of the facsimile apparatus. In the illustrated embodiments paper is used as a recording material but the recording medium is not limited to ordinary paper. Instead of ordinary paper, a photo-sensitive sheet or any other pliable sheet can be used.
Referring to FIG. 5, the cassette 38 will be described in detail:
As described above, the cassette 38 is mounted on the facsimile apparatus by being inserted into a housing chamber 62 through the opening 60. The cassette 38 is shaped like a tray having a shallow bottom. The feed rollers 44 are disposed adjacent to the pocket 42 in which the roll paper 9 is accommodated. The raised plate 45 is provided with frictional members 45b and pawls 45a. The curved plate 50 guides cut papers toward the feed rollers 53. When the roll paper and the cut papers run out of stock, the cassette 38 is pulled out of the housing chamber 62, and fresh roll paper and/or cut papers are loaded therein.
The discharging of paper will be more particularly described:
The discharging tray 15 is disposed in a space 37 in an upper portion of the main body 11 of the facsimile apparatus. The tray 15 has two discharge ports 38a and 39 at opposite terminating ends; the discharge port 38a is for discharging a recorded paper and the discharge port 39 is for discharging a transmitted original. More specifically, the discharging tray 15 is disposed on the extension of the main feeding path 18. There is provided a change-over board 40 for determining either a position A at which a transmitting original is received or a position B at which a transmitting original is allowed to pass. The change-over board 40 comprises a base portion 40a and a rotary portion 40c which is pivotally connected to the base portion 40a by means of a pivot 40b. The position A is achieved by rotating the rotary portion 40c and maintaining it horizontal as shown by imaginary lines in FIG. 1. The position B is achieved as shown in FIG. 1 by folding the rotary portion 40c over the base portion 40a.
It is understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be construed as encompassing all the features of patentable novelty that reside in the present invention, including all features that would be treated as equivalents thereof by those skilled in the art to which this invention pertains. | A compact and efficient facsimile machine sheet feeding device can automatically select either roll or cut sheet paper supplies in response to received signals indicating the size of the remotely located original document being electronically transmitted thereto. The roll paper supply is preferably located in one end of a cut paper supply tray. A dual purpose document receiving bin is also preferably utilized so as to selectively receive scanned original documents at one end and to receive incoming copy documents at the other end. Either a roll sheet or cut sheet paper supply can be selected in accordance with the width of the original document. If the roll sheet supply is selected, it is cut to have the desired length of the original document. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a holder assembly for dispensing baby formula and the like. More particularly, this invention relates to a holder assembly that includes a holder for use with a disposable liner or sac, and a sliding member removably secured to the holder for expelling air from the liner.
[0003] 2. Description of the Prior Art
[0004] Reusable baby bottles or hard bottles, such as made of glass or plastic, have been commonly used to feed babies formula, water, and other liquids. After liquid is placed in the bottle, a nipple is attached to the bottle and the assembly is ready for use. A hard bottle sometimes is cleaned and sterilized between each use, requiring substantial time and effort.
[0005] An alternative to a hard bottle is the flexible or disposable liner or sac (also referred to as a “disposable bottle”) that is used in conjunction with a holder which supports the liner. The liner, which is used only once, is pre-sterilized, and is inserted into the holder. The liner is then filled with liquid, and a nipple is attached to the holder. This alternative is economical and sanitary, and greatly minimizes the time and effort required to prepare for feeding a baby.
[0006] One limitation inherent in hard bottles is the tendency of babies to ingest substantial amounts of air when ingesting the liquid. This air can cause uncomfortable distention and gas in the baby's stomach, and may lead to vomiting and other problems. Disposable liners collapse as liquid is drawn out, thus minimizing the amount of air the baby ingests. However, under some circumstances a small amount of air can be drawn into the liner through the hole of the nipple.
[0007] Attempts have been made to address this problem. U.S. Pat. No. 3,998,348 to Sammaritano provides a roller assembly attached to the lower, closed end of the liner to take up the liner as it empties. U.S. Pat. No. 4,796,767 to McKeown provides a pushrod stored on the outside of the holder. When in use, the pushrod is inserted through the open bottom of the holder to press air out of the liner through hole in the attached nipple. U.S. Pat. No. 4,176,754 to Miller provides a donut-shaped pneumatic roller used to press air out of the liner similarly as discussed above.
[0008] Some patents provide a plunger-type insert having the general shape of the inside of the holder. The plunger can be pushed up within the holder to press air out of the liner. Certain devices use a plunger having a stem extending from the open bottom of the holder. Other devices require the user to reach inside the open bottom of the holder to operate the plunger.
[0009] Other patents provide a refinement on this construction employing a plunger-type insert that is operable by means located on the sides of the holder. U.S. Pat. No. 5,356,016 to Wiedemann provides a flat, circular plunger member having a pair of tab handles on its diameter that extend through a pair of longitudinal slots in the holder.
[0010] U.S. Pat. No. 3,955,698 to Hammer is a device somewhat similar to that shown in the Wiedemann patent. However, the Hammer device has a pair of tab handles that engage with ratcheted indentations on the interior surface of the holder. U.S. Pat. No. 5,301,825 to Di Scala et al. provides a related device in which the tab handles are connected in a ring extending around the holder.
[0011] These devices tend to be unwieldy, unstable and awkward. These devices suffer from the drawback of requiring a complex disassembly of the tab or ring handles to clean the holder assembly. This is inconvenient and time-consuming for the user. Also, removable tab handles can pose a danger to the baby as small parts. These devices also suffer from the drawback of requiring two hands to operate properly. The tab handle devices require the user to hold the holder in one hand, and apply pressure, preferably with the other hand, to the opposing tab handles simultaneously. The ring device requires the user to grasp the holder in one hand, and the ring, preferably with the other hand and at opposing points, to slide it. If used with one hand, slight movements of the ring might be possible, but any greater pressure may force the ring's edge into the holder surface and arrest further movement. These devices additionally suffer from the drawback of being bulkier than the present holder, thereby making these known devices less attractive and more expensive to manufacture.
[0012] Patents disclosing a holder assembly designed to alleviate such drawbacks are disclosed in U.S. Pat. No. 5,878,899 to Manganiello et al. and U.S. Design Pat. No. 411,886, which are assigned to the assignee of the present application. Applicant hereby incorporates the disclosures of these patents by reference. The holder assembly is for use with disposable baby feeding liners and has a holder with a longitudinal slot and a member. The member has a disk and a finger-operated attachment joined to the disk at a single location. The attachment engages the longitudinal slot to mount the disk slidably within the holder. The holder has markings for determining the volume of liquid entering into the liner and the volume of liquid remaining in the liner as the baby is feeding. While a significant improvement over the known devices, this holder can have a simpler assembly and disassembly procedure. This device also does not provide significant leverage to the user for squeezing out the air in the liner.
[0013] Accordingly, there is a need for holders for flexible liners that facilitate assembly and operation while maintaining safety for the infant and reducing cost of manufacture.
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide a holder assembly that provides for efficient expulsion of air from a disposable flexible liner or preformed sac.
[0015] It is another object of the present invention to provide such a holder assembly that allows air removal from the liner, and can be held and operated effectively, easily and comfortably by the user, and preferably by use of one hand.
[0016] It is a further object of the present invention to provide such a holder assembly that facilitates operation, assembly, disassembly and cleaning.
[0017] These and other objects and advantages of the present invention are provided by a holder assembly for a disposable liner that expels air from the liner, which comprises a holder having an outer circumference and an axial slot; and a plunger having a disk and a positioner connected to the disk. The disk is removably disposed in the holder and movable in an axial direction in the holder to urge air from the liner. At least a portion of the positioner is accessible from outside of the holder along the axial slot and movable along the axial slot. The plunger engages the axial slot without engaging the holder in an area opposite the axial slot. The holder can have an axial channel inwardly recessed from the outer circumference with the axial channel having a width that allows at least a portion of the positioner to move through the axial channel along the axial slot and the axial slot can be formed in the axial channel.
[0018] In another aspect of the present invention, a holder assembly for a disposable liner that expels air from the liner is provided. The assembly comprises a holder having a first axial track, a second axial track and an outer circumference, and a plunger having a disk and a positioner. The disk is removably disposed in the holder and movable in an axial direction with respect to the holder to urge air from the liner. At least a portion of the positioner is accessible from outside of the holder along the first and second axial tracks. The positioner engages the first and second tracks without engaging the holder in an area opposite the first and second axial tracks. The positioner is movable along the first and second tracks.
[0019] In another aspect of the present invention, a holder assembly for a disposable liner that expels air from the liner is provided. The assembly comprises a holder having an outer circumference, an opening, and an axial slot in communication with the opening and formed by first and second walls, and a plunger having a disk and a positioner connected to the disk. The disk is removably disposed in the holder and movable in an axial direction in the holder to urge air from the liner. At least a portion of the positioner is accessible from outside of the holder along the axial slot. The positioner engages the axial slot along the first and second walls without engaging the holder in an area opposite the axial slot. The opening is at least partially defined by the first and second walls. The positioner can be selectively engaged and disengaged with the axial slot though the opening. The holder can have a first contact area and a second contact area. The first contact area is a first surface area of those portions of the first and second walls that are engaged with the positioner when the positioner is remote from the opening. The second contact area is a second surface area of those portions of the first and second walls that are engaged with the positioner when the positioner is in proximity to the opening. The first contact area can be greater than the second contact area.
[0020] In another aspect of the present invention, a holder assembly for a disposable liner that expels air from the liner is provided. The assembly comprises a holder having an outer circumference and an axial slot, and a plunger having a disk, a positioner connected to the disk and a pad connected to the positioner. The disk is removably disposed in the holder and movable in an axial direction in the holder along the axial slot to urge air from the liner. The positioner engages the axial slot without engaging the holder in an area opposite the axial slot. The pad is accessible from outside of the holder along the axial slot. The pad is made from a first material, and the positioner is made from a second material. The first material is softer than the second material.
[0021] In another aspect of the present invention, a holder assembly for a disposable liner that expels air from the liner is provided. The assembly comprises a holder having an outer circumference, a single axial slot, and a single axial channel. The axial slot is formed by first and second walls and is disposed in the axial channel. The first and second walls have inner and outer surfaces. The holder assembly further comprises a plunger having a positioner. The plunger is partially disposed in the holder and movable along a longitudinal axis of the holder to urge air from the liner. The positioner engages the inner and outer surfaces of the first and second walls. A portion of the positioner is accessible from outside of the holder and adjacent to the axial slot. The axial slot has an opening at its first end. The opening has an area smaller than an area of the portion of the positioner to allow selective removal of the positioner from the holder. The positioner can engage the inner and outer surfaces of the first and second walls without engaging the holder in an area opposite the axial slot.
[0022] In another aspect of the present invention, a holder assembly for a disposable liner that expels air from the liner is provided. The assembly comprises a holder having an axial slot and an opening, and a plunger having a positioner removably engaged with the axial slot. The plunger is partially disposed in the holder and movable along the axial slot to urge air from the liner. At least a portion of the positioner is accessible from outside of the holder and adjacent to the axial slot. The positioner engages the axial slot without engaging the holder in an area opposite the axial slot. The positioner is disengageable from the axial slot by moving the positioner in only a first single direction when the positioner is in proximity to the opening. The positioner can engage with the axial slot by moving the positioner in only a second single direction when the positioner is in proximity to the opening. The second direction can be opposite to the first direction. The first single direction can be a rotational direction. The axial slot can have at least one detent structure disposed adjacent to the opening that allows disengagement of the positioner from the axial slot by movement of the positioner in only the first single direction when the positioner is in proximity to the opening. The detent structure can be a first tapered edge and a second tapered edge. The first tapered edge can be formed on a first wall along a first end of the axial slot adjacent to the opening, and the second tapered edge can be formed on a second wall along the first end of the axial slot adjacent to the opening.
[0023] The holder can have an axial channel inwardly recessed from the outer circumference that has a width that allows at least a portion of the positioner to move through the axial channel along the axial slot. The axial slot can be formed in the axial channel. The holder can be transparent. The holder assembly can further have a nipple ring and a nipple removably securable to the holder. The axial channel can be partially formed by a first wall and a second wall. The first and second walls can be disposed along a bottom of the axial channel and the axial slot can be disposed between the first and second walls. The holder can have an opening in communication with the axial slot that allows for engagement and disengagement of the plunger with the axial slot. The opening can be at least partially formed by the first and second walls.
[0024] The pad can be co-molded with the positioner. The first material can be a thermoplastic elastomer. The axial channel can be partially formed by a third wall and a fourth wall, and the third and fourth walls can be disposed along opposing sides of the axial channel. The holder can have an opening in communication with the axial slot that allows for engagement and disengagement of the plunger with the axial slot, wherein the opening is defined by a portion of the first, second, third and fourth walls. The third and fourth walls can be substantially orthogonal to the first and second walls.
[0025] The positioner can have a plate, a rib, and an actuator. The plate can be secured to the disk. The actuator can be accessible from outside of the holder. The rib can connect the plate to the actuator. The rib can be disposed in the axial slot. The actuator can be at least partially disposed in the axial channel when the plunger is engaged with the axial slot. The rib, the plate and the actuator can define a pair of channels that engage with the first and second walls. The positioner can have a plurality or number of glide ridges that contact the first and second walls when the positioner is moved along the axial slot. In a front view, the positioner can have a square or rectangular shape and the opening can have a trapezoidal shape. The disk can have a circumferential lip to form a cup-like shape.
[0026] The holder can have an upper end with a first diameter and a lower end with a second diameter. The second diameter can be larger than the first diameter. The holder can have a middle portion with a third diameter. The first and second diameters are greater than the third diameter. The lower end can have a stabilizing structure. The stabilizing structure can be an outwardly extending bead.
[0027] Other and further objects, advantages and features of the present invention will be understood by reference to the following.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] [0028]FIG. 1 is a front perspective view of a holder assembly of the present invention;
[0029] [0029]FIG. 2 is an exploded perspective view of the holder assembly of FIG. 1;
[0030] [0030]FIG. 3 is a front view of the holder assembly of FIG. 1;
[0031] [0031]FIG. 4 is a rear view of the holder assembly of FIG. 1;
[0032] [0032]FIG. 5 is a side view of the holder assembly of FIG. 1;
[0033] [0033]FIG. 6 is a top view of the holder assembly of FIG. 1;
[0034] [0034]FIG. 7 is a bottom view of the holder assembly of FIG. 1;
[0035] [0035]FIG. 8 is a top perspective view of the plunger of FIG. 1;
[0036] [0036]FIG. 9 is a bottom perspective view of the plunger of FIG. 8; and
[0037] [0037]FIG. 10 is a side view of the holder assembly of FIG. 1 when the plunger is being disassembled.
DESCRIPTION OF THE INVENTION
[0038] Referring to the drawings and, in particular, FIGS. 1 and 2, there is shown a holder assembly according to the present invention generally represented by reference numeral 10 . The holder assembly 10 includes a hollow body, sleeve or holder 100 and a plate, burper or plunger member 200 adapted to be selectively retained with the holder but movable with respect to the holder.
[0039] The holder assembly 10 may include for use a nipple 300 , a nipple retaining ring 400 , a cap 500 and a disposable or flexible liner 600 . Examples of such liners are found in U.S. Pat. No. 6,123,222 to Richiger et al., U.S. Pat. No. 6,110,091 to Morano, and U.S. Pat. No. 5,806,711 to Morano et al., which are assigned to the assignee of the present application. Applicant hereby incorporates the disclosures of these patents by reference.
[0040] Referring to FIGS. 1 through 7, the holder 100 is preferably a hollow cylindrical tube that is open at an upper end 110 and a lower end 120 . Holder 100 has an ergonomic shape that facilitates gripping by the parent when the feeding process is being prepared and also facilitates gripping during the feeding process. In this embodiment, lower end 120 smoothly transitions into upper end 110 over the length of the holder. Preferably, lower end 120 has a diameter d 1 that is larger than a diameter d 2 of upper end 110 . More preferably, holder 100 has a middle portion with a diameter d 3 that is smaller than diameters d 1 and d 2 such that the holder has a narrowed or reduced waist for the user to hold while feeding. The outer surface of holder 100 can also have gripping structures and/or information, such as, for example, measurements.
[0041] Upper end 110 preferably has a diameter between about 2.0 inches to about 2.4 inches. More preferably, the diameter of upper end 110 is about 2.25 inches. Preferably, lower end 120 has a diameter between about 2.45 inches to about 2.75 inches. More preferably, the diameter of lower end 120 is about 2.56 inches. The enlarged diameter of lower end 120 facilitates access to the interior volume of holder 100 for cleaning and for positioning of liner 600 . The enlarged diameter of lower end 120 also facilitates disassembly of plunger member 200 from holder 100 , as will be discussed later in detail. Holder 100 preferably has a substantially uniform wall thickness of between about 0.03 inches to about 0.10 inches, and more preferably about 0.06 inches. The shape and size, including wall thickness, of the holder 100 facilitates manipulation by the user.
[0042] Lower end 120 of the holder 100 preferably has a bottom edge 125 , which is more preferably in the form of a bead or other stabilizing projection or structure. The edge 125 is preferably about 0.13 inches high and about 0.06 inches wide. Alternative structures can also be used for edge 125 such as, for example, an enlarged solid bottom edge to provide strength and rigidity to the structure. The edge 125 can be flared outward to provide stability to the holder 100 when it is placed in an upright position.
[0043] The holder 100 can be any material that will hold the liner 600 in position therein. The holder 100 is preferably formed of a rigid molded material, such as a rigid thermoplastic that will not warp. More preferably, the holder 100 is made of polypropylene. However, the holder 100 can be made of other materials, such as, for example, polycarbonate or other rigid thermoplastics. The holder 100 preferably is made of a transparent or semi-transparent material that allows the user to view the liner 600 in the holder and also allows the user to view the position of the plunger 200 . Preferably, plunger 200 has a contrasting color with respect to holder 100 to facilitate visual indication of the positioning of the plunger in the holder.
[0044] The holder 100 has a longitudinal or axial recess or channel 130 that is formed by a first wall 132 , a second wall 133 , a third wall 136 , and a fourth wall 137 . First and second walls 132 , 133 are substantially parallel with the outer circumference of holder 100 and inwardly recessed from the outer circumference of the holder. Third and fourth walls 136 , 137 are substantially orthogonal to the outer circumference of holder 100 and to first and second walls 132 , 133 . Preferably, channel 130 extends along a substantial length (from upper end 110 to lower end 120 ) of holder 100 .
[0045] First and second walls 132 , 133 have a space or slot 150 disposed therebetween. Preferably, slot 150 extends along a substantial length of channel 130 . More preferably, slot 150 is centrally disposed along channel 130 . The channel 130 and the slot 150 preferably have a uniform width or circumferential extant. The width of channel 130 is preferably between about 0.70 inches to about 0.85 inches. More preferably, the width of channel 130 is about 0.77 inches. The width of slot 150 is preferably between about 0.10 inches to about 0.18 inches. More preferably, the width of slot 150 is about 0.13 inches. Channel 130 and slot 150 are guides or tracks for the axial or longitudinal movement of plunger member 200 with respect to holder 100 . Preferably, holder 100 provides at least two guides or tracks for the movement of plunger 200 , i.e., channel 130 and slot 150 . The size of first and second walls 132 , 133 and third and fourth walls 136 , 137 are such that the channel 130 facilitates movement of plunger member 200 . First and second walls 132 , 133 , third and fourth walls 136 , 137 , and slot 150 have a size and shape that reduce or eliminate lateral movement of plunger member 200 , while allowing axial movement of the plunger along a substantial length of the holder 100 .
[0046] Referring to FIGS. 8 and 9, the plunger member 200 is, preferably, a single integral piece that includes a disk 210 and a tangentially connected positioner 250 . The disk 210 is preferably slim and circular, and corresponds to the interior shape of holder 100 . Where an alternative shape for holder 100 is used, such as, for example, oblong or ellipsoidal, disk 210 would have the corresponding shape so that the disk could move within the interior volume or space of the holder. Disk 210 preferably has a lip 215 about its circumference that forms a cup-shaped surface on the disk. The outer diameter of disk 210 and lip 215 is sized slightly less than the inner diameter of the holder 100 so as to permit the disk to move up and down within the holder. The cup-shaped configuration of the disk 210 can hold the bottom of the liner 600 therein, and can help to prevent the liner from falling or being pinched between the disk and the inner wall surface of the holder 100 as the plunger member 200 slides along the inside of the holder. While disk 210 is preferably integrally formed with positioner 250 , alternatively, the disk and positioner can be secured or attached to each other, such as, for example, adhesive.
[0047] The positioner 250 preferably has a plate 255 that is formed integrally with the disk 210 and extends upward and beyond the lip 215 of the disk. The positioner 250 also has an actuator 260 having a pad 265 , and an elongated bridge or rib 270 that connects the plate 255 and the actuator together, preferably at their center portions. On either side of rib 270 between plate 255 and actuator 260 , there are formed channels 275 . Each channel 275 is designed to accept and engage first and second walls 132 , 133 of channel 130 such that rib 270 is disposed in axial slot 150 . Channels 275 are engaged with the inner and outer surfaces of first and second walls 132 , 133 . Plunger 200 is movably secured to holder 100 along axial channel 130 and axial slot 150 but is preferably not secured to the holder on the side opposite the axial channel and slot. The disk 210 is separated from the holder 100 along the side opposite to the axial channel 130 and the axial slot 150 .
[0048] Pad 265 is preferably arched in shape to approximate the contours of the user's thumb. Preferably, actuator 260 has an upper edge 262 that flares outwardly away from the outer surface of holder 100 to form a thumb-accepting flared surface 267 in pad 265 . Upper edge 262 extends between about 0.25 inches to about 0.85 inches from holder 100 , and more preferably extends about 0.45 inches from the holder. The extended distance of upper edge 262 from the holder 100 provides a user with added leverage for sliding plunger 200 along the inner volume of the holder. This added leverage is of great benefit to the user where a force is needed to squeeze out air from the liner 600 , and is especially significant to facilitate preparation and use of the holder assembly 10 with only one hand.
[0049] Pad 265 is preferably made of a soft material to provide comfort to a user, such as, for example, thermoplastic elastomer (TPE). Preferably, pad 265 has a Shore A hardness between about 30 to about 70, and more preferably about 50. Pad 265 is preferably co-molded with actuator 260 , but the present invention contemplates the use of other attachment methods or structures between pad 265 and actuator 260 .
[0050] When plunger member 200 is to be moved axially upward, the user's thumb or other finger can engage and press up on the flared surface 267 or the underside of the pad 265 . When plunger 200 is to be moved axially downward, the thumb can rest on and press down on the top side of the same flared surface 267 .
[0051] Channels 275 can also have glide ridges 280 formed along the inner surfaces of either or both of plate 255 and/or actuator 260 . The glide ridges 280 are disposed adjacent to the inner and outer surfaces of first and second walls 132 , 133 and reduce the contact area between the first and second walls and the positioner 260 to reduce friction when the positioner 250 is moved with respect to the holder 100 . Any number of glide ridges 280 can be used.
[0052] Plunger member 200 and/or holder 100 can have frictional engagement structures, such as, for example, detent or ratcheting structures, to keep the plunger from sliding in slot 150 absent any pressure from the user or to prevent the plunger from sliding back down the holder. The force applied by the user to pad 265 to overcome this frictional engagement would be small enough to allow easy and smooth one-handed operation of holder assembly 10 .
[0053] Referring to FIGS. 1 through 9, channel 130 preferably has a lower end 140 defining an opening 142 . More preferably, opening 142 has a trapezoidal shape. First and second walls 132 , 133 terminate at the upper extant of opening 142 and have holding or detent structures 145 for selectively holding or retaining plunger 200 in opening 142 . In the preferred embodiment, detent structures 145 are tapered or angled edges of first and second walls 132 , 133 that partially define the trapezoidal shape of the opening. The opening 142 provides for insertion and removal of plunger 200 into channel 130 and slot 150 , while the detent structures 145 facilitate such insertion and removal by providing a limited resistance to the insertion and removal. Tapered edges 145 provide a reduced contact area, as opposed to the entire width of first and second walls 132 , 133 , to facilitate the insertion and removal of plunger 200 . In the preferred embodiment, a trapezoidal-like shape is used for opening 142 . However, the present invention contemplates other shapes for opening 142 that provide detent structures 145 to selectively hold plunger 200 in engagement with holder 100 but that can also be overcome with minimal force and manipulation to facilitate the assembly and disassembly of the plunger with the holder. Also, while the preferred embodiment has opening 142 at lower end 140 , the present invention contemplates positioning of opening 142 at other positions along axial channel 130 and axial slot 150 .
[0054] Referring to FIGS. 1 through 10, the user can disassemble plunger 200 from holder 100 by lowering positioner 250 into opening 142 so that plunger 200 is only being retained in channel 130 by tapered edges 145 of first and second walls 132 , 133 . The user can push down on outer edge 262 of actuator 260 so that the opposite end of plunger 200 is rotated upwards (towards upper end 110 of holder 100 ) as shown by arrow 700 in FIG. 10. The upward rotation of the plunger 200 releases the engagement between channels 275 and tapered edges 145 so that the plunger is disassembled from the holder 200 . The tapered shaped of edges 145 provide for a snap-like disengagement or disassembly of the plunger 200 and holder 100 . The plunger 200 can then be removed from the holder 100 through open lower end 120 . The plunger 200 is reinserted or assembled with holder 100 by reversing this process. The disassembly of plunger 200 from holder 100 preferably requires only movement of the plunger in a single direction 700 . More preferably, the single direction 700 is a rotational direction or movement. Similarly, assembly of plunger 200 with holder 100 preferably only requires movement of the plunger in an opposing single direction, which is more preferably a rotational direction or movement.
[0055] In use, liner 600 is inserted into holder 100 . Liquid is poured into the liner, and nipple 300 and nipple retaining ring 400 are secured to holder 100 , thus securing the liner in the holder. The plunger 200 is moved up firmly against the liner 600 maintaining the pressure on the liner until all the air is purged through an aperture in nipple 300 and a small amount of liquid is dispensed. The holder assembly 10 is inverted into feeding position and the fluid can be withdrawn by the infant. The actuator 260 and pad 265 is pressed with the thumb (or other finger) to slide plunger member 200 , and in particular disk 210 , up within the holder 100 . The disk 210 maintains slight compression on the fluid-filled liner 600 and thereby minimizes any air returning to the liner.
[0056] The upper end 110 of holder 100 has a neck 112 , preferably of reduced diameter, adapted to accept the retaining ring 400 . Preferably, the neck 112 has a threaded surface 115 , which mates with interior threads on retaining ring 400 . Liner 600 can have a rim that rests on the rim of neck 112 of holder 100 and is secured in place by retaining ring 400 . Alternatively, the neck 112 can be a smooth surface and/or biased inward from the top to the bottom in order to receive the retaining ring 400 having an alternative non-threaded interior surface. The bias would be approximately ten degrees to the vertical axis with a tolerance of plus or minus one-half degree. The cap 500 can be removably secured to nipple ring 400 . Preferably, nipple ring 400 has an upper lip 410 with an outer diameter corresponding to the inner diameter of the lower end of cap 500 so that a snap-fit engagement of the cap and lip is provided. Upper lip 410 and/or the lower end of cap 500 can have detents or detent means such as, for example, annular beads, to provide for a snap fit between nipple ring 400 and the cap.
[0057] The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined in the appended claims. | A holder assembly for use with a flexible liner is provided having a holder with a longitudinal slot and a plunger. The plunger has a disk and a positioner joined to the disk. The positioner engages the longitudinal slot to mount the disk slidably in the holder. The plunger is readily adapted for assembly and disassembly with the holder. | 0 |
FIELD OF THE INVENTION
The invention refers to a control equipment for an electro-magnetic linear motor and, more particularly.
DISCUSSION OF THE PRIOR ART
It is a known fact that electro-magnetic linear motors are used for driving vehicles which are running on rails. Basically, the linear motor functions in the same way as a threephase current squirrel cage induction motor where a rotating field drives the armature. If a threephase current motor is cut open in the axial direction and spread out on a plane, the result is a flat rotor and what is called a plane inductor fitted with coils which generates a linear travelling wave. Such induction combs are arranged adjacent to and alongside of the rails and at a certain distance with respect to the rails. A plate functioning as a flat armature is mounted on each trolley so that the plate moves past the induction combs with the shortest possible distance. By energizing the induction combs, a linear thrust is transmitted without contact with the trolley. This thrust is strongest when the trolley is stationary, and diminishes in a reciprocally proportional way to the trolley speed. FIG. 7 is a very simplified and schematic illustration of two such trolleys 1. Trolley 1 is equipped with running wheels 2 running on rails 3. On each one of these trolleys 1, a plate 4 functioning as a flat armature is fastened which extends in parallel to rail 3. Above the rail 3 the stationary induction combs 5 are arranged at a defined distance. The coils of the induction combs 5 and their connecting transmissions are not represented in FIG. 1. Since a linear motor not only transfers forces in the horizontal direction of motion of the travelling field, but forces of attraction between the induction comb 5 and the plate 2 also exist, two air gap spacing rollers 6 are mounted both in front and behind each induction comb 5 to guarantee a constant air gap between the induction comb 5 and the plate mounted below. Elastic elements 8 are arranged between the frame 7 of each trolley 1 and the associated plate 4 which press the plates slightly onto the air gap spacing rollers 6.
It is also possible to use single-phase induction combs which, for example, have four grooves each where one main coil and one auxiliary coil which are powered via a capacitor are located. These coils generate the travelling field. In order to keep the electric energy consumption as low as possible, it is common practice to energize each induction comb only when and as long as it is used for driving a trolley. Therefore, the energizing of the coils of the induction combs is switched on and off by the trolley without contact by means of a linear motor switch 9 which is mounted on each inductor. In connection with the linear motor switch 9, a sensor 10 which is mounted at the rear end of each induction comb 5 guarantees a gentle stacking of the trolleys, i.e. they smoothly drive against each other. By means of one transmission line 11 each, the sensor 10 of the following induction comb 5 is connected to the linear motor switch 9 of the preceeding induction comb, so that the induction comb 5 can only be energized by the linear motor switch 9 if there is no plate 5, i.e. no trolley 1, below the succeeding induction comb 5.
SUMMARY OF THE INVENTION
It is the purpose of the present invention to design a control equipment of the afore-mentioned kind which eliminates the linear motor switches and sensors mounted on the induction combs.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from the following detailed description which is provided in connection with the accompanying drawings in which:
FIG. 1 is a schematic representation of trolleys which are motorized by means of known electro-magnetic linear motors alongside a rail;
FIG. 2 shows a simple functional diagram of the control equipment based on the present invention;
FIG. 3 represents the basic diagram for generating the measuring signals;
FIG. 4 is a functional chart of the control equipment according to FIG. 2, containing more details;
FIG. 5 is the wiring diagram of an alarm circuit of the control equipment according to FIG. 2;
FIG. 6 is the wiring diagram of a delay circuit of the control equipment according to FIG. 2; and
FIG. 7 shows the series connection of several control equipments according to FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 depicts a functional diagram of an embodiment of control equipment 12 according to the present invention. A linear motor 17 is connected to four supply terminals 13, 14, 15 and 16 which (as can be seen from FIG. 3) contains a main coil 18, an auxiliary coil 19 and a capacitor 20 connected in line to the auxiliary coil 19. The control equipment comprises a switching circuit 21 for switching the linear motor 17 on and off, an alarm circuit 22 for the supervision of the currents flowing through the main coil 18 and the auxiliary coil 19 of the linear motor 17, a delay circuit 23 for the delayed switching-on of the linear motor 17, and a supply circuit 24 for generating the operation voltage for the alarm circuit 22 and the delay circuit 23.
Furthermore, there are the supply terminals P and N to which the phase and the neutral conductor of an A.C. power supply 220 V are connected. Further supply terminals P' and N' are connected in parallel to the supply terminals P and N so that the alternating voltage 220 V can be connected to the succeeding control equipment.
An output signal of the alarm circuit 22 appears at a supply terminal 25 if a plate (not shown) and which corresponds to the plate 4 in FIG. 1, is situated in the active area of the linear motor 17. The mentioned output signal is hereafter called the "engaged signal".
Via a supply terminal 26, an engaged signal generated by another control equipment can be transmitted to the delay circuit 23. By means of a conductor 28, a supply terminal 27 is connected with a supply terminal 29 which can be used for transmitting an engaged signal from a succeeding control equipment to a preceding control equipment. An output signal which is complementary to the above-mentioned output signal of the alarm circuit 22 is transmitted as a switch signal via a conductor 30 to the delay circuit 23. Via the transmission lines 31 and 32, blocking signals which are generated and delayed by the delay circuit 23 are transmitted to the alarm circuit 22 when the linear motor 17 is switched on and off.
FIG. 3 shows the basic diagram for the generation of the measuring signals 33 and 34 which are dependent on the currents flowing through the main coil 18 and the auxiliary coil 19 of the linear motor 17. In FIG. 3, a switching equipment 35 of the switching circuit 22 is represented above the linear motor 17, and a part of the alarm circuit 22 is represented below the linear motor 17. For the protection of the switching equipment 35, a series connection consisting of a resistance 36 and a capacitor 37 is mounted in parallel with switching equipment 35.
If the switching equipment 35 is electrically conductive, a current is flowing on one hand from the supply terminal P via the switching equipment 35 through the main coil 18 and through an antiparallel connection of two diodes 38 and 39 to the supply terminal N. In addition to this current, a compensating current which is defined by a resistance 40 flows through the two antiparallel connected diodes 38 and 39. A voltage appears at the antiparallel connection of diodes 38, 39 which is dependent on the sum of the two above-mentioned currents. This voltage is the rectangular measuring signal 33. On the other hand, a current flows from the supply terminal P via the switching equipment 35 through the series connection consisting of the capacitor 20 and of the auxiliary coil 19 and through another antiparallel connection consisting of two diodes 41 and 42 to the supply terminal N. The voltage appearing above the antiparallel connected diodes 41 and 42 is the rectangular measuring signal 34. The amplitude of the measuring signals 33 and 34 depends on the characteristics of the diodes 38, 39 and 41, 42 and rates for example approximately 0.7 V.
It should be noted that even when switching equipment 35 is non-conductive, a current flows via the series connection consisting of a resistance 36 and of a capacitor 37 through the auxiliary coil 19 as well as through the main coil 18. This means that the measuring signals 33 and 34 are present even if the switching equipment 35 is switched off. The rectangular form of the measuring signals 33 and 34 and their amplitude are always the same. However, the phase shift between these two measuring signals 33 and 34 depends on the respective operating measuring signals 33 and 34 depends on the respective operating status, i.e. if a plate corresponding to plate 4 in FIG. 1 is located in the active area of the linear motor 17 or not, and on the amount of resistance of the resistance 40.
The value of the resistance 40 is selected so as to guarantee that the phase shift difference between the measuring signals 33 and 34 is the same in the switched-on and in the switched-off condition of the switching equipment 35, if the aforementioned plate is in contact with 50% of the active area of the linear motor 17, i.e. if the front or the rear edge of the plate is in the center of the linear motor 17. The measuring signal 34' which is represented in FIG. 3 by a full bar appears if the mentioned plate is not within the active area of the linear motor 17, and the measuring signal 34" represented by a broken bar appears if the plate is in the active area. In other words: the measuring signal 34" derived from the current flowing through the auxiliary coil 19 is phase shifted by the presence of the plate.
FIG. 4 shows the wiring diagram of the control equipment according to FIG. 2. The switching circuit 21 is equipped with a triac 43 functioning as a switching equipment to the control electrode of which a control voltage is applied if required via a control medium 44 which may be a dry-reed contact or the receiver of an optocoupler. Moreover, there is a signalling lamp 45 which is illuminated when the triac 43 is conductive and which indicates if the linear motor 17 is switched on.
The supply terminal N for the neutral conductor is connected to the ground of the control equipment 12, and a PTC resistance 46 mounted between the supply terminal P and the ground of the control equipment serves for the protection of the control equipment 12 if the connection between the ground of the control equipment and the neutral conductor is missing.
The antiparallel mounted diodes 38, 39 and 40, 42 described with regard to FIG. 3, are contained in the bridge connected rectifies circuit 47 represented in FIG. 4, the D.C. connections of which are bridged-over and connected to the supply terminal N and the A.C. connections of which are connected respectively to the main coil 18 and to the auxiliary coil 19. The current rectifier supplies a stabilised operating voltage of 15 V for the alarm circuit 22 and the delay circuit 23 as well as a supply voltage of approximately 24 V which is transmitted via a conductor 48 to a driver circuit 49 of the delay circuit 23.
The measuring signal 33 available at the A.C. connection of the bridge connected rectifier circuit 47 which is connected with the main coil 18 of the linear motor 17, is transmitted to an evaluation circuit 52 via a low-pass filter 50 and a delay circuit 51. The measuring signal 34 available at the A.C. connection of the bridge connected rectifier circuit 47 which is connected with the auxiliary coil 19 is also transmitted to the evaluation circuit 52 via a low-pass filter 50'. On the conductor 30 which is connected to the output Q of the evaluation circuit 52, binary signal "1" appears if the afore-mentioned plate is within the active area of the linear motor 17, and a binary signal "0" appears if there is no plate in the active area of the linear motor 17. The binary signals which appear at the supply terminal 25 which is connected to output Q of the evaluation circuit 52, are exactly opposed to those on conductor 30.
The switch signal on conductor 30 is transmitted to an adjustable switch rise-delay time circuit 53 which conveys a signal retarded by 0 to 1.5 s to the driver circuit 49, if the binary signal "1" is transmitted to the delay time circuit 53. Via the transmission path 54 represented by a broken line, the driver circuit either mechanically, magnetically or electrically actuates the control medium 44 which controls the triac 43 which in turn supplies the operating voltage to the main coil 18 and to the auxiliary coil 19 of the linear motor 17 after the rise-delay time circuit has generated the signal for the driver circuit 49. As described in detail hereafter with regard to FIG. 7, the signal appearing at the supply terminal 25 can be transmitted as a busy signal to another control equipment 12.
In dependence upon the output signal of the rise-delay time circuit 53, a blocking signal is returned via a delay circuit 55 to the evaluation circuit 52 in order to block the latter during approx. 0.2 s; this prevents the evaluation circuit from responding to starting transients during the switch-on procedure which is initiated by the control medium 44. A blocking signal is transmitted to the evaluation circuit 52 via a second delay circuit 56 in order to block the latter during approx. 0.2 s after the output signal of the rise-delay time circuit 53 has been switched off; this prevents the evaluation circuit from responding to transient decay currents which occur immediately after the control medium 44 has been switched off. The first delay circuit 55 responds to the leading edge of the signal which is generated by the switch delay time circuit 53, while the second delay circuit responds to the trailing edge of the mentioned signal.
Via the supply terminal 26, an engaged signal from another control equipment 12 can be transmitted to the input of the rise-delay time circuit 53 via a resistance 57 (preferrably PTC). The function of this engaged signal is explained hereafter with regard to the description of FIG. 7.
The following paragraphs again describe the functioning method of the control equipment 12 represented in FIG. 4. If none of the mentioned plates are in the active area of the linear motor 17, the binary signal "0" is present on the conductor 30 because the phase relation between the two measuring signals 33 and 34 shows a value which is determined by the value selection of the resistance 40. As long as the signal "0" appears on the conductor 30, the switch delay time circuit 53 cannot transmit a signal to the driver circuit 49 and to the first delay circuit 55. When one of the mentioned plates enters into the active area of the linear motor 17, the phase of the measuring signal 34 is shifted in opposition of the measuring signal 33, which is detected by the evaluation circuit 52. The evaluation circuit then transmits a signal "1" to the conductor 30, and--depending on the adjustment--the switch delay time circuit 53 generates a signal for the driver circuit 49 after 0 to 1.5 s which causes the triac 43 in the switching circuit 21 to become conductive. At the same time, the evaluation circuit 52 is blocked via the delay circuit 55 in order to prevent the evaluation circuit from responding to transient signals.
Should an engaged signal be present at the supply terminal 26 even before the signal "1" appears on conductor 30, the switch delay time circuit 53 cannot respond to the signal "1" on the conductor 30. As soon as the engaged signal disappears at the supply terminal 26, the switch delay time circuit 53 responds immediately if the signal "1" continues to appear on conductor 30. When the plate leaves the active area of the linear motor 17, the phase shift between the two measuring signals 33 and 34 is cancelled which is detected by the evaluation circuit 52. Therefore, the signal "10" appears again on the conductor 30. This causes the switch delay time circuit 53 to stop transmitting signals to the driver circuit 49, and thus the triac 43 becomes non-conductive and the operation voltage for the main coil 18 and for the auxiliary coil 19 of the linear motor 17 is switched off. As soon as the signal at the output of the switch delay time circuit 53 disappears, the second delay circuit 56 generates a blocking signal for the evaluation circuit which is transmitted to the latter via conductor 31. This blocking signal persists approximately 0.2 s and prevents the evaluation circuit 52 from responding to the delay transient signals which occur when the operating voltage of both coils of the linear motor 17 is switched off.
FIG. 5 represents the wiring diagram of an execution example of the alarm circuit 22 of the control equipment according to FIGS. 2 and 4. The measuring signals 33 and 34 are available at the current rectifier bridge connection 47. The measuring signal 33 is transmitted via a resistance 58 to the inverting input of an operational amplifier 59. The resistance 58 and the parallel connection consisting a capacitor 60 and of a resistance 61 form a simple low-pass filter, and the operational amplifier 59 acts as an inverting amplifier. The serial connection consisting of a resistance 62, of an adjustable resistance 63 and of a capacitor 64 as well as of an operational amplifier 65, the non-inverting input of which is connected to the connecting point between the capacitor 64 and the adjustable resistance 63, constitute the delay circuit 51 of FIG. 4.
The evaluation circuit 52 comprises two D-flip-flops 66 and 67. The delayed measuring signal 33 is transmitted via an inverter 68 to the data input D and to the set input S of the D-flip-flop as well as to the cycle input T of the D-flip-flop 67. Output Q of the D-flip-flop 66 is connected with the data input D of the D-flip-flop 67. The second measuring signal 34 measured at the current rectifier bridge connection 47 is transmitted via the simple low-pass filter 52 which is constituted by the resistances 79 and 70 as well as by a capacitor 71, and via an operational amplifier 72 and an inverter 73 to the cycle input D of the D-flip-flop 66. Via the respective inverting drivers 74 and 75 with open collectors, the outputs Q and Q of the D-flip-flop are connected with the conductors 30 and 25 respectively. The set input S of the D-flip-flop 67 is connected to the conductor 31 and the reset input R to the conductor 32.
If a plate is within the active area of the linear motor 17, a rectangular signal appears at the output of the D-flip-flop 66, and the binary signal "1" appears if no plate is within the mentioned active area. Therefore, the signal appearing at the output Q of the D-flip-flop 67 is the binary signal "1" if no plate is within the active area of the linear motor 17, while the signal "0" appears if a plate is within the active area. The signals available at the outputs Q and Q of the D-flip-flop are inverted by the respective drivers 74 and 75, so that for example the signal "1" is present on the conductor 30 if the plate is within the mentioned active area, and at the same time the signal "0" appears at the conductor 25.
FIG. 6 shows the wiring diagram of the delay circuit 23. The switch delay time circuit 53 of the delay circuit comprises an operational amplifier 76, to the non-inverting input of which a reference voltage generated by a voltage divider containing the resistances 77 and 78 is fed. The conductor 30 is connected to a time constant circuit consisting of a resistance 79 and of a capacitor 80, and the connecting point between the resistance 79 and the capacitor 80 is connected to the inverting input of the operational amplifier 76. The conductor 30 is further connected via a serial connection consisting of a resistance 81 and of an adjustable resistance 82 to the positive terminal of the supply circuit 24 and via the PTC resistance 57 to the supply terminal 26.
As long as no plate is within the active area of the linear motor 17, the signal on the conductor 30 is "0", i.e. the output transistor of the driver 74 is conductive. Therefore, the voltage at the connecting point between the resistances 79 and 81 is practically zero and the capacitor 80 is discharged. Accordingly, the output signal of the operational amplifier 76 is equal to "0". Via an inverter 84, this signal is inverted and transmitted to a conductor 85. This inverted signal arrives at an inverting driver 86, the output of which is connected to an excitation medium 87, for example, an exciting coil of a dry-reed contact or a transmitter of an opto-coupler. The driver 86 and the excitation medium 87 together constitute the high level 49 of FIG. 4. The operation voltage of the excitation medium 87 is supplied via the conductor 48 by the supply circuit 24.
On one hand, the conductor 85 is connected to an input of inverter 88, the output of which is connected to the input of an inverter 91 via the serial connection consisting of a resistance 89 and of a capacitor 90, and on the other hand the conductor 85 is connected to an inverter 94 via another serial connection consisting of a resistance 92 and of a capacitor 93. The connecting points between the capacitor 90 and the inverter 91 and between the capacitor 93 and the inverter 94 are each connected to the positive terminal of the supply circuit 24 via a respective parallel connection consisting of a resistance 95 and of a diode 96.
The inverters 88 and 91, the resistance 89 and the capacitor 90 as well as the associated parallel connection consisting of the resistance 95 and of the diode 96 constitute the first delay circuit 55 of the delay wiring system 23 of FIG. 4. The inverter 94, the capacitor 93 and the resistance 92 as well as the associated parallel connection of the resistance 95 and of the diode 96 together constitute the second delay circuit 56.
The inverter 91 generates a blocking signal which lasts approximately 0.2 s, if the signal at the output of the operational amplifier 76 increases, this blocking signal being transmitted via the conductor 32 to the reset input R of the D-flip-flop 67 of the alarm circuit 22. The inverter 94 generates a blocking signal of approximately 0.2 s, if the signal at the output of the operational amplifier decreases, this signal being transmitted via the conductor 31 to the set input of the D-flip-flop 67.
As soon as the plate enters into the active area of the linear motor 17, the signal on the conductor 30 changes from "0" to "1", i.e. the output transistor of the driver 74 becomes non-conductive. The result of this is that the capacitor 80 is charged via the resistances 79, 81 and the adjustable resistance 82 if there is no busy signal at the supply terminal 26. After a period, adjustable by means of the adjustable resistance 82 between 0 and 1.5 s, the voltage at the capacitor 80 reaches the value of the above-mentioned reference voltage, and the output voltage at the output of the operational amplifier 76 quickly increases. The result of this is that the signal "1" on conductor 85 changes to "0" and the excitation medium 87 is excited, which in turn causes the triac 43 in the switching circuit 21 to become conductive and the main coil 18 and the auxiliary coil 19 to be energized by the operating voltage and the plate is thus moved forward by the linear motor 17.
The signal change from "1" to "0" on the conductor 85 causes the inverter 91 to supply the above-mentioned blocking signal, the duration of which depends on the value of resistance 89 and of the capacitor 90, whereas the inverter 94 does not react to this signal change.
After the plate has been moved away from the active area of the linear motor 17, the signal on conductor 30 changes back to "0". The result of this is that the capacitor 80 is quickly discharged via the resistance 79. This causes the voltage at the inverting input of the operational amplifier 76 to sink below the mentioned reference voltage, which in turn causes the output voltage of the operational amplifier 76 to revert to its initial value. This results in a signal change from "0" to "1" which occurs on conductor 85. Thereupon, the inverter 94 transmits a blocking signal via conductor 31 to the set input S of the D-flip-flop 67 during a period which is determined by the capacitor 93 and by the resistance 92. This blocking signal maintains the D-flip-flop in the set status until the transient decay effects which have been caused by the switching-off of the operation voltage for the main coil 18 and the auxiliary coil 19 of the linear motor by the triac 43 have been damped. The inverter 91 does not react to the signal change from "0" to "1" on the conductor 85; however, the excitation medium 87 is de-energized, which results in the already mentioned switching-off of the operation voltage by the triac 43.
If, for the reason described hereafter with regard to FIG. 7, an engaged signal in the form of a binary signal "0" is present at the supply terminal 26, the capacitor 80 of the delay wiring system 23 will not be charged, not even if the driver 74 is actuated by the output signal at the output Q of the D-flip-flop 67.
FIG. 7 is a rough schematic representation of a part of an installation with four consecutively arranged linear motors 17, 17a, 17b and 17c, including the associated control equipments 12, 12a, 12b and 12c. Of course the linear motors 17 through 17c are each equipped with a main coil and an auxiliary coil, even though FIG. 7 shows only one coil. Furthermore, only the plates 4' and 4" are represented. In order to simplify the drawing, the associated trolleys have been left out. The general sense of movement of the plates 4' and 4" has been indicated by an arrow 97.
According to the situation represented in FIG. 7, the plate 4" is within the active area of the linear motor 17b. This fact has been detected by the control equipment 12b, and the associated switching equipment 35 is closed, i.e. conductive, which means that the linear motor 17b is active and drives the plate 4" in the direction of the arrow 97 because no engaged signal is present at the supply terminal 26 of the control equipment 12b. The alarm circuit 22 of the control equipment 12b generates an engaged signal which is transmitted via the output terminal 25, a link circuit 98, the conductor 28 of the control equipment 12 a and a further link circuit 99 to the supply terminal 26 of the control equipment 12. This engaged signal blocks the delay circuit 23 of the control equipment 12 which prevents the associated linear motor 17 from being switched on even though the plate 4' is within the active area of this linear motor 17. This fact has of course been detected by the alarm circuit 22 of the control equipment 12 which therefore transmits an engaged signal to the output terminal 25 of the control equipment 12. This engaged signal is transmitted in the same way as mentioned above with regard to the engaged signal of the control equipment 12b to a preceeding control equipment which is not represented in FIG. 7.
The plate 4' moving below past the linear motor 17 is accordingly not accelerated, unless the plate 4" leaves the active area of the linear motor 17b before the plate 4' has moved out of the active area of the linear motor 17. This is when the busy signal generated by the control equipment 12b is switched off, and after the switch delay time adjusted in the delay circuit 23 of the control equipment 12 has expired, the linear motor 17 is switched on, provided that the plate 4' is still within its active area.
As soon as the plate 4" enters into the active area of the linear motor 17c, this fact is detected by the alarm circuit 22 of the control equipment 12c which generates an engaged signal that is transmitted via the supply terminal 25 of the control equipment 12c, a link circuit 100, the conductor 28 of the control equipment 12b, a link circuit 101 and the supply terminal 26 to the delay circuit 23 of the control equipment 12a. This prevents the linear motor 17a from being activated, which in turn prevents an acceleration of the plate 4' that has entered into the active area of this linear motor for as long as the plate 4" is within the active area of the linear motor 17c.
The wiring method described above can be used for the entire track of an installation; however, it is particularly advantageous to use it on so-called accumulation track sections in front of point mechanisms or chain drive units. This wiring method prevents trolleys from colliding harshly with each other. Furthermore, only those linear motors are switched on which are absolutely required. This allows for a considerable energy savings. During the stacking procedure, the trolleys smoothly approach each other and are subsequently separated when they move on, which is also the case on the normal track sections.
The engaged signal can also be transmitted to the control equipment which follows immediately. The switch delay time, caused by the delay circuit 23, is adjustable and influences the average speed of the trolleys. A long switch delay time results in a slow average speed, while a short switch delay time results in a high average speed. | A control apparatus for a linear motor, having main and auxiliary driving coils and which drives a movable plate is disclosed. The control apparatus, which determines if the plate is within an active area of the motor and, if so, supplies current to the coils, includes an alarm circuit for generating a first measuring signal dependent on the current flowing through the main coil and a second measuring signal dependent on the current flowing through the auxiliary coil. The phase relation between the two measuring signals changes depending on whether the plate is within the active area of the linear motor or not. The alarm circuit senses the measuring signals and generates a switch signal at a first output and an engaged signal at a second output if the plate is within the active area of the linear motor. The switch signal is coupled to an adjustable delay circuit which transmits the delayed switch signal to a switching circuit to actuate a switching medium connected in series with the linear motor. The delay circuit has another input for an engaged signal generated by another control apparatus and, if such an engaged signal is present, the transmission of the switch signal to the switching circuit is prevented. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates, in general, to a method and apparatus for maintaining and improving the growth density of turf grass root systems in residential lawns, commercial lawns, athletic fields, recreational areas including golf courses and agricultural fields used for cattle grazing or hay production.
The invention described and claimed provides a more efficient and cost effective way of applying a variety of naturally occurring mineral based aggregates and soil amendments in a system which greatly improves the growing conditions for ornamental grass areas. In addition, the apparatus disclosed for these applications is of a unique design, which greatly improves growing conditions of grass turf and other planting materials by increasing the depth and density of the plant's root system. In addition, the efficiency of the process can be seen particularly in the application of granular aggregates as well as compost, fertilizer and other soil amendments.
To improve the appearance of an ornamental lawn it is desirable to eliminate the harmful effects of the thatch of dead grass and clippings which accumulate during the life of the lawn. In the past, this was accomplished by “dethatching” using power rakes or hand rakes to loosen the thatch and then raking the thatch from the lawn and disposing of it in a land fill or other dumping areas. This operation is time consuming as well as labor intensive. Since lawn improvements are most effective if carried out during the peak growing season, the labor described above is, of necessity done in hot and often humid weather conditions.
Another step in the traditional methods of lawn improvements is to deliver any materials to be applied to the lawn by truck and dump them in a pile on the site. Next, the material must be shoveled into wheelbarrows or distribution apparatus to be applied to the lawn. Again, the process is labor intensive and must be done under adverse weather conditions. If the shoveling task is to be avoided in the present systems, a front-end loader or similar machine must be trucked to the site for loading the distribution machine and picked up after the job is finished; another time consuming and costly event for the contractor.
The present invention also discloses a system including the order of application of various aggregates and amendments, which give the optimum growing conditions for ornamental grasses. If certain soil amendments are applied in the wrong sequence in the process or are not covered quickly by the next application, their effectiveness is diminished or totally lost.
SUMMARY OF THE INVENTION
The present invention overcomes these disadvantages by improving the efficiency of distribution of the materials to be applied to the lawn as well as using a specific order of application and selection of materials, which may be varied according to site conditions.
With the present invention any materials which are to be spread on the area are delivered to the site in a unique vehicle which allows the materials to be loaded directly into the final distribution machine thereby eliminating the labor intensive shoveling as well as speeding up the time for completing the job.
After application of the materials, they are smoothed using a unique drag screen which spreads the material evenly over the treated area and leaves a smooth eye-appealing surface.
Finally, this system disclosed herein provides a systematic method for applying the materials in the order that will give the most benefit to the growing area treated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the primary material distribution vehicle and the secondary distribution vehicle in the loading position.
FIG. 2 is a view of the discharge end of the vehicle of FIG. 1 .
FIG. 3 is an isometric view of the drag mat of the invention.
FIG. 4 is a view of the drag mat of FIG. 3 in operation.
FIGS. 5A and 5B illustrate the size and spacing of aeration holes.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown generally at 10 , the primary delivery vehicle for the system. The vehicle comprises a basic truck frame for a truck having a total vehicle gross weight of 16,000 t0 33,000 pounds. The vehicle is equipped with a hopper type body 11 having sloping sides 13 to allow the load to be funneled toward the bottom of the hopper as the load is dispensed. Extending from the rear of the truck is the dispensing mechanism 23 . Note that the dispensing mechanism 23 is located approximately four feet above the ground so that a topdressing vehicle 22 can be backed under the dispenser 23 for loading. This will be described in more detail below.
The dispensing mechanism 23 consists of a chain link conveyer of any known type. The chain link conveyer runs the entire length of the lower surface of the hopper 11 . The chain link convey is activated by a pair of hydraulic motors 14 supplied with high-pressure hydraulic fluid from a pump driven by a power-takeoff from the truck engine. The pump speed is controlled by an electronic control panel 12 on the side of the apparatus 10 . Aggregate 20 is released from the hopper type body 11 by opening a gate 16 which is opened by a hydraulic piston 18 controlled by the electronic control panel 12 . The rate of delivery of aggregate can be controlled by regulating the speed of the motors 14 , by adjusting the opening of the gate 16 and by the speed of the vehicle truck engine which powers the power take-off feeding the hydraulic pump.
The topdressing vehicle or cab 22 is shown backed up to the dispensing mechanism 23 of the primary delivery vehicle loaded with aggregate 20 . The cab 22 has at its rear end a hopper 24 (FIG. 2) for receiving the aggregate 20 . Note that the hopper 24 of the cab 22 moves under the raised dispensing mechanism 23 of the hopper type body 11 . The cab 22 is of any commercially available machine and includes hopper 24 and a dispenser 26 . The cab 22 , hopper 24 and dispenser 26 together form the prior noted topdresser. The cab 22 is a power-driven vehicle similar in size to a standard golf cart on which the hopper 24 and dispenser 26 are mounted.
Referring now to FIG. 2, there is shown a more close-up view of the dispensing 26 of the primary delivery vehicle. Again, the hopper type body 11 is opened by use of the gate 16 operated by the hydraulic cylinder 18 . As can be seen, the aggregate 20 falls from the conveyer of the dispensing mechanism 23 directly into the hopper 24 of the topdresser. The advantages of this combination of apparatus allows the topdresser to be loaded directly from the primary delivery vehicle rather than having the primary load dumped in a pile on the site and then shoveled into the topdresser by hand, thus eliminating a substantial amount of labor and its associated costs. Using the equipment and method of this invention, a single operator can load ¾ to one ton of aggregate into the hopper of the topdresser in about 20 seconds after engaging the conveyer switch at the control panel 12 .
Referring now to FIG. 3, there is shown a detail drawing of the drag mat used in the practice of this invention. The leading edge of the mat 30 is made of a hardened steel bar approximately ⅜″ square. A frame 34 is a rectangle 3′6″ long and 2″4″ wide made of angle iron of about 1″×1″. In the area enclosed by the frame a flexible chain link material is fastened. At the front edge of the mat there is attached two loops 38 to which is attached to a cable or chain 40 . The cable or chain is joined at its distal end by a ring or other suitable means 42 for hooking the mat to a vehicle when it is to be used in the method. FIG. 4 shows the mat in operation. The detailed function of the mat will be described more fully in the description of the operation of the system.
FIGS. 5A and 5B show specified area of soil 44 to be treated, and the general plan for spacing, size and depth of aeration holes made in the first step of the method. “a” dimension indicates the core diameter, while the “e” and “f” dimensions indicate the center to center spacing of the cores, and the “d” dimension indicates the depth of the cores. The choice of these dimensions depends on the conditions set forth in Table 1 below.
In this first aerating step, a mechanized aerator unit is first sprayed with a cleansing solution to eliminate contamination from pathogens from previous applications. This cleansing step prevents the spread of turf grass diseases from one application site to another. The mechanized aerator unit is one that is adjusted for size, density and depth of core according to the information on Table 1 below.
TABLE 1
Aeration core spacing
spacing
dia.
length
inches on
density
inches
inches
center
cores per
Soil Type
(a)
(d)
(f)
M sq. ft.
Heavy clay - clean
¾″
3.0″
3′
6,000
Heavy clay - sandy
⅝
2.5
2.25
23,000
Sandy Loam
½
2.5
2.25
23,000
Sand
⅜
3.0
2.25
23,000
Loam
⅝
3.0
2.25
16,000
Topsoil - clean
¾
2.5
2.25
23,000
All soils - containing rock
¾
4.5
6.25
7,000
All soils - lightly
¾
4.5
6.25
7,000
Compacted
The second step which is an optional step is to apply an even coating of a mycorrhizal fungus such as basidomycete ( Coprinus macorhizus ). Much of the fungus, which is spread in a powdered or pellet form, will fall into the aeration holes. This type of fungus forma a closely woven mass around the roots of the existing grass and may even penetrate the root structure enhancing the root system depth of growth and density of growth. An additional option in this second step is the application of fertilizer in pellet form. The selection of fertilizer blend of nitrogen, phosphate and potash is dependent on turf type, soil conditions and environmental conditions.
The next step is to spread an aggregate material, commonly called topdressing, over the area. The aggregate must be spread quickly after the application of the fungus (within 30 minutes) since the fungus will be damaged by exposure to the air for an extended period of time. This aggregate is preferably, a mixture of river washed sand of sieve size 33 with no more than 5% of fines sand, composted organic materials as well as other naturally occurring soil amendments, the selection of which are dictated by the soil conditions and environment. This application of aggregate material will, at least partially, fill the aeration holes thus protecting the fungus from deterioration as well as lightening the general character of the soil. This is particularly true when the basic composition of the soil is clay or other soil which resists the absorption of water and other nutrients. The sand will absorb water and nutrients and feed the grass roots needed amendments applied in the next step of the process.
After the sand has been spread, the entire area is dragged using the drag mat shown in FIG. 3 . The construction of the mat results in two benefits from the dragging step. First, the drag mat evens out the coating of sand to provide a uniform coating and breaks up the aeration plugs and distributes the soil therefrom with the sand. Secondly, the mat, because of its construction, levels the area treated. This is accomplished by providing the mat with a hardened steel leading edge about ⅜″ square in cross section and extending along the length of the front edge the mat. This hardened steel bar scrapes off the high points in the surface of the area and deposits the scraped-up soil into the low spots of the area. Soil scraped from high spots tends to flow over the leading edge of the mat and be dispersed through the openings in the chain link mat with the sand and aeration plugs.
It is to be understood that all of the aggregates applied, sand, compost, fertilizer as well as the fungus powder may be applied using the equipment described above. In the alternative, some of these may be applied using conventional manual spreaders if the makes this equipment more efficient.
Since many lawn areas have an uneven surface and also include planted areas which cannot be accessed easily by mechanized spreaders. In these areas all of the aggregates may be applied and smoothed manually. Also, even in the areas treated mechanically, it is often necessary to fill small voids using hand scoops and rake these areas by hand.
The final step in this process is to apply a liberal amount of water over the treated area. This step feeds the grass roots that needed moisture and helps in settling the various aggregate applied into a uniform aggregate coating.
The following table lays out the steps described above in a graphical manner to aid in understanding the method of the invention.
TABLE 2
1
Aeration
mechanically breaks up thatch and provides
access to roots by aggregates
2
Spread fungus
Encourages root growth
3
Spread sand
Protect fungus & receive aggregates
4
*Spread compost
Add organic matter to soil
5
*Spread fertilizer
Enhance growth
6
Drag
Spread aggregate and smooth
7
Scoop
Fill open spots
8
Rake
Distribute and smooth scoops
*denotes optional step
Thus it can be seen that there is herein described unique apparatus for delivering and dispensing soil aggregates and a unique method of combining combinations of these aggregates in a specified order that will have a maximum effect in lawn improvement. | Method and apparatus for dispensing aggregates for lawn improvement. Aggregates are delivered to the site in a primary dispensing vehicle, which is configured to allow a smaller secondary dispensing vehicle to be loaded with the aggregate directly from the primary vehicle. The process includes aerating the soil, distributing a variety of soil amendments evenly over the area to be treated and then dragging a unique drag mat over the area to make a smooth contour and to even the distribution of the aggregate. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/037,536 filed on Aug. 14, 2014, titled, “Sleep Data Chain of Custody”, which is hereby incorporated by reference in its entirety.
BACKGROUND
This document is related to sleep monitoring/tracking, and more particularly to a system and method for establishing manageable, verifiable and accurate chain of custody for sleep monitoring/tracking data.
Establishing such chain of custody for sleep regulation is crucial as mandated rest periods for employees become more common. Rest periods fall into three primary categories: those that are required by law; those that are not yet required by law but are garnering public support for implementation (for example, for physicians and other health care workers); and those that employers electively require to promote safer workplaces.
Thus far, increased monitoring/tracking of sleep has proven successful. For example, in the decade ending in 2011 in the trucking industry, large truck crashes declined 26 percent from 5,111 to 3,757, because new sleep research showed that working long hours daily and weekly eventually caused chronic fatigue, slow reaction times and reduced ability to assess situations, including personal fatigue levels. As another example, in 2010 and 2011, federal agencies tightened regulations governing rest periods for both airline pilots and air traffic controllers due to research supporting links between adequate rest and safety. Other transportation industries, including railroad and shipping groups, have voluntarily implemented better policies requiring adequate rest for workers. Some industry groups including the U.S. Occupational Safety and Health Administration, Accreditation Council for Graduate Medical Education, and the consumer-advocacy group Public Citizen, have been or will be considering whether better sleep and/or rest requirements for health care workers might ultimately benefit both professionals and patients.
Currently, there is no way to effectively monitor compliance with sleep requirements (i.e., whether employees are actually taking mandated rests.) This does not honor the spirit of the law, which is to promote safer environments for workers and the public. It also makes assessing the efficacy of these regulations difficult.
Some trucking companies have “electronic logs” situated near steering wheels, which record when the motor is on or off, whether or not the trucker is off-duty, and gas mileage. These devices prevent truckers from taking unauthorized short-cuts or driving over the speed limit, but they do not track whether drivers are sleeping. In some instances, they are also noisy and distracting.
Some professionals, for example, pilots and physicians, may be mandated or requested to self-report fatigue, sleepiness or exhaustion. However, they may feel professionally pressured to underreport these experiences. Additionally, exhausted individuals may not be able to recognize their own state of exhaustion.
What is needed is a more effective solution than self-reporting or electronic logs.
SUMMARY
This document presents a wearable sleep tracking device that maintains chain of custody of sleep-related, and biometric data, which can include time an individual is asleep and time the individual is awake or alert. The sleep tracking device can track a large number of data sources to maintain and ascertain various compliance thresholds with one or more configurable sleep-related regulations or requirements.
In one aspect, a wearable device includes one or more biometric sensors. Each of the one or more biometric sensors to gathering biological data from a wearer of the wearable device, the wearable device further having a computer processor for receiving the biological data from the one or more biometric sensors and generating biometric information based on the biological data and according one or more biometrical algorithms. The biometric information includes validation information to validate the wearer as a source of the biological data gathered by each of the one or more sensors. In some implementations, the biometric information includes sleep information to provide or generate a sleep profile of the wearer.
In some aspects, a system can further include a transceiver coupled with the wearable device, the transceiver for transmitting the biometric information as a digital signal to one or more web servers via a communications network. The system can further include a chain of custody engine associated with the wearable device, the chain of custody engine to provide a chain of custody validation for the biometric information from the wearer to the one or more web servers.
In other aspects, A computer-implemented method includes the steps of gathering, by one or more biological sensors of a wearable device, biological data from a wearer of the wearable device, and generating biometric information by a computer processor of the wearable device based on the biological data and according one or more biometrical algorithms. The biometric information includes validation information to validate the wearer as a source of the biological data gathered by each of the one or more sensors, the biometric information further including sleep information to provide a sleep profile of the wearer. The method further includes transmitting, by a transceiver coupled with the wearable device, the biometric information to one or more web servers via a communications network. The method further includes maintaining, by the computer processor, a chain of custody of the biometric information from the wearer to the one or more web servers.
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.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects will now be described in detail with reference to the following drawings.
FIG. 1 illustrates a wearable sleep tracking device and its component parts.
FIG. 2 is a block diagram of a wearable sleep tracking device and system.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
This document describes a wearable sleep tracking device that gathers biometric information from a wearer, and that maintains chain of custody of sleep-related data generated from the biometric information.
The broad definition of chain of custody is considered as establishing the identity and integrity of physical evidence by tracing its continuous whereabouts. In the case of wearable sleep tracking devices, identity refers to the person whose rest was being monitored; for example, a truck driver, pilot, air traffic controller, or physician. Although the “evidence” collected and transmitted refers to physical quantities; for example, heart rate and other biometrics, here “integrity” refers to the direct and accurate relationship between the biometric data collected and the user. The chain of custody ascertains that the biometric data belongs to the user, throughout the data collection, transmission and aggregation processes. The data's “whereabouts” would be continuously monitored, user-tagged, assessed and stored in an impermeable loop between wearer and end-user.
The wearable sleep tracking device is configured to transfer data from the wearer to a centralized data aggregation and processing system. Examples of data might include actigraphy, GPS coordinates, time worn, and biometric data such as heart rate, EKG readings, skin temperature, and skin galvanic response. Thus, the wearable sleep tracking device can transmit data to a mobile phone or other intermediary device, which then transmits the data with or without processing via Internet pathways (wireless or otherwise) to a central server. In alternative implementations, the wearable sleep tracking device can include a transceiver for direct data transfer from the wearer to the central server. The central server traffics the data to a supervisor terminal or other consumption system.
In some implementations, the wearable sleep tracking device includes at least one sensor that is always in contact with the wearer, such as on the underside of a band, such that at random or programmed intervals the sensor takes a biometric reading to confirm that the authenticated user is wearing the device. This chain of custody confirmation can then be mapped by a computer with other data (GPS, timestamp, etc.) to determine if the wearer is in compliance. The ability to take a biometric reading without user interaction, such as requiring a wearer to touch a sensor, is important to validate chain of custody of the data collected and/or transferred by the wearable sleep tracking device while the wearer is asleep.
When the wearable sleep tracking device is unable to communicate to the central server, it will store any captured data locally for a period of time, until the next time it re-connects with the central server. Further, when the wearable sleep tracking device is not able to communicate directly to the centralized system, it communicates through a connected intermediary; i.e., a smartphone. This centralized system will analyze the data and provide data, information, and alerts to end-users. The chain of custody enables end-users to draw direct, accurate inferences regarding the wearer's episodic and/or accumulated rest patterns to ensure safety and legal compliancy. End-users include the wearer of the sleep tracking device, supervisors, regulatory agencies, etc.
In accordance with some preferred implementations, a device for maintaining chain of custody is a tamper-proof seal, akin to a lock snap. Physically this may employ the same technology as a plastic wristband: waterproof, lightweight, stretch-resistant, durable wristbands that lock into place with permanent locking snaps. The locking snap maintains chain of custody by assuring wearer connection with the sleep tracking device. If the wearer attempts to tamper with the device for removal or unauthorized transfer to another wearer (for example, a passenger in the vehicle) the tamper-proof seal would break.
For best compliance, the tamper-proof seal is preferably applied and monitored manually. This could introduce problems of inefficiency and manageability, requiring person-to-person examination of the tamper-proof seal for signs of damage. Given the physical effort that could be involved in some industries (for example, trucking) wearers with broken seals could make the plausible argument that the appearance of tampering, or a broken or missing lock, happened by accident. Applying, monitoring, repairing and replacing tamper-proof seals can be time-consuming and subject to human error.
While managed employees are subject to the company mandates and requirements provided by employers, independent contractors are not necessarily subject to these same requirements or may not be independently motivated to comply by applying tamper-proof seals. This creates issues of accountability, compared to managed employees. Tamper-proof seals interfere with functions related to recharging devices, or switching devices. (For example, an independently contracted trucker may ferry a container for one company on an outbound trip, but another company on the return trip. This makes tracking devices and users, and maintaining the chain of custody, a difficult task that becomes vulnerable to security breaches or data compromise.
Tamper-proof seals can be physically uncomfortable or distracting for drivers. Plastic wristbands and locking snaps are not designed for long-term use; most wearers limit use to hours or an evening; for example, a theme park or music concert. The cumbersome design could become irritating on long-distance trips because of shape, texture and other factors. Tamper-proof seals might potentially suggest a lack of trust between an employer and driver, resulting in the psychological factor of increased resentment at the notion of always being tracked. This could decrease wearer buy-in for the program, since the seal offers no compensatory benefits.
Accordingly, in some alternative implementations of a device for maintaining chain of custody, heartbeat and ECG information from a wearable device are used to authenticate that the data stream is coming from a specific user. Heartbeat authentication functions the way traditional fingerprinting functions: an individual's unique heartbeat pattern can provide positive identification. Heartbeats can securely communicate a wearer's identity to devices, including wearable devices. Cardiac rhythms function as smart passwords, wirelessly transmitting identity to wireless devices.
In some implementations, wearers place a finger on the device's top sensor, and allow their wrist to contact with the device's bottom sensor, completing an electrical circuit. The device alerts wearers than an electrical circuit has been completed by vibrating and illuminating LEDs. Wearers remain “authenticated” until the device is removed. In some cases, a “three factor security system” helps maintain the chain of custody. The system requires three factors present to complete the positive ID loop: a) the heartbeat tracking device b) the unique heartbeat and c) a third device, such as a smartphone, registered to the device application.
This concept combines heartbeat and ECG sensor and software with sleep tracking sensors and software available in existing consumer fitness and sleep trackers. The device's sensor and software maintains positive identification of the wearer, assuring that the wearer remains the same throughout data collection, transmission, and aggregation. The device can be removed for comfort, or during non-working hours. Further, the device can re-establish chain of custody through biometric authentication solely by the wearer.
Sleep tracking sensors and software monitor the wearer to determine periods of activity and rest. Data for body temperature, heart rate, movement and other factors can be assessed for indicators of adequate rest or sleep. If the sleep tracking and chain of custody data stream is tied to a GPS data stream (i.e., from a smartphone) then it can be inferred that the wearer of the device is at a specific location, within a margin of error (+/−30 feet) if the device is connected to the GPS via Bluetooth. The system can dynamically, in real time, respond to changes in location information and update or alert the supervisors as appropriate.
In some implementations, an exception can be made for when the wearer leaves the planned route/corridor can be preprogrammed into the system, or dynamically updated through human interaction. For example, alerts can be sent if the wearer leaves the preset route, or conversely, the tracking can be switched off if the wearer leaves the route.
This process can track mandated rest periods, and determine if the user is driving or not. In some implementations, an algorithm used by the wearable sleep tracking device is configured to determine between sustained driving versus in-town commuting. The system can switch off as needed or desired to accommodate truckers who are still wearing the device but no longer require the supervision or management of employers or regulatory agencies.
In accordance with the disclosure herein, a wearable sleep tracking device can maintain public safety by ensuring that regulated employees, such as truckers, pilots and air traffic controllers, receive the mandated rest periods required by federal agencies. The device and system can calculate metrics and values in a repeatable and automated matter to ascertain characteristics associated with sleep and rest.
FIG. 1 illustrates a wearable sleep tracking device 100 , which is configured to be worn, attached to, or otherwise affixed to a part of a wearer's anatomy. The sleep tracking device 100 in FIG. 1 is shown as a bracelet or ankle cuff, but can be any type of attachable or wearable structure. The sleep tracking device 100 includes an input/output module 102 that can contain a transceiver or other I/O port, a communications module 104 that can format information collected by the sleep tracking device 100 in a format that can be transmitted by the input/output module 102 , and one or more biometric sensors 106 . The biometric sensors 106 can include, without limitation, a heartrate sensor, a breath rate sensor, a body temperature sensor, a blood pressure sensor, a sleep sensor, or other biometric sensor.
The sleep tracking device 100 further includes a user display 108 for displaying information collected by the one or more biometric sensors 106 , or received by the sleep tracking device 100 via input/output module 102 . For instance, the user display 108 can display feedback or instructions from a monitoring entity that monitors the wearer's sleep status remotely. The user display 108 can also display real-time data such as time, location, task or task status, or the like. The sleep tracking device 100 can further include an accelerometer 110 for monitoring acceleration and movement of the wearer of the sleep tracking device 100 . The sleep tracking device 100 further includes a logic processing unit 112 for processing information collected by the sleep tracking device 100 via the one or more biometric sensors 106 , or from the input/output module 102 , or even the user display 108 (if the display also functions as a touch-sensitive input device). The sleep tracking device 100 may include a battery 114 or other power source. All of the above components of the sleep tracking device 100 can be housed in a housing 101 , which can take any of a number of forms.
FIG. 2 is a block diagram of a sleep tracking system 200 . The system 200 includes one or more wearable devices 206 , as substantially described above, which are in communication with a mobile device 204 and/or industry computing console 208 . The industry computing console 208 can be programmed with logic to process and manage data to and from the wearable devices 206 . The mobile device 204 can be associated with a wearer of the wearable device 206 . In some implementations, communication can be executed through the internet 202 , although other communication mediums can be utilized.
The system 200 further includes user devices 210 , such as any number of computing devices used by the wearer or other employees or customers associated with the wearer, and manager devices 212 . The manager devices 212 can include any number of computing devices that are pre-programmed with logic to assist a manager to monitor the activity of a wearer, such as described below. The system 200 further includes a central server 214 that can store some or all of the data accumulated or transmitted by the various computing devices or wearable devices of the system 200 .
The systems and methods described herein can assure that the metrics and values represented by a device assigned to a particular wearer actually represent the wearer himself/herself rather than another party. These systems and methods provide this chain of custody in a manner that is manageable, feasible and cost-effective for employers, supervisors and regulatory agencies. Finally, the system and method provide this chain of custody in a manner that minimal disruption, discomfort, inconvenience, and intrusion for truckers and other wearers.
Wearers can self-monitor in order to independently and individually plan travel and rest times, assuring compliance with employer or legally mandated rest times. For instance, long-distance truckers have complained that adhering to rest regulations meant sometimes parking in unsafe areas for mandated rest. Planning ahead for primed sleep could help truckers locate safe, geographically optimized destinations for rest if wearable devices were synced with GPS data banks. In this context, supervisors can monitor data remotely from the wearable device to identify wearers who are intentionally or unintentionally not meeting required rest specifications. Supervisors could intervene as wearers approach non-compliance, by sending messages or alerts to the wearable device or other communication device, to remind wearers to plan for upcoming rests. Supervisors/logistics managers could also integrate sleep/rest intervals into route planning and other logistics systems.
Conversely, supervisors could monitor wearer wakefulness. For example, if heart rates, etc. were indicative of oncoming sleepiness in a truck driver or air traffic controllers, supervisors could intervene via alerts or other communication to prevent sleep onset. Regulatory agencies can monitor data depending on desired or legally required intervention levels. For example, companies with a record of non-compliance, or higher-risk industries, could be monitored more closely for non-compliance. Other external agencies, such as research institutions, might partner with employers for monitoring in order to research topics related to sleep, rest, safety, etc. and collect relevant data.
The system functionality could be integrated into logistics planning software so rest periods/downtime can be accommodated as part of the logistics planning, similar to how load weight and routing are factored into route planning Because the wearable can provide real time, objective data on the activities of the wearer, this information can be used to customize any program to the specific behaviors of the wearer. For example, a cognitive behavior program can constantly change and adapt to address the issues that the wearer is experiencing at the time.
The systems and methods described herein offer practical, appealing incentive structures for worker compliance. For instance, in the trucking context, trucker compensation is often calculated based on a fee-mile-structure. To incentivize adoption and compliance for truckers, who may resist sleep or rest that interferes with their ability to quickly log miles, per-mile compensation can be increased. Although truckers completing required rest stops will necessarily be travelling more slowly, this slower pace will be offset by higher compensation rates for complying with mandated rest stops.
The systems and methods described herein also offer practical, appealing incentive structures for adopting companies. For example, motor vehicle crashes, including those that involve trucks, result in higher insurance premiums, wasted fuel (idling time, spilled fuel, etc.) and other costs (15). In some implementations, savings from lower premiums can be passed on as incentives for increasing the trucker mileage payments. Consumers (in this case, insured drivers) may be willing to trade increased transparency—via on-board diagnostic systems (OBDs) to track data such braking time, speed, etc.—for the possibility of lower insurance rates. Companies and drivers can log onto the system's real-time incentive tracking feature for estimates and real-time calculations on their projected discounts/incentives based on adopting the sleep-tracking wearable device chain of custody system.
Although a few embodiments have been described in detail above, other modifications are possible. Other embodiments may be within the scope of the following claims. | A wearable device includes one or more biometric sensors, each of the one or more biometric sensors gathering biological data from a wearer of the wearable device, the wearable device further having a computer processor for receiving the biological data from the one or more biometric sensors and generating biometric information based on the biological data and according one or more biometrical algorithms, the biometric information including validation information to validate the wearer as a source of the biological data gathered by each of the one or more sensors, the biometric information further including sleep information to provide a sleep profile of the wearer. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 897,909, filed Aug. 9, 1986 which is abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a method of inhibiting the production of interleukin-1 by monocytes and/or macrophages in a human in need thereof which comprises administering to such human an effective, interleukin-1 production inhibiting amount of a diaryl-substituted imidazole fused to a thiazole, pyrrolidine or piperidine ring or a pharmaceutically acceptable salt thereof.
Ciba-Geigy AG., U.K. patent application GB 2,039,882, published Aug. 20, 1980, discloses compounds of the formula ##STR1## wherein the 1,3-diazacyclopent-2-ene ring may have a further double bond, Alk represents lower alkylene that separates the sulfur atom from the nitrogen atom by 2 to 4 carbon atoms, Ar 1 and Ar 2 represent, independently of one another, an optionally substituted phenyl, pyridyl or thienyl radical and n is 0, 1 or 2, provided that at least one of the radicals Ar 1 and Ar 2 is not phenyl when Alk represents ethylene and the 1,3-diazacyclopent-2-ene ring represents an imidazole ring, and the salts thereof. The Ciba-Geigy reference alleges that such compounds exhibit antiinflammatory and antiexudation effects in the rat kaolin paw-oedema test or in the rat turpentine pleuritis test; that the unsaturated compounds in particular exhibit an excellent effect in the adjuvant arthritis test; and that such compounds also have an analgesic effect as shown in the phenyl-p-benzoquinone test in mice; inhibit prostaglandin synthetase in vitro; protect against fatal pulmonary embolism in rabbits (i.e., are anti-thrombotic); and that the tetrahydro compounds exhibit a strong effect in the pertussis oedema test. The rat kaolin paw oedema test and the rat turpentine pleuritis test are useful in detecting compounds which are cyclooxygenase inhibitors but are of no known utility in detecting or suggesting compounds which are inhibitors of interleukin-1 (IL-1) production by monocytes and/or macrophages. The adjuvant arthritis test is useful for detecting compounds which are inhibitors of prostanoid synthesis, but is of no utility for disclosing or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages. The phenyl-p-benzoquinone test is useful for detecting compounds which are cyclooxygenase inhibitors, but is of no known utility in detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages. The observation that compounds of the Ciba-Geigy reference inhibit prostaglandin synthetase in vitro (cyclooxygenase) is of no utility in detecting or suggesting compounds which are inhibitors of IL-1 product or by monocytes and/or macrophages. The observation that the compounds of the Ciba-Geigy reference are anti-thrombotic in rabbits is of no known utility in detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages. The pertussis oedema test is useful in detecting compounds which are cyclooxygenase inhibitors, but is of no known utility in detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages.
Bender et al., U.S. Pat. No. 4,175,127, issued Nov. 20, 1979 disclose compounds of the formula ##STR2## in which R 1 and R 2 are the same or different, but one of which always being pyridyl, are pyridyl or phenyl optionally monosubstituted by a lower alkoxy, lower alkyl, lower alkylthio, chloro, fluoro, bromo, or trifluoromethyl or a pharmaceutically acceptable acid addition salt or oxide derivative thereof. Bender et al. also discloses that such compounds have utility as antiarthritic agents. Such antiarthritic activity is disclosed as the result of test results from adjuvant-induced polyarthritis in rats. Although not claimed, the Bender patent also suggests, at column 3, lines 66-68, that compounds of Formula A also have inflammatory or immunoregulatory properties in addition to their antiarthritic activity. The Bender patent states, at column 4, lines 47-50, that such anti-inflammatory activity is produced by some of the Formula A compounds in the carrageenan-induced rat paw edema test which is useful for detecting compounds which are inhibitors of the cyclooxygenase pathway, but is of no known utility for detecting or suggesting compounds which are inhibitors of IL-1 production of monocytes and/or macrophages. The Bender patent also states, at column 4, lines 51-65, that species of the Formula A compounds have the ability to regulate cell-mediated immunity as shown in procedures such as the oxazolone-induced contact sensitivity test procedure in which mouse paw volume is measured. The oxazolone-induced contact sensitivity test is useful for detecting compounds which have immunostimulatory activity like levamisole but is of no known utility for detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages.
Lantos et al., J. Med. Chem., 27, 72-75 (1984), also disclose that certain 5,6-diaryl-2,3-dihydroimidazo[2,1-b]thiazoles have antiinflammatory activity in the carrageenan-induced rat paw edema and adjuvant arthritis assay in rats. Both the adjuvant-induced polyarthritis assay in rats and the carrageenan-induced rat paw edema test are useful in detecting compounds which are inhibitors or prostanoid synthesis, mediated by the prostanoids formed by the enzyme cyclooxygenase, but are of no known utility in detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages. The oxazolone-induced contact sensitivity test in which mouse paw volume is measured is useful in detecting compounds which have immunostimulatory activity like levamisole, but is of no known utility in detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages.
Lantos et al., U.S. Ser. No. 737,137, filed May 29, 1985, disclose an improved method for the preparation of compounds of the formula: ##STR3## in which R is H, halo, C 1-2 -alkyl, C 1-2 -alkoxy or trifluoromethyl. Lantos et al. state that such compounds have antiarthritic activity. There is no further statement in this reference as to how such antiarthritic activity was determined. Such a blanket statement of antiarthritic utility does not disclose to one of skill in the art that such compounds are inhibitors of IL-1 production by monocytes and/or macrophages.
Cherkofsky et al., U.S. Pat. No. 4,064,260, issued Dec. 20, 1977 discloses compounds of the formula ##STR4## in which n is 0, 1 or 2, and R and R 1 are independently selected from monosubstituted phenyl wherein said substituent is selected from monosubstituted phenyl wherein said substituent is selected from C 1-4 alkoxy. Cherkofsky et al. also disclose that such compounds have utility as antiinflammatory agents as demonstrated by their activity in the established adjuvant-induced arthritis assay in rats or the phenylquinone writhing test in mice. As stated above, the adjuvant arthritis test is of no utility for disclosing or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages.
Bender et al., U.S. Pat. No. 4,263,311 issued Apr. 21, 1981, discloses compounds of the formula ##STR5## wherein n is 0, 1 or 2, and R 1 and R 2 are independently selected from (a) monosubstituted phenyl wherein said substituent is selected from lower alkoxy, chloro, fluoro, bromo, trifluoromethyl, amino, di-N-N-lower alkylamino or (b) 3,4-methylenedioxyphenyl. Bender et al. also disclose that such compounds have utility (a) in the treatment of arthritis based on their activity in the adjuvant-induced arthritis test in rats and in the carrageenan-induced rat paw edema test; and (b) as immunoregulatory agents based on their activity in the oxazolone-induced contact sensitivity test in which mouse paw volume is measured. As stated above, none of the adjuvant arthritis test, carrageenan edema test or oxazolone sensitivity test have any known utility in detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages.
Bender et al., U.S. Pat. No. 4,186,205, issued Jan. 29, 1980, disclose compounds of the formula ##STR6## wherein R is 4-monosubstituted phenyl and said substituent is selected from C 1-4 alkoxy or chloro, or a non-toxic, pharmaceutically acceptable salt thereof. Bender et al. also disclose that such compounds are useful as (a) antiarthritic agents based on their activity in the adjuvant-induced arthritis assay in rats; and (b) regulators of cell-mediated immunity based on their activity in the oxazolone-induced contact sensitivity test in which mouse paw volume is measured. As stated above, neither the adjuvant arthritis test nor the oxazolone sensitivity test are of any known utility in disclosing or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages.
Bender et al., J. Med. Chem., 28, 1169-1177 (1985), disclose compounds of the formula ##STR7## wherein n is 0, 1 or 2, and R and R 1 are independently selected from (a) monosubstituted phenyl wherein said substituent is selected from C 1-4 alkoxy, halo, 4-amino, 4-acetamido, 4-trifluoromethyl, 4-N(ethyl)-acetamido, 4-ethylamino, and 4-ethyl(methyl)amino; or (b) 3,4-methylenedioxyphenyl. Bender et al. also disclose that some of such compounds are useful as immunoregulatory, antiinflammatory and antiarthritic agents based on their activity in the adjuvant-induced arthritis test and the mouse subliminal oxazolone-induced contact sensitivity assay. As stated above, the adjuvant arthritis assay is of no utility in detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages. The mouse subliminal oxazolone sensitivity assay is useful in detecting compounds which are immunostimulatory but is of no known utility in detecting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages.
Baetz et al., U.S. Pat. No. 4,110,460, issued Aug. 29, 1978, disclose compounds of the formula ##STR8## wherein R and R 1 are independently selected from monosubstituted phenyl wherein said substituent is selected from chloro, bromo, C 1-4 alkoxy, or a pharmaceutically acceptable acid addition salt thereof. Baetz et al. also disclose that such compounds have anti-inflammatory activity based on their activity in the carrageenan-induced edema assay in rats, cotton-induced granuloma assay in rats, ultraviolet induced erythema assay in guinea pigs, and Freund's-adjuvant induced arthritis assay in rats. All of such assays are useful for detecting compounds which are inhibitors of prostanoid synthesis, but none of such assays is of any known utility for disclosing or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages. Baetz et al. also disclose that such compounds have utility as antipyretic agents based on their activity in an assay in which hyperthermia was induced in rats by subcutaneous injection with yeast. Such assay is useful for detecting compounds which are cyclooxygenase inhibitors but is of no known utility in detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages. Baetz et al. also disclose that such compounds have analgesic activity based on their activity in the acetic acid writhing test in mice. The acetic acid writhing test is useful for detecting compounds which are cyclooxygenase inhibitors but is of no known utility in detecting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages.
Bender et al., U.S. Pat. No. 4,153,706, issued May 8, 1979, disclose compounds of the formula ##STR9## wherein R 1 is 4-substituted phenyl wherein said substituent is selected from lower alkoxy, lower alkylthio, fluoro, chloro, bromo or trifluoromethyl; and R 2 is 4-substituted phenyl wherein said substituent is an election withdrawing group, in particular, fluoro, chloro, bromo or trifluoromethyl. Bender et al. also state that such compounds have antiarthritic activity as measured in the adjuvant-induced polyarthritis assay in rats; and immunoregulatory activity as measured by the oxazolone-induced contact sensitivity test in mice. As stated above, such assays do not disclose or suggest that such compounds are inhibitors of IL-1 production by monocytes and/or macrophages.
Davidson et al., U.S. Pat. No. 4,507,481, issued Mar. 26, 1985, disclose compounds of the formula ##STR10## wherein X is 0 or S(0)n;
n is 0, 1 or 2;
R 1 can be H;
R 2 can be H;
A is CH 2 or CH 2 CH 3 ;
R 3 and R 4 are independently selected from phenyl substituted with lower alkyl, lower alkylamino, lower alkoxy or halogen;
R 5 and R 6 are each H or join to form a double bond at the 2,3-position.
Davidson et al. also disclose that such compounds are immunostimulants or immunosuppressants based on (a) their inhibiting or stimulating activity in a chemotaxis assay which measures the ability of a drug substance to influence the movement of murine macrophages responding to complement; (b) their immunosuppressing or activating activity in the Kennedy plaque assay in which an animal's humoral immune system is depressed artificially with 6-mercaptopyrine. Such chemotaxis assay is of no known utility for detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages. Davidson et al. also disclose that such compounds have antiinflammatory activity as determined by the carrageenan-induced paw edema assay in rats. As stated above, such assay has no known utility in detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages. Davidson et al. also disclose that such compounds have antiviral activity in mice with hepatitis; but such activity is of no known utility in detecting or suggesting compounds which are inhibitors of IL-1 production by monocytes and/or macrophages.
Hagmann et al., Naturwissenschaften, 69, 594 (1982), demonstrated that certain leukotriene antagonists and a Ca-calmodulin-specific inhibitor, calmidazolium, prevented endotoxin lethality in the murine model of endotoxin shock discussed in Galanos et al., Proc. Natl. Acad. Sci. USA, 76, 5939 (1979).
SUMMARY OF THE INVENTION
This invention relates to a method of inhibiting the production of interleukin-1 (IL-1) by monocytes and/or macrophages in a human in need thereof which comprises administering to such human an effective, IL-1 production inhibiting amount of a compound of the formula ##STR11## wherein: One of R 1 and R 2 must be 4-pyridyl and the other is selected from 4-pyridyl or monosubstituted phenyl wherein said substituent is selected from halo or C 1-4 alkoxy;
X is CH 2 , CH 2 CH 2 or S(0)n; and
n is 0, 1 or 2;
or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
The preparation of all compounds of Formula (I) and pharmaceutically acceptable salts thereof is disclosed in Bender et al., U.S. patent application Ser. No. 856,875 filed Apr. 28, 1986 and Bender et al., U.S. patent application Ser. No. 856,928, filed Apr. 28, 1986, the disclosures of both of which are hereby incorporated by reference.
By the term "inhibiting the production of IL-1" is meant the down regulation of excessive in vivo IL-1 levels in a human to normal levels.
By the term "production of IL-1 by monocytes and/or macrophages" is meant the in vivo release of IL-1 by such cells.
Interleukin-1 (IL-1) has been recently demonstrated to mediate a variety of biological activities thought to be important in immunoregulation and other physiological conditions such as inflammation [See, e.g., Dinarello et al., Rev. Infect. Disease, 6, 51 (1984)]. The myriad of known biological activities of IL-1 include the activation of T helper cells, induction of fever, stimulation of prostaglandin or collagenase production, neutrophil chemotaxis, induction of acute phase proteins and the suppression of plasma iron levels. However, much remains to be learned about the synthesis, processing and secretion of IL-1. For example, there is recent evidence suggesting that there are two separate human interleukin-1 genes, and that the products of these two genes differ in their isoelectric points. It is also clear that the published data on the cloning of the cDNA of the IL-1 gene(s) suggest that IL-1 is synthesized as a 31 kilodalton (Kd) precursor, which is subsequently processed to yield a smaller mature protein of about 17 Kd, the activity of which is detectable in culture supernatants. One interesting feature of the precursor protein is that it lacks a classical signal peptide sequence, suggesting that the molecule is probably not secreted in a classical manner. There is very little information available as to how the 31 Kd precursor is processed and secreted.
The discovery of a compound which specifically inhibits IL-1 production will not only contribute to the understanding of how this molecule is synthesized, processed and secreted, but will also provide a therapeutic approach for diseases in which excessive or unregulated IL-1 production is implicated.
It has now been discovered that compounds of Formula (I) and pharmaceutically acceptable salts thereof are useful for inhibiting the production of IL-1 by monocytes and/or macrophages in a human in need of such inhibition.
There are several disease states in which excessive or unregulated IL-1 production by monocytes and/or macrophages is implicated in exacerbating and/or causing the disease. These include rheumatoid arthritis [See, e.g., Fontana et al., Arthritis Rheum., 22, 49-53 (1982)]; osteoarthritis [See, e.g., Wood et al., Arthritis Rheum., 26, 975 (1983)]; toxic shock syndrome [See, e.g., Ikejima and Dinarello, J. Leukocyte Biology, 37, 714 (1985)]; other acute or chronic inflammatory disease states such as the inflammatory reaction induced by endotoxin [See, e.g., Habicht and Beck, J. Leukocyte Biology, 37, 709 (1985)]; and other chronic inflammatory disease states such as tuberculosis. [See, e.g., Chesque et al., J. Leukocyte Biology, 37, 690 (1985)]. Benjamin et al., "Annual Reports in Medicinal Chemistry--20", Chapter 18, pages 173-183 (1985), Academic Press, Inc., disclose that excessive IL-1 production is implicated in: Psoriatic arthritis, Reiter's syndrome, Rheumatoid arthritis, Osteoarthritis, Gout, Traumatic arthritis, Rubella arthritis, and Acute synovitis.
Dinarello, J. Clinical Immunology, 5 (5), 287-297 (1985), reviews the biological activities which have been attributed to IL-1 and such activities are summarized in Table A.
Table A
Biological Activities Attributed to IL-1
Fever (in rabbits, mice and rats)
Hypoferremia
Hypozincemia
Hypercupremia
Increased
Blood neutrophils
Hepatic acute-phase proteins
Bone resorption
Cartilage breakdown
Muscle proteolysis
Slow-wave sleep
Endothelial procoagulant
Chondrocyte proteases
Synovial collagenase
Endothelial neutrophil adherence
Neutrophil degranulation
Neutrophil superoxide
Interferon production
Proliferation of
Fibroblasts
Glial cells
Mesangial cells
Synovial fibroblasts
EBV B-cell lines
Chemotaxis of
Monocytes
Neutrophils
Lymphocytes
Stimulation of PGE 2 in
Hypothalamus
Cortex
Skeletal muscle
Dermal fibroblast
Chondrocyte
Macrophage/monocyte
Endothelium (PGI 2 )
Decreased
Hepatic albumin synthesis
Appetite
Brain binding of opioids
Augmentation of
T-cell responses
B-cell responses
NK activity
IL-2 production
Lymphokine production
An effective, IL-1 production inhibiting amount of a compound of Formula (I) or a pharmaceutically acceptable salt thereof is useful in treating, prophylactically or therapeutically, any disease state in a human which is exacerbated or caused by excessive or unregulated IL-1 production by such human's monocytes and/or macrophages. Preferably, the disease state is endotoxin-induced shock.
This invention relates to a method of inhibiting the production of IL-1 by monocytes and/or macrophages in a human in need thereof which comprises administering an effective, IL-1 production inhibiting amount of a compound of Formula (I) or a pharmaceutically acceptable salt thereof to such human. A compound of Formula (I) or a pharmaceutically acceptable salt thereof can be administered to such human in a conventional dosage form prepared by combining a compound of Formula (I), or a pharmaceutically acceptable salt thereof, with a conventional pharmaceutically acceptable carrier or diluent according to known techniques, such as those described in Bender et al., U.S.S.N. 856,875 filed Apr. 28, 1986 and Bender et al., U.S.S.N. 856,928, filed Apr. 28, 1986. It will be recognized by one of skill in the art that the form and character of the pharmaceutically acceptable carrier or diluent is dictated by the amount of active ingredient with which it is to be combined, the route of administration and other well-known variables. A compound of Formula (I) or a pharmaceutically acceptable salt thereof is administered to a human in need of inhibition of IL-1 production by its monocytes and/or macrophages in an amount sufficient to inhibit such excessive IL-1 production to the extent that it is regulated down to normal levels. The route of administration may be oral, parenteral or topical. The term parenteral as used herein includes intravenous, intramuscular, subcutaneous intranasal, intrarectal, intravaginal or intraperitoneal administration. The subcutaneous and intramuscular forms of parenteral administration are generally preferred. The daily oral dosage regimen will preferably be from about 5 to about 100 mg/kilogram of total body weight. The daily parenteral dosage regimen will preferably be from about 2 to about 80 mg per kilogram (kg) of total body weight, most preferably from about 3 to about 60 mg/kg. The daily topical dosage regimen will preferably be from about 2 mg to about 10 mg per site of administration. It will be recognized by one of skill in the art that the optimal quantity and spacing of individual dosages of a compound of Formula (I) or a pharmaceutically acceptable salt thereof will be determined by the nature and extent of the condition being treated, the form, route and site of administration, and the particular patient being treated, and that such optimums can be determined by conventional techniques. It will also be appreciated by one of skill in the art that the optimal course of treatment, i.e., the number of doses of a compound of Formula (I) or a pharmaceutically acceptable salt thereof given per day for a defined number of days, can be ascertained by those skilled in the art using conventional course of treatment determination tests.
EXAMPLES
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following Examples are, therefore, to be construed as merely illustrative and not a limitation of the scope of the present invention in any way.
As used herein, the term "Compound 1" refers to the compound of Formula (I) wherein R 1 is 4-pyridyl, R 2 is 4-fluorophenyl, X is S(0)n and n is 0, and the term "Compound 5" refers to the compound of Formula (I) wherein R 1 is 4-pyridyl, R 2 is 4-flurophenyl and X is CH 2 .
EXAMPLE 1
Inhibitory Effect of a Compound of Formula (I) on in vitro IL-Production by Human Monocytes
The effects of antiinflammatory/antiarthritic drugs of different classes, including Compound 1 on the in vitro production of IL-1 by human monocytes was examined.
Bacterial lipopolysaccharide (LPS) was used to induce IL-1 production by human peripheral blood monocytes. IL-1 activity was measured by its ability to stimulate a Interleukin 2 (IL-2) producing cell line (EL-4) to secrete IL-2, in concert with A23187 ionophore, according to the method of Simon et al., J. Immunol. Methods, 84, 85, (1985). Human peripheral blood monocytes were isolated and purified from either fresh blood preparations from volunteer donors, or from blood Bank buffy coats, according to the procedure of Colotta et al., J. Immunol., 132, 936 (1984). 1×10 6 of such monocytes are plated in 24-well plates at a concentration of 2 million/ml per well. The cells were allowed to adhere for 2 hours, after which time non-adherent cells were removed by gentle washing. Test compounds were then added to the cells for 1 hour (hr) before the addition of lipopolysaccharide (10 ng/ml unless otherwise noted), and the cultures were incubated at 37° C. for an additional 24 hours. At the end of the incubation period, culture supernatants were removed and clarified of cells and all debris. Culture supernatants were immediately assayed for IL-1 biological activity as well as prostaglandin and/or leukotriene concentrations by radioimmunoassay.
The results indicated that human peripheral blood monocytes are exquisitely sensitive to bacterial endotoxin. Nanogram or even picogram quantities of LPS stimulated high levels of IL-1 production as well as prostaglandin production; however, little, if any, leukotriene was detected in such supernatants. These observations are consistent with previous reports [(See, Humes et al., J. Biol. Chem., 257, 1591 (1982)]. As shown in Table 1, ibuprofen, although highly active in inhibiting prostaglandin synthesis, had virtually no effect on IL-1 production. The 5-lipoxygenase (5-LO) inhibitors phenidone and nordihydroguaiaretic acid (NDGA) were marginally active in inhibition of IL-1 production and, interestingly, had little inhibitory effect on prostaglandin synthesis. Compound 1, however, was active in submicromolar range (10 -7 M), resulting in greater than 80% inhibition of both prostaglandin synthesis and IL-1 production. Chloroquine, an antiarthritic/antimalarial compound previously demonstrated to inhibit IL-1 production, [See, Lipsky, Amer. J. Med. 75, Supp. 1A, 19 (1983)] was only marginally active at doses one or two logs higher than that of Compound 1.
Inhibition of IL-1 production by Compound 1 is not due to a carryover effect of the drug on the cells sed in the IL-1 readout assay. Various doses of Compound 1 were tested for its activity effects on a preparation of Il -1 standard on the EL-4/CTLL assay. At high concentrations (i.e., 10 -5 or higher), compound 1 had an effect on the assay system, perhaps a result of toxic effects on the cells; however, at lower doses of Compound 1 there was no direct effect on the IL-1 assay per se. It has been further demonstrated that Compound 1 does not exert a nonspecific toxic effect on other functions of activated monocytes. LPS-treated human monocytes can mediate a potent tumoricidal activity in the kill of A375 melanoma cells, as previously demonstrated [See, Kleinerman et al., J. Clin. Inves., 72, 304 (1983)]. Compound 1, at concentrations ranging from 10 -5 to 10 -8 M did not effect that biological activity. Furthermore, the possibility that Compound 1 treatment of monocytes in presence or absence of LPS may have induced an inhibitor which interfered with the IL-1 assay was also ruled out (data not shown).
The in vitro inhibition of IL-1 production by Compound 1 is dose dependent. There is little, if any, difference between the effect of the drug at any given concentration of LPS. This observation, along with the fact that there was always a residual IL-1 activity remaining over a wide range of LPS used, suggests that the inhibitory effect of Compound 1 on IL-1 production remains constant, i.e., about 80% inhibition of 10 -6 M and about 40% inhibition at 10 -7 M.
The exact mechanism by which Compound 1 inhibits in vitro IL-1 production by monocytes is not presently known. It is clear, however, that while Compound 1 inhibits IL-1 production induced by a variety of activators, its inhibition is IL-1 specific, i.e., other inducible proteins such as alpha interferon are not effected. It is also clear that Compound 1 is not immunosuppressive and does not inhibit lectin-stimulated mitogenesis of human peripheral blood lymphocytes. Furthermore, it does not inhibit either IL-2 production or response.
The data in Table 1 shows that Compound 1 inhibits IL-1 production by human monocytes in vitro. This inhibitory activity does not seem to correlate with the property of the compound in mediating arachidonic acid metabolism inhibition since other nonsteroidal antiinflammatory drugs with potent cyclooxygenase and/or lipoxygenase inhibitory activity do not inhibit IL-1 production at nontoxic doses. Furthermore, inhibition of prostaglandin and/or leukotriene synthesis by a compound does not correlate with its ability to inhibit IL-1 production.
TABLE 1______________________________________ % InhibitionCompound.sup.(a) M PGE.sub.2.sup.(c) IL-1______________________________________Ibuprofen 10.sup.-5 97 9 10.sup.-6 71 0 10.sup.-7 63 0Phenidone 10.sup.-7 63 0 10.sup.-6 0 18 10.sup.-7 0 0NDGA 10.sup.-5(b) 25 88 10.sup.-6 0 33 10.sup.-7 0 31Compound 1 10.sup.-5 99 99 10.sup.-6 94 96 10.sup.-7 79 88Chloroquine 10.sup.-5 84 89 10.sup.-6 0 46 10.sup.-7 0 36______________________________________ .sup.(a) All compounds, except chloroquine, were dissolved in absolute ethanol at 10.sup.-2 M, which was subsequently diluted further in tissue culture media. Ethanol control at dilution indicated that it did not affect the IL1 assay. None of t he compounds had a direct effect on the assay system at doses tested. Furthermore, test samples were dialyzed prior to testing in the IL1 assay. .sup.(b) At doses at or above 10.sup.-5 M, this compound exerted some toxic effects on monocytes, i.e., viability ˜50% after 24 hours. .sup.(c) PGE.sub.2 was assayed using an RIA kit.
EXAMPLE 2
Inhibitory Effect of Major Metabolites of Compound 1 on In Vitro Production of IL-1 by Human Monocytes
In order to elucidate the mechanism by which Compound 1 mediates its anti-inflammatory activity, the ability of this compound and two closely related analog metabolites, (i.e., the analogs of Compound 1 wherein X is S(0)n and n is 1 or 2) to inhibit human IL-1 production in vitro was evaluated according to the method of Example 1. Briefly, 1×10 6 human peripheral blood monocytes were plated in 24-well plates and allowed to adhere for 1 hr at 37° C. The above compounds were added to a final concentration of 10 -5 M to 10 -8 M. The monocytes were stimulated to produce IL-1 with 1 ng/ml LPS after a 1 hr pretreatment of the cells with the respective compounds. Table 2 summarizes the results obtained and shows that all three compounds of Formula (I) dramatically inhibit IL-1 production. Compound 1 appears to be slightly more potent than the two analogs tested.
TABLE 2______________________________________ ##STR12## Formula (I)Compound IC.sub.50No. R.sup.1 R.sup.2 X n (μM)______________________________________1 4-pyridyl 4-fluorophenyl S(O)n 0 0.252 4-pyridyl 4-fluorophenyl S(O)n 1 0.803 4-pyridyl 4-fluorophenyl S(O)n 2 0.61______________________________________
EXAMPLE 3
Effect of Compounds of Formula (I) on IL-1 Production by Human Monocytes
The inhibitory effect of additional compounds of Formula (I) on the in vitro production of IL-1 production of IL-1 by human monocytes was determined according to the procedure of Examples 1 and 2. Table 3 summarizes the results obtained. As indicated by Table 3, all compounds of Formula (I) inhibit IL-1 production.
TABLE 3______________________________________ ##STR13## Formula ICompound % InhibitionNo. R.sub.1 R.sub.2 X n @ 10.sup.-6 M______________________________________1 4-pyridyl Fφ.sup.(a) S(O)n 0 702 4-pyridyl Fφ S(O)n 1 563 4-pyridyl Fφ S(O)n 2 544 Fφ 4-pyridyl S(O)n 0 465 4-pyridyl Fφ CH.sub.2 -- 786 4-pyridyl MeOφ.sup.(b) S(O)n 0 647 4-pyridyl MeOφ CH.sub.2 -- 408 4-pyridyl MeOφ CH.sub.2 CH.sub.2 -- 30______________________________________ .sup.(a) Fφ = 4-fluorophenyl .sup.(b) MeOφ = 4-methoxyphenyl
EXAMPLE 4
Adjuvant-induced arthritis in the rat is a model of systemic inflammation with characteristics similar to rheumatoid arthritis in man. Arthritic rats exhibit many alterations associated with macrophage activation including increased production of IL-1 by LPS-stimulated splenic adherent macrophages in vitro. This model was employed to assess the effect of Compound 1 in vivo on this elevated IL-1 production. Briefly, rats were injected on day 0 with Freund's complete adjuvant in the right hind leg. Drugs were prepared as a suspension in tragacanth and administered daily per os either prophylactically (days 1 to 16) or therapeutically in a short-term modality (days 14 to 16). In all cases, final administration of drug occurred at 3 hours prior to sacrifice. Spleens were removed from these rats and the adherent cells were assessed for their ability to produce IL-1 in vitro in response to stimulation by LPS.
Tables 4a and 4b summarize the data from a typical experiment. In the case of prophylactic administration, Compound 1 produced a more dramatic decrease in IL-1 production than indomethacin which resulted in nearly complete normalization of this parameter. It is interesting to note that no effect was also observed in adjuvant arthritic rats therapeutically treated with Compound 1 or with a variety of clinically effective and commercially marketed human antiarthritic agents such as auranofin, methotrexate, d-penicillamine and indomethacin. Hence, the prescribed short-term treatment of an ongoing arthritic disease in the adjuvant-induced arthritic rat model does not adequately reflect therapeutic efficacy of known or potentially useful antiarthritic drugs.
Based on the widely held belief of the role of unmodulated (i.e., excessive) in vivo IL-1 production in causing or aggravating inflammatory responses and other disease states (see, e.g., Fontana et al., supra; Wood et al., supra; Akejima and Dinarello, supra; Habicht and Beck, supra; Chesque et al., supra; Benjamin et al., supra; and Dinarello, supra), and based on the fact that compounds of Formula (I) inhibit in vitro IL-1 production by human macrophages and/or monocytes (see, Tables 1, 2 and 3), as well as the fact that a compound of Formula (I) prophylactically inhibited such IL-1 production in the adjuvant-induced arthritic rat (see, Table 4a), and also the fact that compounds of Formula (I) prophylactically inhibited LPS-induced endotoxin shock in a murine model (Example 5, infra), it is expected that all compounds of Formula (I) inhibit the in vivo IL-1 production by monocytes and/or macrophages in a human in need thereof when used according to the method of the subject invention.
TABLE 4A__________________________________________________________________________% NORMAL CONTROL INDO- D-PENI- AA COMPOUND 1 METHACIN PREDNISOLONE METHOTREXATE CILLAMINE__________________________________________________________________________PROPHYLACTICS STUDIESRIGHT LEG PAW 197 ± 9 134 ± 9*** 113 ± 8*** 125 ± 22*** 96 ± 4*** 184 ± 20EDEMASPLENICADHERENT CELLS% Adherent Cells 357 ± 235 98 ± 29** 480 ± 189 184 ± 79 134 ± 10* 372 ± 117IL-1 Production 368 ± 148 139 ± 28*** 274 ± 100 168 ± 40** 67 ± 56*** 336 ± 170THERAPEUTIC STUDIESRIGHT LEG PAW 193 ± 6 159 ± 7*** 145 ± 18*** 147 ± 18*** 194 ± 2 191 ± 13EDEMASPLENICADHERENT CELLS% Adherent Cells 271 ± 118 216 ± 137 394 ± 253 82 ± 47 284 ± 175 217 ± 6IL-1 Production 461 ± 201 392 ± 129 330 ± 121 300 ± 280 436 ± 178 374__________________________________________________________________________ ± 187.sup.a PROPHYLACTIC TREATMENT: Drugs were administered daily p.o. as a suspensio in tragacanth from day 1 to day 16. Final dose given 3 hrs before sacrifice. THERAPEUTIC TREATMENT: Drugs were administered daily p.o. as above from day 14 to day 16. Final dose given 3 hrs before sacrifice. ***P < 0.01 Indomethacin 2.0 mg/kg **P < 0.05 Compound 1 60 mg/kg *P < 0.10 Prednisolone 10 mg/kg Methotrexate 0.3 mg/kg D-Penicillamine 50 mg/kg .sup.a N = 2
EXAMPLE 5
EFFECT OF COMPOUNDS OF FORMULA I IN ENDOTOXIN SHOCK
Model of endotoxin shock in C57B1/6 Mice
Mice are very resistant to the lethal effects of bacterial lipopolysaccharides (LPS). D-Galactosamine (D-GALN) induces a high degree of sensitization to the lethal effects of LPS in mice and other experimental animals. [See, Galanos et al., Proc. Natl. Acad Sci. USA., 76, 5939 (1979)]. In mice, depending on the strain and age, the sensitivity to endotoxin can be increased many thousand-fold.
A number of preliminary experiments were carried out to establish this model of lethal endotoxin shock. LPS concentrations of up to 1 mg/mouse are not lethal in C57B1/6 mice. When injected i.v. with D-GALN (500 mg/kg), however, the sensitivity increases so that 0.1 ug becomes a lethal dose (Table 5). The concentration of D-GALN required to obtain this effect is 400-500 mg/kg.
RESULTS
Dexamethasone provided protection when administered to the animals 24 hours and 1 hour prior to LPS/GALN administration.
Compound 1 also protected the animals from the lethal effects of LPS/GALN. Protection was obtained when Compound 1 was administerrd 1 hour prior to the injection of LPS/GALN and varied from 50 to 100% protection. Other compounds tested that have shown protective effects in this model are, Compound 5 phenidone (a dual inhibitor of arachidonic acid metabolism), and the histamine H 1 antagonist chlorpheniramine (but not the H 2 antagonist cimetidine).
TABLE A______________________________________Lethality of LPS in D-GalactosamineTreated C57B1/6 Mice Lethality No. of Death/Total No.Treatment 6 Hr. 24 Hr.______________________________________LPS 100 ug 0/10 0/10D-Galactosamine 500 mg/kg 0/10 0/10D-Galactosamine 500 mg/kg+LPS1 ug 8/10 10/10.1 ug 9/10 10/10.01 ug 1/10 5/10______________________________________ All compounds were administered i.v.
D-Galactosamine sensitized mice to the lethal effect of 0.1 ug of LPS. Treatment with 0.01 ug of LPS resulted in 50% lethality 6-24 hours following the injection of LPS/D-GALN. | A method of inhibiting the 5-lipoxygenase pathway in an animal in need thereof which comprises administering an effective, 5-lipoxygenase pathway inhibiting amount of a diaryl-substituted imidazole fused to a thiazole pyrrolidine, thiazide or piperidine ring to such animal. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to an apparatus for producing water for preparation of a dialysis solution.
BACKGROUND ART
[0002] Dialysis is known as one effective treatment for patients with renal failure whose renal function is deteriorated such that he/she cannot urinate to adjust the amount of moisture and remove bodily toxic substances including bodily waste products, such as urea. Hemodialysis is a treatment that involves a continuous operation of drawing blood outside the body using a blood pump, bringing the blood in contact with a dialysis solution through a dialyzer to thereby remove bodily toxic substances and moisture by utilizing the phenomenon of diffusion based on the concentration gradient, and then returning the purified blood into the body.
[0003] In recent years, it is known that hemodialysis generates oxidative stress in dialysis patients. Since this is believed to be caused by active oxygen generated during dialysis, proposals have been made to reduce oxidative stress by eliminating active oxygen. Japanese Patent Laying-Open No. 2000-350989 (PTD 1), for example, discloses a method for producing a dialysis solution for hemodialysis. The method includes the steps of providing an electrolytic water generator having a cathode compartment including a cathode and an anode compartment including an anode, the cathode and anode compartments being separated from each other with a dividing membrane, supplying raw water containing at least sodium, potassium, magnesium, and calcium ions into each of the cathode and anode compartments, passing current between the anode and the cathode to electrolyze the raw water, and drawing out the water inside the cathode compartment. In the method, the water inside the cathode compartment has an actually measured value of oxidation-reduction potential in the range of −150 to 0 mV as measured using a platinum electrode, and a pH in the range of 8.0 to 9.5. The method is capable of eliminating active oxygen generated in the body.
[0004] In connection with this effect of reduced water, an apparatus for generating electrolyzed reduced water that is externally attached to an apparatus for generating reverse osmosis water, and an apparatus for readily generating reverse osmosis water made by integrating an apparatus for generating reduced water with a reverse osmotic membrane, have been developed.
[0005] Here, FIG. 3 is a diagram showing a typical conventional water treatment system 101 for a dialysis solution. As shown in FIG. 3 , for example, in conventional water treatment system 101 for a dialysis solution, raw water (municipal water) 102 is pressurized with a pressurizing pump 103 , solids in raw water 102 are treated with a filter 104 having a pore size of 10 to 30 μm, hypochlorous acid contained in raw water 102 is removed with an activated carbon filtration device 105 , and the hardness of raw water 102 is reduced with a softening device 106 . Reduced water obtained by electrolyzing the raw water with an electrolytic water generation device 107 is then stored in a reduced water tank 108 . The reduced water from reduced water tank 108 is pressurized with a pressurizing pump 109 , and passed through a reverse osmotic membrane inside a reverse osmosis membrane treatment device 110 . The reduced water that has passed through the reverse osmotic membrane is stored in an RO tank 111 . The reduced water delivered from RO tank 111 is subjected to a sterilization treatment with an UV sterilization lamp 112 , passed through a microfilter 113 , and supplied to a dialysis solution supply device 114 . Dialysis solution supply device 114 mixes the supplied reduced water that has been subjected to the reverse osmosis membrane treatment with a dialysis A raw solution 115 and a dialysis B raw solution 116 , and supplies the mixture to each patient monitor device (not shown) as a dialysis solution. A patient's blood is then purified through a dialyzer attached to the patient monitor device.
[0006] Moreover, Japanese Patent Laying-Open No. 2010-63629 (PTD 2), for example, discloses a dialysis apparatus utilizing reduced water. The dialysis apparatus includes gas-liquid mixing means for mixing water with hydrogen and causing dissolution of the hydrogen in the water by pressurization, microbubble generating means for generating microbubbles in the water containing the dissolved hydrogen obtained by the gas-liquid mixing means, and dialysis solution supplying means for supplying the water containing the microbubbles obtained by the microbubble generating means as a dialysis solution. With the dialysis apparatus as described in PTD 2, a dialysis solution capable of eliminating active oxygen in the blood of a dialysis patient can be supplied. Moreover, since electrolysis is not performed, anode water that has conventionally been drained without being used is not generated, thus leading to a reduced amount of drained water.
CITATION LIST
Patent Document
PTD 1: Japanese Patent Laying-Open No. 2000-350989
PTD 2: Japanese Patent Laying-Open No. 2010-63629
SUMMARY OF INVENTION
Technical Problem
[0007] FIG. 4 is a schematic diagram showing an electrolytic cell 202 used in a typical conventional electrolytic water generation device 201 . Generally, as reduced water, water is used which is obtained at a cathode 204 -side by electrolysis within electrolytic cell 202 in which a dividing membrane 205 is placed between an anode 203 and a cathode 204 . In electrolysis, the following reactions occur at the anode 203 -side and the cathode 204 -side:
[0000] Anode Side: H 2 O→½O 2 +2H + +2e −
[0000] Cathode Side: 2H 2 O+2e − →H 2 +2OH −
[0008] By the electrolysis shown above, electrolyzed acid water is generated at the anode 203 -side of electrolytic cell 202 and drained. This draining of the electrolyzed acid water not only increases the water charge, but can also be regarded as wasting natural resources. Reducing the amount of drained water, therefore, has a significant advantage. In the electrolytic cell of a usual electrolytic water generation device, however, elimination of drained electrolyzed acid water is not possible based on its principles. Moreover, if the amount of drained electrolyzed acid water is reduced, hypochlorous acid and the like generated at the anode side are mixed into reduced water, and therefore, the amount of drained water that can be reduced has been limited.
[0009] Furthermore, in the typical conventional electrolytic water generation device 201 , the anode 203 -side becomes acidic due to the generation of H + ions, and the cathode 204 -side becomes alkaline due to the generation of OH − ions. Since the amount of dissolved hydrogen is proportional to the intensity of electrolysis, increasing dissolved hydrogen increases alkalinity at the cathode 204 -side. It is, however, considered to be undesirable to pass water having a pH of 10 or higher as water to be passed through a reverse osmotic membrane for application to a dialysis apparatus, and the amount of dissolved hydrogen has also been restricted by the pH limit.
[0010] The present invention was made to solve the above-described problem, and an object of the invention is to provide an apparatus for producing water for preparation of a dialysis solution, including an electrolytic water generation device that is capable of reducing drained water as much as possible, and performing intense electrolysis to increase the amount of dissolved hydrogen without raising pH.
Solution to Problem
[0011] An apparatus for producing water for preparation of a dialysis solution according to the present invention includes an electrolytic water generation device that performs electrolysis using a solid polymer membrane, and a reverse osmosis membrane treatment device.
[0012] In the apparatus for producing water for preparation of a dialysis solution according to the present invention, water that has passed through the reverse osmosis membrane treatment device may be electrolyzed by the electrolytic water generation device, or water generated by the electrolytic water generation device may be passed through the reverse osmosis membrane treatment device.
Advantageous Effects of Invention
[0013] According to the present invention, since the electrolytic water generation device using a solid polymer membrane is applied, it is unnecessary to drain water formed at the anode side after electrolysis, and an amount of water that has decreased by electrolysis may only be supplied. Moreover, in the electrolytic water generation device using a solid polymer membrane, since the pH does not change before and after electrolysis, water that has been subjected to intense electrolysis can be supplied to the reverse osmosis membrane treatment device. Since the pH does not change even if a high voltage is applied to increase the amount of dissolved hydrogen, the water after being subjected to such electrolysis can be subjected to a reverse osmosis membrane treatment. Furthermore, since electrolytic water generation device 2 using a solid polymer membrane 5 can also electrolyze pure water, water after being subjected to the reverse osmosis membrane treatment in a reverse osmosis membrane treatment device 3 may be electrolyzed by electrolytic water generation device 2 . This obviates the need to provide a separate tank for storing the water after electrolysis in electrolytic water generation device 2 or a pump therefor, in addition to a tank (RO tank) 21 for storing water after the reverse osmosis membrane treatment. This leads to reductions in size and cost. Furthermore, deposition of minerals does not occur in electrolytic water generation device 2 using solid polymer membrane 5 . This also achieves an effect of preventing electrolysis from being hindered by deposition of minerals.
BRIEF DESCRIPTION OF DRAWINGS
[0014] FIG. 1 is a schematic diagram showing an apparatus 1 for producing water for preparation of a dialysis solution in one preferred embodiment of the present invention;
[0015] FIG. 2 is a schematic diagram showing an electrolytic cell 4 in electrolytic water generation device 2 in apparatus 1 for producing water for preparation of a dialysis solution according to the present invention;
[0016] FIG. 3 is a diagram showing typical conventional water treatment system 101 for a dialysis solution; and
[0017] FIG. 4 is a schematic diagram showing electrolytic cell 202 used in typical conventional electrolytic water generation device 201 .
DESCRIPTION OF EMBODIMENTS
[0018] FIG. 1 is a schematic diagram showing apparatus 1 for producing water for preparation of a dialysis solution in one preferred embodiment of the present invention, and FIG. 2 is a schematic diagram showing electrolytic cell 4 in electrolytic water generation device 2 in apparatus 1 for producing water for preparation of a dialysis solution according to the present invention. As shown in FIG. 2 , apparatus 1 for producing water for preparation of a dialysis solution according to the present invention includes electrolytic water generation device 2 that performs electrolysis using solid polymer membrane 5 , and reverse osmosis membrane treatment device 3 .
[0019] As solid polymer membrane 5 used in electrolytic water generation device 2 in the present invention, a suitable solid polymer membrane that is conventionally used in the field of fuel cells can be used without being particularly limited. For example, solid polymer membrane 5 formed of a resin material having an ion-exchange function, such as fluorine-based ion-exchange resin, can be suitably used. Specifically, a commercially available product such as Nafion (from Du Pont), Flemion (from Asahi Glass Co., Ltd.), Aciplex (from Asahi Glass Co., Ltd.), or the like can be suitably used as solid polymer membrane 5 in the present invention.
[0020] As shown in FIG. 2 , in electrolytic water generation device 2 used in the present invention, a structure in which an anode 7 and a cathode 8 electrically connected to each other are placed with a metal layer 6 formed on opposing surfaces of solid polymer membrane 5 being present therebetween, is immersed in electrolytic cell 9 containing water 10 to be electrolyzed.
[0021] Examples of materials of anode 7 include those obtained by coating conductive substrates such as titanium, tantalum, niobium, nickel, zirconium, SUS, and the like, with platinum and/or iridium alone or in combination.
[0022] Examples of materials of cathode 8 also include those obtained by coating conductive substrates such as titanium, tantalum, niobium, nickel, zirconium, SUS, and the like, with platinum and/or iridium alone or in combination.
[0023] Examples of metal materials forming metal layer 6 present between anode 7 and solid polymer membrane 5 and between cathode 8 and solid polymer membrane 5 include platinum (Pt) and/or iridium (Ir) alone or in combination. The thickness of metal layer 6 is not particularly limited.
[0024] Electrolytic cell 9 is not particularly limited, and a suitable electrolytic cell used for electrolysis in the pertinent field may be used as electrolytic cell 9 . In electrolysis in electrolytic water generation device 2 using solid polymer membrane 5 as described above, the following reactions occur at an anode 7 side and at a cathode 8 side:
[0000] Anode Side: H 2 O→½O 2 +2H + +2e −
[0000] Cathode Side: 2H + +2e − →H 2
[0025] In electrolytic water generation device 2 using solid polymer membrane 5 as described above, it is unnecessary to drain water formed at the anode 7 side after electrolysis, and an amount of water that has decreased by electrolysis may only be supplied. Hence, although it is necessary to remove oxygen gas generated, the amount of drained water can be reduced to almost zero, as compared to conventional electrolytic water generation devices.
[0026] Furthermore, in electrolytic water generation device 2 using solid polymer membrane 5 , the pH does not change before and after electrolysis. Since the pH does not change even if intense electrolysis is performed by applying a high voltage in order to increase the amount of dissolved hydrogen, even when the water after being subjected to such electrolysis is supplied to the reverse osmosis membrane treatment device, it can be subjected to a reverse osmosis membrane treatment without damage to the reverse osmotic membrane.
[0027] Alternatively, since electrolytic water generation device 2 using solid polymer membrane 5 can also electrolyze pure water, the water after being subjected to the reverse osmosis membrane treatment in reverse osmosis membrane treatment device 3 may be electrolyzed by electrolytic water generation device 2 . In this way, according to the present invention, water that has passed through reverse osmosis membrane treatment device 3 may be electrolyzed by electrolytic water generation device 2 , or water generated by electrolytic water generation device 2 may be passed through reverse osmosis treatment device 3 . FIG. 1 shows the case where the water that has passed through reverse osmosis membrane treatment device 3 is electrolyzed in electrolytic water generation device 2 . This obviates the need to provide a separate tank for storing the water after electrolysis in electrolytic water generation device 2 or a pump therefor, in addition to a tank (RO tank) 21 for storing water after the reverse osmosis membrane treatment. This leads to reductions in size and cost.
[0028] Furthermore, in conventionally used electrolytic water generation devices, deposition of minerals such as calcium (Ca) and the like on a cathode surface hindered electrolysis. In contrast, in electrolytic water generation device 2 using solid polymer membrane 5 as in the present invention, deposition of minerals does not occur, so that electrolysis can be prevented from being hindered by such deposition of minerals.
[0029] As reverse osmosis membrane treatment device 3 in apparatus 1 for producing water for preparation of a dialysis solution according to the present invention, a conventionally known suitable reverse osmosis (RO) device can be used without being particularly limited, and specifically, HM500CX (from Japan Water Systems Corporation), for example, is preferable. As used herein, the reverse osmosis membrane treatment refers to the following treatment: when there are solutions with different concentrations with a semi-permeable membrane as a boundary between them, pressure is applied toward a solution with a higher concentration to thereby obtain water that has permeated through a solution with a lower concentration, as opposed to osmosis that is a phenomenon in which water moves from the solution with a lower concentration toward the solution with a higher concentration. By this reverse osmosis membrane treatment, impurities such as trace metals can further be removed from the raw water obtained by the series of treatments described above, and the resulting water can thus meet the water quality standards defined in ISO 13959 described below.
[0030] Apparatus 1 for producing water for preparation of a dialysis solution according to the present invention is not particularly limited in structure, except for electrolytic water generation device 2 using solid polymer membrane 5 and reverse osmosis membrane treatment device 3 described above, and can have a structure similar to those of conventional apparatuses for producing water for preparation of dialysis solutions. For example, in exemplary apparatus 1 for producing water for preparation of a dialysis solution shown in FIG. 1 , raw water (municipal water) 22 is pressurized with a pressurizing pump 23 , treated with a filter 24 , and then sequentially subjected to treatments with an activated carbon filtration device 25 and a softening device 26 .
[0031] In apparatus 1 for producing water for preparation of a dialysis solution according to the present invention, tap water, well water, or ground water can be used as raw water 22 . As filter 24 for filtering raw water 22 to remove coarse foreign substances such as iron rust (precipitated from a supply pipe), sand, and the like contained in raw water 22 , a filter with a pore size of 10 to 30 μm can be suitably used, and specifically, a 25 μm filter (from Japan Water Systems Corporation), a 10 μm filter (from Japan Water Systems Corporation), or the like is preferable.
[0032] Activated carbon filtration device 25 is for subjecting the raw water to a treatment to remove residual chlorine, chloramine, organic substances and the like contained in the raw water by a physical adsorption effect, using activated carbon, which is a porous adsorptive material. As activated carbon filtration device 25 , a conventionally known suitable activated carbon treatment device can be used without being particularly limited, and specifically, fibrous activated carbon MOF250C2 (from Futamura Chemical Co., Ltd.), for example, is preferable.
[0033] Softening device 26 is for subjecting the raw water, which is hard water containing dissolved solids (calcium ion, magnesium ion, and the like) as hard water components, to a treatment to turn the raw water into soft water by removing the hard water components through a replacement reaction using ion exchange. As softening device 26 , a conventionally known suitable softening device can be used without being particularly limited, and specifically, MARK-915U (from Japan Water Systems Corporation), for example, is preferable.
[0034] Water subjected to the reverse osmosis membrane treatment that has passed through reverse osmosis membrane treatment device 3 is thereafter supplied to electrolytic water generation device 2 for electrolysis, and then stored in an RO tank 21 . Reduced water delivered from RO tank 21 is subjected to a sterilization treatment with an UV sterilization lamp 27 , passed through a microfilter 28 , and supplied to a dialysis solution supply device 29 . Dialysis solution supply device 29 mixes the supplied reduced water that has been subjected to the reverse osmosis membrane treatment with a dialysis A raw solution 30 and a dialysis B raw solution 31 , and supplies the mixture to each patient monitor device (not shown) as a dialysis solution. A patient's blood is then purified through a dialyzer attached to the patient monitor device.
REFERENCE SIGNS LIST
[0035] 1 : apparatus for producing water for preparation of a dialysis solution; 2 : electrolytic water generation device; 3 : reverse osmosis membrane treatment device; 4 : electrolytic cell; 5 : solid polymer membrane; 6 : metal layer; 7 : anode; 8 : cathode; 9 : electrolytic cell; 10 : water; 21 : RO tank; 22 : raw water; 23 : pressurizing pump; 24 : filter; 25 : activated carbon filtration device; 26 : softening device; 27 : UV sterilization lamp; 28 : microfilter; 29 : dialysis solution supply device; 30 : dialysis A raw solution; 31 : dialysis B raw solution. | There is provided an apparatus for producing water for preparation of a dialysis solution, including an electrolytic water generation device that performs electrolysis using a solid polymer membrane, and a reverse osmosis membrane treatment device, the electrolytic water generation device being capable of reducing drained water as much as possible, and performing intense electrolysis to increase the amount of dissolved hydrogen without raising pH. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/952,261, filed Mar. 13, 2014, which is hereby incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The disclosed subject matter relates to grounded walking devices.
BACKGROUND
[0003] “Grounding” is a process through which a person is connected electrically to an Earth ground, such as soil. Grounding is known to provide various health benefits.
[0004] It is desirable to provide new mechanisms to facilitate grounding of people.
SUMMARY
[0005] Grounded walking devices are provided. In some embodiments, the grounded walking devices comprise: a conducting rubber handle; a support shaft assembly that is conductive; and a ground contact that is conductive and coupled to the handle via the support shaft assembly. In some embodiments, the support shaft assembly is a part of a cane, an umbrella, a walking stick, a ski pole, a walker, and/or a crutch.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an illustration of a grounded walking device in accordance with some embodiments.
[0007] FIG. 2 is an illustration of a grounded walking device handle and shaft in accordance with some embodiments.
[0008] FIG. 3 is an illustration of a grounded walking device shaft and tip in accordance with some embodiments.
[0009] FIG. 4 is an illustration of a grounded walking device shaft and base in accordance with some embodiments.
[0010] FIG. 5 is an illustration of a grounded walking device conductor in accordance with some embodiments.
[0011] FIG. 6 is an illustration of a grounded walking device shaft wrist strap in accordance with some embodiments.
[0012] FIG. 7 is an illustration of an extendable grounded walking device in accordance with some embodiments.
[0013] FIG. 8 is an illustration of a grounded walking device implemented as a walker with wheels in accordance with some embodiments.
[0014] FIG. 9 is an illustration of a grounded walking device implemented as a walker without wheels in accordance with some embodiments.
[0015] FIG. 10 is an illustration of a grounded walking device implemented as crutches in accordance with some embodiments.
[0016] FIG. 11 is another illustration of a grounded walking device implemented as crutches in accordance with some embodiments.
DETAILED DESCRIPTION
[0017] In accordance with various implementations, mechanisms (which can include systems and methods) for a grounded walking device are provided.
[0018] In some implementations, the mechanisms described herein can disclose a grounded walking device. For example, the walking device can include any suitable walking device such as a walking stick, a hiking pole, a cane, a walker, crutches, a walking staff, an umbrella, a wheelchair, and/or any other suitable walking device.
[0019] In some embodiments, the walking device can allow for a complete flow of electrons between a ground (e.g., a grounded floor, a grounded carpet, a surface of the Earth, etc.) and a user's body (e.g., a user's hand and/or wrist). The mechanisms of the walking device can maintain conductive contact with the ground and the user's body using any suitable technique or techniques. For example, the walking device can incorporate electrically conductive elements throughout the walking device. In such an example, the conducive elements can connect a tip or bottom portion of the walking stick (e.g. portion of the walking stick contacted the ground) with a handle or top portion of the walking stick (e.g., portion of the walking stick being held by a user).
[0020] FIG. 1 shows an example of a walking device in accordance with some embodiments of the disclosed subject matter. As illustrated, a walking device 100 can include a handle 102 , a shaft 104 , and a tip 106 . In some embodiments, handle 102 can be made out of any suitable electrically conductive material, such as a conductive rubber, a conductive plastic, a conductive thermoplastic, a conductive grippable sheath, a conductive grippable coating, a conductive wrap, a conductive carbon fiber, a conductive leather, a conductive polymer, a conductive resin, and/or any other suitable conductive material. The conductive material can contain any suitable conductive metal, such as carbon, aluminum, tinned cooper, stainless steel and/or any other suitable electrical conductive metal. In some embodiments, handle 102 can be any suitable handle such a walking handle, a walker handle, a grip (e.g., as shown in FIG. 5 ), an umbrella handle, a crutch handle, and/or any other suitable handle.
[0021] In some embodiments, shaft 104 can be made out of any suitable electrically conductive material, such as aluminum, carbon, brass, stainless steel, silver, a silver alloy, and/or any other suitable electrically conductive material. For example, turning to FIG. 2 , as illustrated, walking device 100 can include a conductive rubber handle 202 and a conductive aluminum shaft 204 . In some embodiments, shaft 104 can be any suitable structure, such as a solid shaft, a hollow shaft, a curved shaft, a ribbed shaft, and/or any other suitable structure.
[0022] Turning back to FIG. 1 , in some embodiments, tip 106 can be made out of any suitable electrically conductive material, such as a conductive rubber, a conductive plastic, a conductive thermoplastic, a conductive sheath, a conductive coating, a conductive carbon fiber, a conductive leather, a conductive polymer, a conductive resin, and/or any other suitable conductive material. The conductive material can contain any suitable conductive metal, such as carbon, aluminum, tinned cooper, stainless steel, and/or any other suitable electrical conductive metal. For example, turning to FIG. 3 , as illustrated, walking device 100 can include a conductive rubber tip 302 .
[0023] Turning back to FIG. 1 , in some embodiments, walking device 100 can allow electrons to flow between the ground (e.g., a floor, a carpet, a dirt, etc.), tip 106 , shaft 104 , handle 102 , and a user holding handle 102 . For example, as long a user can hold handle 102 , electrons can continuously flow between the ground and the user's hand. In such a situation when the walking device can be a pair of crutches, the handle can be the under arm support of the pair of crutches. In such an example, electrons can flow between the ground and the user's under arm area (e.g., when a user's under arm is exposed and in contact with an under arm support). Additionally and/or alternatively, electrons can flow between the ground and the user's hand (e.g., when a user is in contact with hand grips of the pair of crutches).
[0024] FIG. 4 shows an example of a quad point base of a walking device in accordance with some embodiments of the disclosed subject matter. As illustrated, a walking device can include a quad point base 402 . Quad point base 402 can allow for a greater weight distribution for a user. Additionally and/or alternatively, the base of the walking device can be a tripod base.
[0025] FIG. 5 shows an example of a conductive metal wire inside the shaft of a walking device in accordance with some embodiments of the disclosed subject matter. As illustrated, a walking device can be made of any suitable nonconductive material. For example, walking device can be made of any suitable wood, fiberglass, and/or Kevlar. In such an example, the electrons may not be able to flow between the walking device and a user. In some embodiments, the shaft of the walking stick can include a conductive wire 502 extending from a handle 504 of the walking device to a tip 506 of the walking device. Conductive wire 502 can be made of any suitable electrically conductive metal material, such as copper, aluminum, tinned copper, stainless steel, silver, and/or any suitable conductive metal material. Additionally, conductive wire 502 can be any suitable structure, such as a solid wire, a stranded wire, a braided wire, and/or any other suitable structure. In some embodiments, conducive wire 502 can be placed inside any suitable walking device to allow for the flow of electrons between the ground and the user.
[0026] FIG. 6 shows an example of a conductive wrist strap connected to the handle of a walking device in accordance with some embodiments of the disclosed subject matter. As illustrated, a walking device can include a wrist strap 602 . For example, wrist strap 602 can be connected to a walking device at any suitable location. For example, wrist strap 602 can be connected to a handle of the walking device. Wrist strap 602 can be made of any suitable electrically conductive material, such as a conductive rubber. In some embodiments, wrist strap 602 can wrap around a user wrist to allow electrons to flow between the ground and the user's body.
[0027] FIG. 7 shows an example of a walking device with a spring suspension in accordance with some embodiments of the disclosed subject matter. As illustrated, a walking device can include a spring suspension 702 . For example, spring suspension 702 can be any suitable hidden spring suspension. In some embodiments, spring suspension 702 can be adjusted at adjust points 704 to either loosen or stiffen the springs of spring suspension 702 . As also illustrated, the walking device can include a conductive grip 706 .
[0028] FIG. 8 shows an example of a walker in accordance with some embodiments of the disclosed subject matter.
[0029] FIG. 9 shows another example of a walker in accordance with some embodiments of the disclosed subject matter.
[0030] FIG. 10 shows an example of crutches in accordance with some embodiments of the disclosed subject matter.
[0031] FIG. 11 shows an example of a conductive metal wire inside a pair of crutches in accordance with some embodiments of the disclosed subject matter.
[0032] Although some of the figures have been illustrated as a walking stick, it is understood that the walking device can be any suitable walking device, such as a walking stick, a hiking pole, a cane, a walker, crutches, a walking staff, an umbrella, a wheelchair, and/or any other suitable walking device.
[0033] Although the invention has been described and illustrated in the foregoing illustrative embodiments, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the details of embodiment of the invention can be made without departing from the spirit and scope of the invention, which is limited only by the claims that follow. Features of the disclosed embodiments can be combined and rearranged in various ways. | Grounded walking devices are provided. In some embodiments, the grounded walking devices comprise: a conducting rubber handle; a support shaft assembly that is conductive; and a ground contact that is conductive and coupled to the handle via the support shaft assembly. In some embodiments, the support shaft assembly is a part of a cane, an umbrella, a walking stick, a ski pole, a walker, and/or a crutch. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a hydraulic excavator.
In general, in earth moving vehicles called hydraulic excavators, the implement attached boom-arm linkage adapted to operate an implement such as a bucket etc. has a long reach. Therefore, it has been a normal practice for such a vehicle to keep it stationarily to ensure the stability thereof during its earth moving work.
For this reason, vehicles of the type specified are not adapted to carry out satisfactorily operations requiring running, for example, transporting and running operations with the earth and sand loaded in the bucket thereof. Further, it is difficult for such vehicles to self-propel under a stable condition on inclined lands.
Besides, the implement attached boom-arm linkage having a long reach requires increasing the overall length of the vehicle, and therefore the vehicles of the type specified are inconvenient from the viewpoint of transportation thereof.
Further, in order to employ the vehicles of such a type for multi-purposes, replacements of their buckets for converting back hoe operation into front loading operation and vice versa have been made. However, such replacements of buckets have been conducted manually requiring a considerable time, and so it has been substantially impossible for the operator to carry out the replacement work rapidly.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a hydraulic excavator having an implement attached boom-arm linkage which can be fully retracted and folded on a vehicle's base member thereby improving the stability of the vehicle when it travels and providing a good transportabilily thereof due to the compactness in size of the folded boom-arm linkage.
Another object of the present invention is to provide a hydraulic excavator which is versatile enough to provide both back hoe and front loading operations.
In accordance with an aspect of the present invention, there is provided a hydraulic excavator, comprising: a base; a first boom mounted on said base for movement in a vertical plane about a first pivot; a second boom mounted on said first boom for movement in the same vertical plane about a second pivot; an arm assembly mounted on said second boom for movement in the same vertical plane about a third pivot; an implement mounted at the swinging end of said arm assembly for movement about a fourth pivot; means for swinging said first boom with respect to said base about the first pivot, said means including a lever pivotally mounted on said base and first and second hydraulic cylinders; a third hydraulic cylinder for swinging said second boom with respect to said first boom about the second pivot; a fourth hydraulic cylinder for swinging said arm assembly with respect to said second boom about the third pivot; and a fifth hydraulic cylinder for swinging said implement with respect to said arm assembly about the fourth pivot.
Due to the unique two piece boom and an associated boom operating structures, the entire boom-arm linkage can be fully retracted and folded on a base member of the vehicle. The arm assembly has a built-in means for rotating a part of the assembly with respect to the second boom and therefore the implement such as a bucket can be rotated to provide both back hoe and front loading operations.
The above and other objects, features and advantages of the present invention will be readily apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a hydraulic excavator according to the present invention with a bucket attached boom-arm linkage being in fully retracted and folded position;
FIG. 2 is a side elevatinal view of a hydraulic excavator showing the bucket attached boom-arm linkage being in an extended position;
FIG. 3 is a schematic plan view of FIG. 1;
FIG. 4 is a front elevational view of FIG. 1;
FIG. 5 is similar to FIG. 1 but showing the bucket being rotated and adapted to front loading operation;
FIGS. 6 and 7 are side elevational views of the embodiment shown in FIG. 5 each showing how the bucket attached boom-arm linkage is operated;
FIG. 8 is a side elevational view of a hydraulic excavator with the bucket being rotated for 90 degrees to face sideways;
FIG. 9 is a side elevational view of another embodiment of a boom operating linkage mechanism; and
FIG. 10 is similar to FIG. 9 but showing still another embodiment of a boom operating linkage mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described by way of example only with reference to the accompanying drawings.
Reference numeral 10 denotes a full-revolving base. The full-revolving base 10 has an implement attached boom-arm linkage 11. The implement attached boom-arm linkage 11 comprises a first or base boom 12, a second boom 13 and an arm assembly 14, all of the three components being articulated. The base boom 12 is pivotally connected at its base by means of a pin 16 to a pair of base brackets 15 mounted on the full-revolving base 10 and is adapted to be oscillated by means of a boom pivoting linkage mechanism 17 in the longitudinal direction of the vehicle.
The boom pivoting linkage mechanism 17 comprises a pair of levers 18 pivotally mounted on the same axis as that of the pin 16 pivotally connecting the base boom 12 to the pair of base brackets 15. Connected to the lower ends of the levers 18 by means of pins 29 are the base ends of a pair of second jacks 20 each having a rod 22 pivotally connected to the respective base booms 12 by means of a pin 23. The full-revolving base 10 has a pair of mounting brackets 24 fixedly secured thereto each of which is connected by means of a pin 25 to the base end of each first jacks 19. Each of the first jacks 19 has a rod 26 connected to the upper end of each lever 18 by means of a pin 27.
The base boom 12 has a mounting bracket 28 fixedly secured thereto and which is connected by means of a pin 30 to the base end of a second-boom operating cylinder 21. The second-boom operating cylinder 21 has a rod 31 which is connected by means of a pin 32 to the rear end of the second boom 13. The second boom 13 has a mounting bracket 33 fixedly secured thereto and which is connected by means of a pin 35 to the base end of an arm operating cylinder 34. The arm operating cylinder 34 has a rod 36 which is connected by means of a pin 37 to the rear end of the arm assembly 14. The second boom 13 has a pair of brackets 50 fixedly secured thereto and the arm assembly 14 is pivotally mounted by means of a pin 51 to the brackets 50.
The arm assembly 14 has a holder member 45 fitted to the base end thereof and on which the base end of an arm 46 is rotatably mounted and in which a hydraulic motor (not shown) adapted to rotate the arm 46 is accommodated. The arm 46 is operatively connected to the hydraulic motor by way of, for example, reduction gears. A bucket 38 is connected to the leading end of the arm 46 so that the bucket may be tilted by means of a bucket operating cylinder 39 mounted on the arm 46 through a linkage 47.
The implement attached boom-arm linkage 11 thus constructed is located on the longitudinal center line C of the vehicle body B. Located on the left and right sides of the implement attached boom-arm linkage 11 are a driver's cab 40 and a counter-weight 42 and a tank 41, all of which are mounted on the full-revolving base 10, such mounted equipments 40, 41 and 42 forming therebetween and in the central part of the vehicle body B an accommodating portion 44 in which the implement attached boom-arm linkage 11 is accommodated after being retracted and folded. The arrangements of the implement attached boom-arm linkage 11, the accommodating portion 44 and the mounted equipments are made such that when the boom-arm linkage 11 is retracted and folded in the accommodating portion 44 a major part of the boom-arm linkage is located within a locus circle S having a straight distance R between the center P of the vehicle body B and the front outer edge Q of the driver's cab 40 as the radius thereof.
The operation of the excavator according to the present invention will now be described hereinbelow. The first jacks 19 serve to oscillate or swing and hold the levers 18, whilst the second jacks 20 serve to oscillate and hold the base boom 12. Stating in brief, when the base boom 12 is held by means of the second jacks 20 and the levers 18 are oscillated by means of the first jacks 19, the base boom 12 is rotated together with the second jacks 20 about the pin 16. When the levers 18 are fixed by holding the first jacks 19 and the second jacks 20 are rendered operative, the base boom 12 can also be turned about the pin 16. Thus, both the first jacks 19 and the second jacks 20 serve to turn the base boom 12 about the pin 16.
The above-mentioned movement of the base boom 12 will carry or displace the second boom 13 longitudinally and vertically of the vehicle body B. When the base boom 12 is displaced rearwardly of the vehicle body B and then the rod 31 of the second-boom operating cylinder 21 is extended, the second boom 13 is retracted and folded on the base boom 12. (Refer to FIGS. 1 and 3). As shown in FIG. 3, under such condition, the greater part of the implement attached boom-arm linkage 11 is accommodated in the locus circle S. When, the second boom 13 is displaced forwardly of the vehicle body B and then moved vertically together with the movement of the arm 14, back hoe operation as shown in FIG. 2 is effected.
The above-mentioned arrangement enables the overall length and the overall height of the vehicle to be reduced or made compact and also enables a stability thereof during running to be obtained by drawing the implement attached boom-arm linkage 11 near the center of gravity of the vehicle.
FIGS. 5, 6 and 7 show another mode of operation of the excavator according to the present invention in which a hydraulic motor in the arm assembly 14 is driven to turn the arm 46 thereby effecting front loading operation. As shown in FIG. 5, when the base boom 12 and the second boom 13 are retracted and folded in the accommodating portion 44, the booms 12 and 13 will not give a bad influence on the running posture of the vehicle thereby enabling the self-running of the vehicle with excavated earth loaded in the bucket 38 to be made satisfactorily.
FIG. 6 shows the bucket 38 raised to its dumping reach or height. FIG. 7 shows the excavator is under front loading operation wherein the opening of the bucket 38 is directed forwardly and the implement attached boom-arm linkage 11 is controlled to effect the front loading operation.
When the arm 46 is turned to direct the opening of the bucket 38 transversely as shown in FIG. 8 and the full-revolving base 10 is rotated, it is pssible to scoop the earth and sand into the bucket 38, lay them evenly on the ground, readjust the land and remove the earth and sand.
FIGS. 9 and 10 show further embodiments of the boom pivoting linkage mechanism 17 mountings to the full-revolving base 10. In brief, the levers 18 and the base boom 12 are connected by means of pins 54 and 55, respectively, to independent brackets pairs 54 and 55 projecting from the full-revolving base 10 and the respective pivots of the base boom 12 and the levers 18 are displaced longitudinally of the vehicle body.
As described in detail hereinabove, the present invention is characterized by comprising a base boom 12 mounted for a pivotal movement on a full-revolving base 10, a second boom 13 operatively connected to the base boom 12 and adapted to be raised and lowered by means of a boom operating cylinder 21, an arm assembly 14 operatively connected to the second boom 13 and arranged to rotate an arm 46 having a bucket 38 fitted to the leading end thereof, said arm assembly 14 being arranged to be raised and lowered by means of an arm cylinder 34, and a boom pivoting linkage mechanism 17 mounted on the full-revolving base 10 and adapted to raise and lower the base boom 12.
Therefore, the greater part of the implement attached boom-arm linkage can be folded and retracted on the side of the vehicle body so that the overall length and the overall height of the vehicle can be reduced thereby enabling an improved stability thereof when it is running to be obtained. In addition thereto, the base boom can be moved longitudinally of the vehicle body by oscillating it and the second boom can be displaced longitudinally and vertically of the vehicle body so that both booms can be freely displaced from its folded and retracted condition on the side of the vehicle body to its operating condition and vice versa. Further, even when a back hoe bucket is converted to a front loading operation bucket and vice versa, an operational capacity can be obtained which is equivalent to those of excavators exclusive to back hoe operation or to front loading operation. Further, since in the arm assembly 14 the arm 46 having the bucket 38 fitted thereto can be rotated, a switch-over between the back hoe operation and the front loading operation can be made rapidly and smoothly.
Although the present invention has been shown and described in terms of the preferred embodiment and modifications thereof, it is to be understood that a variety of other modifications and changes may be made without departing from the spirit of the invention as defined in the appended claims. | A hydraulic excavator having first and second booms pivoted end to end, plus an arm pivotally connected to a swinging end of the second boom. A bucket is pivotally mounted at the leading end of the arm. A boom operating linkage mechanism including a lever and hydraulic cylinders is mounted on a full-revolving base for swinging the first boom with respect to the base. The arm is adapted to rotate with respect to the second boom and therefore the bucket is capable of providing both back hoe and front loading operations. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national stage entry of PCT/SE2006/000642, having an international filing date of May 31, 2006, which claims priority to Swedish patent application no. SE 0501253-9, filed Jun. 1, 2005. Each of the foregoing disclosures is expressly incorporated herein in its entirety.
FIELD OF THE INVENTION
The invention concerns a positioning device and a system for engagement with vertebrae in a spinal column including such a positioning device.
BACKGROUND OF THE INVENTION
For patients diagnosed with disc degeneration, surgical operations are performed more and more often. The most common operation for these patients today is fusion, where an ossified connection of vertebrae is obtained. Also, metallic connection devices can be used. Movability then ceases between the vertebrae in question but the patient will become free from pain. As the patient becomes more active and movable, the segments above and below the fused region will, however, be subjected to greater strains. The risk of new symptoms from surrounding segments thereby increases.
As an alternative to fusion, disc implants have been presented. A known disc prosthesis generally consists of two mutually articulated plates that are positioned between two vertebrae instead of the disc. The positioning of a disc implant results in eliminating the disc that causes pain, reinstating the distance between the vertebrae and reinstating movability between them.
In order to obtain sufficient certainty against a disc implant moving, over time, in an undesired manner from the intended position between two vertebrae, two mutually articulated plates of a previously known prosthesis are provided with different kinds of projecting engagement means, such as fin-shaped elements, pointed elements, pins and like plural projections for the engagement with the meeting surfaces of the vertebrae.
An operative method that is used for inserting a disc implant requires positioning of the prosthesis from the abdomen side in order to allow access to the vertebral column from the front. The disc to be replaced is cleared out, whereby the vertebrae are drawn apart with the aid of tension pliers.
After using instruments for shaping grooves in the surfaces of vertebrae for the cooperation with possible projecting protrusions for the purpose of achieving a correct position for the disc prosthesis, the latter is now to be positioned.
According to today's methods, this is achieved by placing the prosthesis on a holder and hammering it in with great force between the vertebrae, guided by the prepared grooves. This step in the operation is very problematic, since the vertebrae tend to be drawn against each other and then it is often difficult to implant the prosthesis between the vertebrae. For this reason, implantation by hammering is risky.
When the prosthesis is finally positioned, which is verified with X-ray radioscopy, tension pliers are used in order to again span apart the vertebrae, and thereby the disc plates of the prosthesis, in order to be able to position a joint detail between these plates. Also this step is troublesome and sometimes laborious.
When using prostheses that are completely assembled which include the joint detail, this second step is not necessary. Such prostheses are, however, thicker and thus, more troublesome to position between the vertebrae. Sometimes, unfortunately, damage to the vertebrae can occur during the positioning of the prosthesis. Such damage can be serious and have serious consequences. For that reason, the surgical operation puts great demands on the skill and experience of the surgeon.
When, finally, everything is place, the operation is terminated and a final X-ray is made. Sometimes, it is discovered that the disc prosthesis is positioned in such a way that it is not placed exactly on the middle line or is not in a proper position. The possibilities of adjusting the position are at this stage almost none.
Since the disc prosthesis rests on the brittle covering plate of the vertebra, the prosthesis must have maximal size in order to support on a relatively strong peripheral rim of the vertebra. Exact positioning is therefore very essential. Patient having osteoporosis are therefore often disqualified for this type of surgical operation depending on lack of congruence between the parts of the disc prosthesis and the vertebra.
Incorrect positioning results in risk of uncontrolled separation and repositioning of the vertebrae.
OBJECTS AND IMPORTANT FEATURES OF THE INVENTION
It is an aim of the present invention to provide a positioning device of the kind mentioned initially and a system which makes it possible to eliminate or at least reduce the problems of the background art.
These aims and advantage of the present invention can be achieved in a positioning device according to features disclosed herein.
Hereby it is achieved that when two vertebrae of the vertebrae in a spinal column are push apart, a prosthesis device, such as for example a disc prosthesis or a vertebral prosthesis, can be correctly positioned with respect to at least one vertebra when the vertebrae are spanned, e.g., pushed, apart, so that, when the separation is ended, the prosthesis is indeed in the right position. X-ray radioscopy can be used in connection with adjusting holding means of the disclosed embodiments in order to assist the surgeon during the positioning. The invention is, however, not limited to this method, but also other corresponding methods for this are possible to use, such as for example translucence with NMR-camera, magnet camera. Also, other fluoroscopy and positioning indication methods can be used.
When the pushed apart vertebrae are released against the prosthesis device, through X-ray radioscopy or the like, the final position of the prosthesis device can be verified that it is in the desired position. In the event this is not the case, there is a real possibility of repositioning the prosthesis device after a renewed pushing apart of the vertebrae, although this would not be necessary if the positioning is made accurately from the beginning.
After a verified correct positioning, the holding device is released from the prosthesis device, whereafter the used device can be removed permanently. Altogether, the positioning device according to the invention allows essentially more secure and further, more easily handled equipment, which also can be used in a patient-friendly manner with minimized risks of injuries to the patient when it is used.
By providing two fixing elements for different engagement positions and which are mutually lockable, satisfactory stability is obtained and positioning security after possibility of adjustment.
By providing a universal joint, which is lockable/releasable through locking means, great positioning freedom is provided.
In particular, it is preferred that the positioning device according to the invention includes distance means having connection portions which carry engagement means that are constructed for engagement with two vertebrae at a distance from each other. Hereby the prosthesis device is positioned with respect to these vertebrae, which are preferably located on either side of the operation point.
In particular, it is preferred that the distance means are arranged such that they are capable of changing the degree of separation of the vertebrae when the engagement means are in engagement therewith. Hereby, in the positioning device, the means for spanning apart the vertebrae are integrated which is a considerable advantage since the arrangement for spanning apart can be constructed optimally to function as a mechanism for spanning apart, and further, as the base for the fixing means. Greater freedom when removing the old, damaged disc is also achieved. With previously known technology, the tooling for holding apart the vertebrae comprises an obstacle making it difficult to evacuate the old, damaged disc. This process is time consuming and positioning of a disc implant is more difficult. The integrated aspect of this invention essentially simplifies clearing out of the damaged disc, whereby the entire operation is facilitated and speeded up, resulting in a safer operation. The possibility of spanning apart, which is provided according to this aspect of the invention, makes it possible to freely remove the old disc.
The positioning of the holding means will thereby be very stable and no further engagement points, besides the ones belonging to the mechanism for spanning apart, the distance means, are necessary. The number of operation points in the patient in the form of holes for screws or the like can thereby be limited to a minimum.
The distance means preferably includes two distance means arranged in parallel each carrying the engagement means. The adjustment and handling of the holding means and the prosthesis carried thereon takes place between the parallel arranged distance means. The fixing means are suitably comprised of elongate elements, that are arranged on the distance means and are fixable thereon, which in a common crossing point are lockable, which results in a very stable fixation. The crossing point between these elements is preferably also the starting point for locking means, which, in its locked position, fixes the holding means. Preferably the locking means in the locked position also locks the fixing elements in said crossing point.
By providing the fixing elements with one slotted portion in their free regions, in the free state, sideways adjustment of the crossing point is allowed with respect to the operation point, which can be desirable for providing an accurate positioning of the prosthesis device in its rotational direction.
It is previously known to use so called retractors in the kind of surgical operation of the present type in order to hold the soft parts in the abdomen from the operation point. A system according to the invention includes and preferably carries support devices for that purpose. By fastening them to the distance means, they contribute in an optimal manner to hold the abdomen wall pressed down and the operation field free. The clearing out of the old disc is also simplified with these means.
BRIEF DESCRIPTION OF DRAWINGS
The invention will now be described by way of embodiments and with reference to the annexed drawings, wherein:
FIG. 1 shows a positioning device according to the invention during the process of introducing an implant in a spinal column, partly in section,
FIG. 2 shows the positioning device in FIG. 1 in a perspective view,
FIG. 3 shows the positioning device in FIGS. 1 and 2 in a separate perspective view,
FIG. 4 shows the positioning device according to the invention with some details removed for the sake of clarity, and
FIGS. 5 a and b show in different views a holding device for the use with a device according to the invention.
DESCRIPTION OF EMBODIMENTS
FIG. 1 shows a positioning device 1 in the process of positioning a disc implant 2 between two vertebrae 3 and 3 ′ in a spinal column of a living human being. Reference numeral 5 are two healthy discs, whereas between the vertebrae 3 and 3 ′ is cleared out all material from a damaged disc to be replaced by the disc implant 2 .
The disc implant 2 is held by a holding device 6 including a fork-shaped head 10 , which releasably grips around the disc implant 2 and a rod shaped manipulating element 11 which can be manipulated by hand by a surgeon. In the embodiment shown in FIG. 1 , the manipulating element 11 is controlled by a fixing means 7 , which in turn is connected to the distance device 8 (only one shown on FIG. 1 ), which in turn includes engagement means in the form of screws, (indicated with dash dotted lines, and with numerals 4 and 4 ′), for engagement with two vertebrae 3 , 3 ′.
The fixing means 7 includes fixing elements 12 (only one shown in FIG. 1 ) together with a universal joint 9 ′ which is lockable by means of locking means 9 , wherein the universal joint 9 ′, in a first, free state, allows adjustable movement including rotations and displacements of the holding means 6 and thereby for the disc implant 2 . In a second, locked position, the locking means 9 locks the universal joint 9 ′, and thereby the holding device 6 and the disc implant 2 , in a chosen position.
As is indicated by arrows P 1 -P 6 , essentially total freedom of movement is achieved with the shown embodiment with three linear degrees of freedom P 1 -P 3 and three rotational degrees of freedom P 4 -P 6 for the holding device 6 . It should be noted that freedom of movement in the length direction of the distance device 8 is obtained by displacement of the fixing element 12 relative thereto. Locking of the locking means 9 can suitably be arranged by means of a smaller rotation of the fixing element 12 with respect of the distance device 8 and thereby friction locking of these elements with respect of each other.
The function of the spanning device of the arrangement is such that the distance device 8 is extendable in the length direction by displacement in such a way that the engagement elements, which thus have been brought to engagement with two vertebrae because of the extension, will cause a change of the degree of separation between these vertebrae 3 and 3 ′ with respect to each other.
This way the vertebrae can be separated and the space between them be cleared out so that the disc implant 2 , without resistance, can be inserted between the vertebrae 3 and 3 ′ and accurately positioned by the surgeon supported by simultaneous X-ray radioscopy until an optimal positioning of the disc implant 2 has been reached. Thereafter the holding device 6 is locked and thereby the prosthesis device in positioned in the chosen position with the aid of the fixing means 7 , whereafter the distance device 8 is manipulated in such a way that the distance between its outer ends is reduced and the vertebrae 3 and 3 ′ move closer to each other until they come into contact against the outer plates of the disc implant 2 . Thereafter, a final control is made, by means of X-ray radioscopy or the like, that the disc implant 2 is indeed accurately positioned.
If that should not be the case, the degree of separation is again increased between the vertebrae 3 and 3 ′ and the disc implant 2 is repositioned. When accurate positioning has been reached, the holding device 6 is removed from the disc implant 2 , whereafter the distance device 8 and its engagement means 4 and 4 ′ can be removed from the engagement with the vertebrae.
In FIG. 2 , the positioning device 1 is represented in a perspective view in about the same position as is shown in FIG. 1 . Here, it is shown that the spanning device belonging to the positioning device 1 includes two sideways separated distance means 8 and 8 ′, which are positioned such that between them is a sufficient space for introducing a disc implant (not shown in FIG. 2 ), which is carried by a fork head 10 of a holding device 6 .
From each one of the distance means 8 and 8 ′, extend fixing elements 12 and 12 ′, which are longitudinally displaceable on the respectively means 8 and 8 ′ through sleeve portions 19 . The fixing elements 12 and 12 ′ are united at a crossing point, where locking device 9 engages. The locking device 9 also activates and deactivates a universal joint 9 ′, which carries the manipulating element 11 of the holding device 6 .
Fixing means 12 and 12 ′ are arranged longitudinal through slots 20 and 20 ′, in which a bolt belonging to the locking means 9 can run. This way, in a free state of the locking means, it is possible to displace the locking device and the universal joint 9 ′ in height as well as sideways by side displacement of the locking device and the universal joint with respect to the operation point between the vertebrae 3 and 3 ′.
Further, the distance devices 8 and 8 ′ are telescopic and thus axially displaceable in order to allow an increased separation of those vertebrae, with which they are in engagement. In the shown example, distance means 8 and 8 ′ are not in engagement with two adjacent vertebrae, but with a first vertebra 3 ′ and a second vertebra 3 ″, whereas a third vertebra 3 is between these vertebrae. This arrangement allows better space at the place of operation.
Spanning apart the distance devices are made with a pliers device 18 , which forces apart two telescopic parts 15 ′ and 14 ′ belonging to the distance device 8 ′. For fixing of an obtained separation position, a locking ring 16 ′ is used, which locks against the smaller one of the telescopic parts 15 ′ by means of a locking screw 17 . In practice, the spanning apart of the vertebrae are made through step-wise manipulation of the pliers device 18 by first, the one on the distance devices a smaller step, locking thereof, thereafter spanning apart of the second distance device a smaller distance, locking thereof etc. etc.
In FIG. 3 , the device of FIG. 2 is shown in a different perspective and freed from a spinal column. The distance devices 8 and 8 ′ have at their ends known joint devices for cooperation with the engagement means 4 , 4 ′, which are comprised of known skeleton screws. By the engagement means being articulately fastened to the distance devices, excess breaking forces onto the vertebra are avoided in connection with spanning-apart the spinal column. The positioning of the screws 4 , 4 ′ in the vertebrae, which are least porous, and thereby best resist the forces for spanning apart.
On FIG. 3 also illustrates two supporting elements 21 and 21 ′, preferably lockable and slightly curved, which are arranged for cooperation with (not shown) supporting plates for free holding the operation point from body organs in connection with the surgical operation.
In FIG. 4 illustrates the positioning of essential parts, according to the invention, with some details removed.
A holding device 6 is shown in FIG. 5 a and b . The holding device 6 includes a fork-shaped head 10 with fork shanks 10 ′ and 10″, which form an engagement position, where, with the aid of the engagement means 24 , engage a disc implant. Accordingly, holding device 6 can be brought to a position where the disc implant is released. This is achieved when the normally curved element 23 between the fork shanks 24 , by means of an actuating means 22 in the form of an element inside the rod shape maneuvering element 11 , is brought to a straightened state, where it presses apart the fork shanks 24 . See interrupted arrows in FIG. 5 b . The actuating means 22 can be manipulated by hand by a surgeon through a press button outermost on the means 22 . The head 10 is preferably made of a plastic material in one piece in such a way that in an unloaded condition, it is in a position for engagement and with a bent element 23 .
It should be noted that the invention can be modified within the scope of the claims. The shown embodiment with the positioning device directly cooperating with a spanning device in the form of distance means is preferred. However, it is not excluded that the positioning device is separate from the spanning device, and in that case, it is arranged such that the fixing means are fastened otherwise to one or a plurality of vertebrae. This is, however, not desired, since it means that further operations with holes etc. in the spinal column have to be made. It, however, makes it possible to use another type of spanning device for separating the vertebrae than the one that is described and shown here.
In order to arrange that a greater space is provided between two distance devices, the attachments of the engagement means can be positioned sideways outwardly, so that the distance devices can be positioned sideways with respect of the axes of the engagement means.
A modification of the spanning device can have one single distance device, which provides spanning apart instead of two that are shown in the Figures. At the ends, this single distance device can have sideward angled portions for cooperation at different positions after their lengths, with each two engagement means engaged with the vertebrae so that the spanning device includes a shallow U-shaped construction with the distance device as a web and the sideward angled portions as the shanks of the U. In this case positioning, as an example, there may need to be arranged, on the one hand, on the only distance device, and on the other hand, on a fixed point on a vertebra.
The arrangement between the distance device (devices) and the engagements means can be different: For example, an arrangement with three independent joints for allowing movements: 1: in a plane parallel with the axis of the distance device, 2: in a plane at right angle to the axis of the distance device, 3: in a plane at right angle against the axis of the engagement means (screw). Independent locking of these joints results in possibility of changing the angles of the screws, also under load, which gives greater possibilities of influencing the positions and the parallelism of the vertebrae.
The fixing means can, such other cases, be constructed otherwise, thus including portions for cooperation directly with a vertebra. Also other kinds of arrangements for locking the holding means can be envisaged. For example, with a locking device arranged at the fastening point of the fixing means on the spanning device or on the vertebra itself. It is also possible to have other types of locking and a plurality of separate locks for movements in different directions instead of the integrated lock shown in the Figures. The distance devices can be manipulated otherwise, for example, by screwing, with a notched rod with possibly a spring loaded locking device, or with a leaver mechanism.
In a simply handled modification, the distance device is maneuvered with the aid of an adjustment cable, such as a “Bowden cable”, which can have its fastenings on engagement portions on mutually movable parts of a distance device in a manner which is obvious for the person skilled in the art. This way, spanning apart of two vertebrae is initiated from a distance from the area of spanning apart, which is an advantageous, since it enhances control and accessibility. Also, other arrangements, such as with a pawl and rack and corresponding actuating means with hydraulics or with pneumatics, can be used for spanning apart.
It shall be noted that it is not excluded that other prostheses are positioned with a device according to the invention, for example vertebra prostheses. | A positioning device for placing a prosthesis device in a spinal column of a living mammal, the device including at least one holding means for cooperation with the prosthesis device and for guiding thereof during positioning. The positioning device may also include fixing means for fixation with respect to at least one vertebra, where the fixing means includes locking means, which in a first, free state, allows adjustable movement of the holding device and thereby of the prosthesis device, and in a second, locked state, fixes the holding means and thereby the prosthesis device in a selected position. Embodiments of the disclosure also include Embodiments of the invention also include a system. | 0 |
RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional Patent Application Ser. No. 61/599,798, filed Feb. 16, 2012.
FIELD OF THE INVENTION
[0002] The invention relates generally to methods of producing biofuels from carbohydrate and lignocellulosic biomass and more particularly, to a method for conversion of biomass by first converting feedstock into chloromethylfurfural (CMF) then converting the CMF to other intermediates that are condensed together and hydrodeoxgynated to produce diesel and jet fuel products.
BACKGROUND OF THE INVENTION
[0003] Today, global climate change and energy national security as well as improvement of air quality, are absolute global priorities. Most cellulosic biofuels technologies are designed to produce gasoline blendstocks such as ethanol. Diesel cellulosic fuels would reduce greenhouse emissions. A cellulosic fuel that is a viable turbine fuel with application to the renewable jet fuel market would also be of great benefit for climate change mitigation and energy national security.
[0004] Although cellulose is the most abundant plant material resource, its exploitation has been curtailed by its composite nature and rigid structure. As a result, most technical approaches to convert lignocellulosic material to fuel products have focused on an effective pretreatment to liberate the cellulose from the lignin composite and break down its rigid structure. Besides effective cellulose liberation, a favorable pretreatment can minimize the formation of degradation products because of their wastefulness and inhibitory effects on subsequent processes. One way to improve the efficiency of biomass conversion schemes (biorefineries) is to integrate the energy-intensive lignocellulose depolymerization and dehydration (LDD) process with power production and/or other biomass processing. Some biorefineries rely on conversion of lignocellulose to glucose and subsequent fermentation, but this processing can require expensive enzymes and long contact times or can produce compounds that inhibit the fermentation or that are low-value by-products. In addition, fermentation releases carbon dioxide and produces cell mass, which in some examples can only be efficiently reused as a livestock supplement.
[0005] An alternative processing for lignocellulosic materials is acid-catalyzed depolymerization and conversion to the C5 product, levulinic acid, or esters thereof. In general, two methods are used to produce levulinic acid or levulinate ester from lignocellulose. One method uses water with a strong acid catalyst, such as sulfuric acid, to effect the depolymerization and dehydration of lignocellulose to produce the C5 and C1 acids (levulinic and formic acids) (see, for example, U.S. Pat. No. 5,608,105). However, separation of products from the aqueous product solution is difficult. One patent describes a separation scheme that uses an olefin feed to convert the aqueous acid to esters that can be separated from the water and each other (see, for example, U.S. Pat. No. 7,153,996). Of course, a nearby olefin source is required for this process.
[0006] Another method uses an alcohol solvent for the acid-catalyzed depolymerization of cellulose, which results in direct formation of the levulinate ester (see, for example, DE 3621517).
[0007] Another method of liquid phase catalytic conversion of C6 sugars and the cellulose component of lignocellulosic materials into intermediates for fuel production is described in by Mascal (U.S. Pat. No. 7,829,732 B2), in which chloromethylfurfural (CMF) is formed in high yield.
[0008] Another method of liquid phase catalytic conversion of C6 sugars into intermediates, predominately hydroxymethylfurfural (HMF) and further processing for fuel production, is described in by Dumesic (U.S. Pat. No. 7,880,049), in which hydroxymethylfurfural (HMF) is formed in high yield and either self condensed or cross condensed with another aldehydes or ketone before deoxygenating to alkane based fuels.
[0009] Published U.S. Patent Application US 2010/0312028 describes a multiproduct biorefinery based on producing levulinic acid or esters thereof from C6 sugar sources, condensing the levulinate with another aldehyde and deoxygenating the condensation products to alkane fuels and other products.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to a method of making alkanes from lignocellulosic sources of C5 and C6 sugars. The C6 conversion goes through recovered intermediate chlormethylfurfural (CMF) that is further processed into fuel products.
[0011] In a broad aspect the invention provides a method for converting suitable biomass feedstocks into alkane based fuels such as diesel and jet fuel blendstocks, comprising the steps of converting C6 sugar monomers to CMF with a levulinic acid (LA) byproduct, converting the CMF and LA into components suitable for cross aldol condensation reactions, preferably ethyl levulinate (EL) and hydroxymethylfurfural (HMF), condensing the aldehydes and ketone mixture along with furfural made from C5 sugar sources into desired carbon chain lengths, saturating the condensation product by mild hydrotreating, and then deoxygenating the products to a desired mixture of alkanes. The deoxygenation catalyst may be a commercially available NiMo catalyst.
[0012] The carbon chain length of the condensate products may be controlled by controlling the ratios of HMF, furfural, and levulinate. Controlling these ratios will control the ratio of mono- and di-aduct products from the condensation reaction. Control over the product ratios will determine the carbon chain length and to some extent the isomerization of the alkane product. Controlling these parameters can enhance fuel properties.
[0013] The mild hydrotreating step may be conducted in a way that produces cyclic ether compounds, such as a compound that contains at least one tetrahydrofuran group. This embodiment provides several advantages including: reducing the propensity of the product mixture to form tars when hydrotreated at more severe conditions that would have a deleterious effect on the cycle life of a heterogeneous catalyst, providing an opportunity to recover subject compounds as a product with valuable properties, and recovering the alcohols, most preferably ethanol, from the condensation products to allow the alcohols to recycle to the CMF reaction step of the process.
[0014] The condensation step may involve using a catalyst for the condensation reaction, the catalyst being selected from catalyst types tailored to the components that are to be condensed together. Suitable catalysts include liquid base catalysts and solid base catalysts with the preferred being hydrotalcite solid basic catalysts, liquid acid catalysts, and solid acid catalysts.
[0015] The mild hydrotreating step may use a heterogeneous catalyst formulation of active metal components incorporated on either a carbon or alumina base. Active components may be selected from a group consisting of Ru, Re/Ru, Re/Pt, Rear, Fe/Pt, Os/Rh, Rh, Ni/Re, Re, Pd/Re, Pd/Zn, Pd/Fe, Pd/Ni, Pd/W, Pd/Co, Pd/Pr, Pd/Cu, Pd/Mn, Pd/V, and combinations thereof.
[0016] In another embodiment, production of ethoxymethylfurfural (EMF) may be substituted for HMF production, and used as a reactant for the condensation reactions. The use of EMF is potentially advantageous because of relative its superior relative stability compared to HMF. Additionally, LA may be substituted for EL because it does not require the handling and either procurement or recycle of ethanol.
[0017] The invention is useful for the efficient production of alkanes with good fuel properties. For jet fuel these alkanes can have low freeze points and still meet the specifications for gravity and flash point. For diesel fuel, cetane can be high compared to petroleum blends. It is anticipated that a life cycle analysis will qualify both fuels as a cellulosic biofuel for purposes of the Renewable Fuel Standard II (RFS2) as established by the US Environmental Protection Agency. Both fuels can be considered “drop-in” hydrocarbon fuels being compatible with existing petroleum product infrastructure such as terminals and pipelines.
[0018] In addition to fuels, byproducts may be produced that can enter the chemical markets as low carbon footprint chemicals. Formic acid and ethyl formate are produced when a C6 sugar derived component is reduced to a C5 derivative such as levulinic acid or ethyl levulinate. Components used to make fuels may for economic benefit be separated and purified for sales into the chemical market as higher valued products. Examples of optional chemical products include ethyl levulinate and furfural.
[0019] The invention will be more fully appreciated from a reading of the following detailed description with reference to the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
[0020] FIG. 1 is a block diagram depicting biorefinery flow in accordance with the present invention;
[0021] FIGS. 2 , 3 , 4 , and 5 are charts showing conversion and product distribution for two different feeds that were selectively hydrotreated in a catalyst screening study; and
[0022] FIG. 6 is a graph depicting estimated composition of fully deoxygenated alkanes suitable for jet fuel or diesel blendstock.
DETAILED DESCRIPTION
System
[0023] FIG. 1 illustrates a biorefinery system in accordance with a preferred embodiment of the present invention.
[0024] As can be seen therein, feed, which is comprised of any suitable carbohydrate or lignocellulosic feedstock, is fed into 1 , a hydrolysis unit, for conversion to intermediates such as CMF, furfural, and LA. Unit 2 is a Condensation Feed Prep unit that converts CMF and LA into HMF and EL in an advantageous ratio. The Condensation unit, 3 , converts the products of the Feed Prep and furfural into a mixture of larger carbon chain molecules. Unit 4 , a Mild Hydrotreat unit, saturates carbon double bonds and recovers alcohol (such as ethanol) for recycle. Severe Hydrotreating, unit 5 , deoxygenates the mixture of Mild Hydrotreating products to produce a mixture of alkanes suitable for diesel and jet fuel blendstock.
Hydrolysis
[0025] As noted above with reference to FIG. 1 , the first step in a biorefinery in accordance with the present invention is deploymerization of cellulose and the dehydration of the resulting C6 sugar to predominately chloromethylfurfural (CMF). This step can be collectively referred to as acid catalyzed hydrolysis or simply Hydrolysis. The C6 conversion step produces the recovered intermediate CMF by hydrochloric acid catalyzed hydrolysis in a biphasic reactor system. As an example, CMF can be produced and recovered suitably according to the process described by Mascal. The biphasic, using dichlorethane solvent, hydrolysis reaction to CMF can be summarized by the follow reaction:
[0000]
[0026] A key to high yields of CMF(1) is the ability to extract into a solvent that creates a biphasic reactor system the desired product, CMF, from the reaction phase before it can further react into less desirable products. The levulinic acid, LA(2), byproduct stays in the aqueous reaction phase and may be extracted for use in subsequent reactions to make fuels. Suitable effective solvents include: dichloromethane, dichloroethane, MIBK, and toluene.
[0027] The reactor system may be configured for continuous operation. For example, Brasholz, Green Chem., 2011, 13, 1114 describes refinements to the continuously operating reactor system to produce CMF. Also, high yields of furfural can be produced from C5 sugars monomers contained in the hemicellulose component of lignocellulosic biomass.
[0028] The toluene and MIBK can be used as effective solvents for converting fructose to CMF in a flow reactor. In testing, fructose was converted to CMF using 37% HCl concentration at 100 deg C., for 1 minute residence time in toluene solvent. Conversion was measured at 89% of theoretical, with 87% of the conversion to CMF.
Condensation Feed Preparation
[0029] In the Condensation Feed Preparation (Feed Prep) step, CMF and LA produced and recovered in the Hydrolysis step are converted into a mixture of components more suitable for the subsequent condensation reactions.
[0030] In a preferred embodiment, two main reactions are included in this step. First is the conversion of CMF into ethyl levulinate (EL) (6a), as summarized below:
[0000]
[0031] Second is the conversion of CMF(l) to HMF(5) and LA(2) byproduct as below:
[0000]
[0032] Using a combination of these two main reactions, along with conversion of the LA(2) byproduct to EL, a feed is prepared for the condensation reactions that, when combined with furfural from the Hydrolysis step, will lead to carbon chain lengths and degrees of isomerisation that are advantageous to the final fuel properties.
[0033] For example, to obtain a mixture of alkanes with the approximate composition:
[0034] C10, 40%; C11 55%; C17 5% approximately 45% of the CMF may be converted to HMF and 55% to EL (chain lengths and percentages are approximate). Levulinic esters of other alcohols such as methanol, propanol, and butanol may be used as substitutes for EL.
[0035] In another embodiment, EL is not produced or used in the condensation step or may only be partially produced and used for condensation. Instead of EL, LA would be produced and used as a C5 carbon chain contributor in the condensation feed mixture. LA is made from CMF as summarized below:
[0000]
[0000] The LA(2) can be extracted from the aqueous phase, if necessary, to be a component in the condensation step feed.
[0036] In another embodiment, HMF is not produced or used in the condensation step, or may only be partially produced and used for condensation. Instead of HMF, ethoxymethylfurfural (EMF) would be produced and used as a C6 carbon chain contributor in the condensation feed mixture. EMF is made from CMF as summarized below:
[0000]
[0037] EMF may be substituted for HMF if concerns about the stability of this intermediate in the route to fuel become important from a techno-economic standpoint.
[0038] In still another embodiment, HMF is not be produced or used in the condensation step, or may only be partially produced and used for condensation. Instead of HMF, methylfurfural (MF) would be produced and used as a C6 carbon chain contributor in the condensation feed mixture. MF is made from CMF as summarized below:
[0000]
[0039] MF may be substituted for HMF if concerns about the stability of this intermediate in the route to fuel become important from a techno-economic standpoint.
Condensation
[0040] Aldol condensation reactions are well known methods for reacting ketones and aldehydes so that one or more molecules are joined together by C—C bonds. In the present invention, aldol reactions are used to combine one or two furfural or HMF molecules to one EL or LA molecule to control the product carbon chain length, so that the subsequent steps produce fuel products with the desired characteristics.
[0041] In a preferred embodiment, the carbon chain length of the condensate products are controlled by controlling the ratios of HMF, furfural, and EL. Controlling these ratios will control the ratio of mono- and di-aduct products from the condensation reaction. Control over the product ratios will determine the carbon chain length and to some extent the isomerization of the alkane product.
[0042] The Claisen-Schmidt or Stobbe condensation of ethyl levulinate with furfural is effected with liquid base system at lower temperatures (ambient to 60° C.), although removal of base catalyst from the products via neutralization and extraction is needed. Solid base catalysts in the form of hydrotalcites are effective catalysts for the condensation of ethyl levulinate with furfural, but the temperature must be raised to 135°-150° C. The products are a mix of mono- and difuryl substituted levulinates. Much of the product is hydrolyzed to the acid form or is present as the lactone. Acid catalysts were not effective for the condensation of ethyl levulinate with furfural.
[0043] Testing demonstrated that the condensation reactions of levulinic acid obtained from the acid-catalyzed decompositions conducted in aqueous acid were successful, giving good conversions with furfural. Liquid acid catalysts in a solvent, and solid acid catalysts without a solvent, gave 68%-91% conversions when the temperature was over 60° C. Reactions of levulinic acid with furfural with a basic catalyst were not successful.
Mild Hydrotreating
[0044] Products from the Condensation step are next processed in a Mild Hydrotreating step. Performing a mild hydrotreating before the more severe complete hydrodeoxygenation has several advantages, including but not limited to: Reducing the propensity of the product mixture to form tars when hydrotreated at more severe conditions, that would have a deleterious effect on the cycle life of a heterogeneous catalyst; providing an opportunity to recover subject compounds as a product with valuable properties, and recovery the alcohol (most desirably ethanol) from the condensation products; allowing the alcohols to recycle to the CMF reaction step of the invention.
[0045] The products from the Condensation step contain one or more double carbon bonds, commonly shown as C═C. Double bonds are present in both the furan ring portion of the compound and the alkyl or straight chain carbon structures. Double bonds are well known to cause polymerization and tar formation at conditions used for hydrotreating. By saturating the double bonds to single bonds the compound becomes more stable at more severe hydrotreating conditions. When a feed mixture can be hydrotreated with much less tar formation the cycle life life of the heterogeneous catalyst can be greatly extended.
[0046] Mild hydrotreating of the condensation products with certain catalysts can favor the formation of cyclic ethers most preferably compounds containing at least one tetrahydrofuran ring. These components can have properties that would be advantageous as diesel additives. These compounds are anticipated to have very high cetane and lower particulate matter formation in diesel engines.
[0047] When an alcohol (for example, ethanol) is used to create a condensation feed mixture component, that alcohol is potentially not included in the final fuel range product. For example, if ethanol is used to make EL, which in turn is used to make a condensation product that is severely hydrotreated the ethanol will be converted into ethane at the severe conditions. Since ethane is less valuable than ethanol this reaction is generally not desirable. Careful choice of catalyst and reactor conditions can recover the ethanol as ethanol, that can either be recycled to the Feed Prep step or sold a near the same price as it was purchased.
[0048] Several catalyst formulations were screened to determine the amount of conversion to cyclic ether and ethanol recovery. The mild hydrotreating step was tested at a bench scale using a heterogeneous catalyst formulation of active metal components incorporated on either a carbon or alumina base. Active components are selected from a group consisting of Ru, Re/Ru, Re/Pt, Re/Ir, Fe/Pt, Os/Rh, Rh, Ni/Re, Re, Pd/Re, Pd/Zn, Pd/Fe, Pd/Ni, Pd/W, Pd/Co, Pd/Pr, Pd/Cu, Pd/Mn, Pd/V, and combinations thereof.
[0049] Initial catalyst screening investigated the catalyst formulations shown below:
[0000]
Composi-
Catalyst ID
tion
Specifications
14388-79-4
Ru
5.0% Ru on Carbon (Hyperion)
14388-93-2
Re
5.0% Re on Carbon (Norit ROX 0.8)
58419-10-1
Pd/Re
2.5% Pd/2.2% Re on Carbon (Norit ROX 0.8)
14388-87-2
Re/Ru
5.0% Re/3.0% Ru on Carbon (Hyperion)
14388-87-1
Re/Pt
5.0% Re/2.0% Pt on Carbon (Norit ROX 0.8)
102654-A2
Re/Ni
5.0% Ni/1.0% Re on Carbon (Norit ROX 0.8)
14388-87-5
Re/Ir
5.0% Re/5.0% Ir on Carbon (Norit ROX 0.8)
58959-136-7
Fe/Pt
5.0% Fe/1.0% Pt on Carbon (Norit ROX 0.8)
58959-128-2
Os/Rh
5.0% Os/1.0% Rh on Carbon (Norit ROX 0.8)
14388-39-1
Rh
5.0% Rh on Alumina (Puralox)
[0050] Results of catalyst screening are summarized in the FIGS. 2 and 3 . As shown, catalysts 14388-79-4 and 14388-87-2 showed limited conversion of A2 (mono-aduct) in both the flow and batch system. Also, catalysts 58959-136-7 and 58959-128-2 showed the lowest conversion of ethyl levulinate in the flow testing. In the batch system 14388-93-2, 58959-136-7, and 58959-128-2 all showed low ethyl levulinate conversion.
[0051] In addition to looking at overall conversion of the main feedstock components, product distribution was examined. The control catalyst (58419-10-1) showed the highest overall recovery even accounting for ˜10% scatter. In addition, product peak 12 was the major component. This was unique to the Pd/Re composition, since product peak 10 was the major component for the Re/Pt, Fe/Pt, and Os/Rh. This may be a function of the palladium. Only one catalyst from this group was prepared on alumina, 14388-39-1 (5% Ru). Compared to 14388-79-4 (5% Ru on carbon), 14388-39-1 showed a 35% increase in overall product yields and a 40% increase in mono-aduct conversion.
[0052] The final high throughput screening study focused on finding a replacement for the 2.5% Pd/2.5% Re control catalyst. The goal was to create a less expensive catalyst capable of performing the same chemistry. It was considered that this could be done in two ways: 1) replacing the rhenium with a less expensive secondary metal, and/or 2) reducing the amount of palladium.
[0053] The various catalyst compositions were prepared using incipient wetness impregnation techniques that had been automated to run in a high throughput environment. In order to make comparisons between the catalysts tested in the previous batch experiments, three controls were run in this experiment. Catalyst 58419-10-1 (2.5% Pd/2.5% Re) served as the project control. Catalyst 14388-79-4 (5% Ru) provided a control for a catalyst which showed different activity and selectivity. Finally a 1% Pd/4.38% Re on Norit was prepared along with the other new catalysts compositions so that there was a freshly prepared catalyst similar to the control with the same amount and ratio between palladium and the secondary metal, in this case rhenium. Charts for both feedstocks conversions can be seen in FIGS. 4 and 5 .
[0054] Examining the data from the levulinate feedstock emphasized several interesting trends. By reducing the amount of palladium, but doubling the amount of secondary metal (in this case rhenium), albeit was possible to achieve the same amount of conversion as the 58419-10-1 control. However, the product distribution was different: While 58419-10-1 showed almost no product peak 10 and mainly product peak 12 , 1% Pd/4.38% Re showed a 1 to 3 ratio of product peak 10 to product peak 12 . None of the catalysts resulted in anything as selective as 58419-10-1 for product peak 12 . The closest was the Pd/Pr catalyst.
[0055] Comparing the conversion of the four feeds to the product distribution, it appears that the formation of product peak 12 may be linked to the conversion of A2 (mono-aduct). The Pd/Cu composition showed the highest overall relative product yields. The products were highly varied. Product peak 10 was the major product for most compositions, including those with Zn, Fe, Ni, W, Co, and Mn as a secondary metal.
Severe Hydrotreating
[0056] The Severe Hydrotreating, also known as hydrodeoxygenation, is generally the final step in the biorefinery process. In this step, the product mixture from the previous Mild Hydrotreating step is hydrogenated with a different catalyst at more severe conditions (higher temperature, higher pressure, lower space velocity) to remove all or substantially all of the oxygen from the final product.
[0057] A commercially available mixture of catalyst, primarily a sulfided NiMo formulation, was used to hydrodeoxygenate a condensation product including EL and furfural. The product from this treatment was a mixture of alkanes in the C8 to C 15 carbon chain range and containing normal, iso, and cyclic saturated hydrocarbons. Estimated composition is displayed in FIG. 6 .
[0058] Tests on a sample of a similar mixture showed a Freeze Point=−48.4 C with the JP-8 (Mil.) spec<−47 C. Testing also revealed that the material was very close to specification for JP-8 gravity and flash point. This testing is very encouraging for production of a renewable, cellulosic jet fuel. The hydrocarbon distribution is also very favorable for a renewable, cellulosic diesel fuel.
[0059] The fuel discussed above was produced during an extensive research project that was performed using existing pilot scale continuous flow hydrotreating reactor systems. A total of eight mild and severe hydrotreating runs were made with various catalyst loading strategies and the same family of commercial hydro-deoxygenation catalysts (supplied by Haldor Topsoe) for severe hydrotreating, and two catalysts (produced by PNNL) for mild hydrotreating. The goal of the severe hydrotreater runs was to investigate strategies to lengthen catalyst life and to make fuel product for testing. General findings were that pretreating the feed to partially deoxygenate and saturate double bonds is important for catalyst life, and pretreating with a targeted mild hydrotreating catalyst is likely better than pretreating with typical deoxygenation catalysts at lower severity.
[0060] It will be understood that the scope of the appended claims should not be limited by particular embodiments set forth herein, but should be construed in a manner consistent with the specification as a whole. | A method of making alkanes from lignocellulosic sources of C5 and C6 sugars. Suitable biomass feedstocks are converted into alkane-based fuels such as diesel and jet fuel blendstocks. Sugar monomers from the feedstocks are converted to chlormethylfurfural (CMF) with a levulinic acid (LA) byproduct. The CMF and LA are converted to ethyl levulinate (EL) and hydroxymethylfurfural (HMF), which are then combined into longer chain molecules via aldol condensation reactions. The condensation products are partially or fully saturated by mild hydrotreating, followed by deoxygenation to form alkanes with boiling ranges suitable for use as liquid fuels. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed to machines for decorating fabric and, more particularly, to a machine capable of simultaneously hot-pressing, printing, flock impregnating and brushing fabric.
[0003] 2. Description of the Related Art
[0004] At present, there are several fabrics on the market having printed and flocked finishes. These fabrics are manufactured in separate printing and flocking stages, besides intermediate hot-pressing, brushing, drying, imprinting processes, etc.
[0005] The preparation of these fabrics involves numerous disadvantages and problems, due to their complicated logistics, potential lack of quality, and lack of matching between the printed and flocked designs. Further, the different processes involve transport and waiting between the steps, a fact that increases manufacturing costs and the plant area necessary.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is a purpose of the present invention to provide a machine to simultaneously hot-press, print, flock imprint and brush to obtain a quality fabric with matched printed and flocked designs.
[0007] It is another purpose of the present invention to provide a continuous process for executing these operations in a single machine with a perfect match between them, without the production of defects or anomalies.
[0008] To achieve the foregoing and other purposes of the present invention there is provided a machine to simultaneously and continuously hot-press, print, flock, imprint and brush fabric, including the following structures and steps:
[0009] Subjecting the fabric to pre-treatments, like coloring, sizing, closure of pores, fireproofing and/or anti-stain treatments.
[0010] Drying of the pre-treatments prior to the fabric commencing the printing process.
[0011] Hot-pressing of the fabric before the printing process. The fabric is smoothed and wrinkles are eliminated so as not to produce defects and folds prior to the printing process.
[0012] Consecutive printing of colors with a rotary cylinder system and color paste to obtain clear definition, and to avoid saturation of colors between areas of different hues.
[0013] Applying adhesive paste via perforations around a cylinder to correspond to a flock design for the fabric.
[0014] Flocking is carried out by an electrostatic flocking mechanism with a fabric sieve which controls flock distribution, across the entire fabric width, and an electrostatic grid which charges the flock material positively, so that it is orientated vertically relative to a negatively charged adhesive. This way of distributing the flock eliminates free fall of the flock material and produces a better finish.
[0015] Suctioning of surplus flock—any surplus flock is suctioned and re-used.
[0016] Drying and heat setting of the printing and adhesive pastes in an oven, during which a pin stenter system keeps the fabric taught and prevents the formation of wrinkles.
[0017] Passing the fabric through cylinders cooled by water, thereby increasing the rigidity of the flock.
[0018] Continuous smooth brushing. A final brushing of the totally finished surface to eliminate possible remains and to check quality.
[0019] Rolling of the fabric and preparation for its dispatch. Since the fabric is cold and clean, there is no problem of introducing defects, such that rolling may be performed directly.
[0020] Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a schematic diagram of the machine.
[0022] [0022]FIG. 2 is a schematic elevational view of a fabric accumulator.
[0023] [0023]FIG. 3 is a schematic elevational view of a pre-treatment device.
[0024] [0024]FIG. 4 is a schematic elevational view of a first drier, a hot-pressing device and a first cooling device.
[0025] [0025]FIG. 5 is a schematic elevational view of a printing device.
[0026] [0026]FIG. 6 is a schematic elevational view of a flock dispensing device.
[0027] [0027]FIG. 7 is a schematic elevational view of one of the flock dispensers.
[0028] [0028]FIG. 8 is a schematic elevational view of an embossing device and an entrance to a second drier.
[0029] [0029]FIG. 9 is a schematic elevational view of an exit from the second drier, a second cooling device, a brush battery and a roller.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The embodiments of the present invention will now be described in greater detail with reference to FIGS. 1 - 9 .
[0031] As shown particularly in FIGS. 1 - 2 , a first, beginning end (left side of FIG. 1) of the continuous machine (A) of the present invention includes a reel ( 1 ) that feeds a fabric ( 4 ) to an accumulator ( 2 ), across pressure cylinders ( 3 ).
[0032] As best shown in FIG. 2, the accumulator ( 2 ) keeps a certain amount of fabric ( 4 ) ready to be processed. The accumulator ( 2 ) is continuously fed by the reel ( 1 ) and permits the machine (A) to continue operating, even when the reel ( 1 ) is changed. The accumulator ( 2 ) includes the pressure cylinders ( 3 ) at an entrance thereof and cylinder frames between which the fabric ( 4 ) is arranged in an accordion manner. The pressure cylinders ( 3 ) may, at a given moment, stop the feed of the fabric ( 4 ) to the machine (A) and facilitate the union of the next reel ( 1 ), the machine (A) consuming the accumulated fabric.
[0033] As best shown in FIGS. 2 and 3, at the exit of the fabric accumulator ( 2 ), there is a pre-treatment device ( 5 ). As known in the art, such a device usually coats the fabric ( 4 ) with a background color, but can also include other treatments, like sizing, closure of pores with paste, which improves print application, fireproofing and/or anti-stain treatments.
[0034] The device ( 5 ) can apply paste using at least one of three main types of applicators depending on the finish desired. One applicator includes a first pitched knife ( 6 ), over the fabric ( 9 ), such that the paste is applied over the entire fabric surface. A second pitched knife ( 7 ) can be used, again touching the fabric surface and being used when a thinner treatment is desired. Finally a rotary cylinder ( 8 ) can be used around which is a perforated contour having a design engraved thereon. This cylinder includes paste in its interior, and an interior knife (not shown) pushes the paste through the perforated contour of the cylinder ( 8 ) against the fabric.
[0035] As best shown in FIGS. 1, 3 and 4 , after the pre-treatment the device ( 5 ), there is a first continuous oven drier ( 9 ) to dry the fabric ( 4 ) prior to being printed. This drier ( 9 ) fixes the bottom-coat, background color, pore closing treatment, etc. applied by the pre-treatment device ( 5 ). The drier ( 9 ) also eliminates any humidity and cures any additives to prevent the flock applied later from adhering in an undesired manner.
[0036] The first drier ( 9 ) is followed by a hot-pressing device ( 10 ) including two cylinders ( 10 a , 10 b ) opposite each other, through which the still hot fabric ( 4 ) moves under pressure. In this process, the fabric ( 4 ) is smoothed and wrinkles are eliminated so as not to produce defects and folds for the printing step.
[0037] Then, the fabric ( 4 ) moves to a first cooling device ( 25 ) including two cylinders opposite each other, through which water cooled between approximately 5° C. and 10° C. circulates.
[0038] As best shown in FIGS. 1, 4 and 5 , the fabric ( 4 ) then moves to a printing device ( 14 ), which has a lattice apron ( 12 ) covered with adhesive and positioned on a bedplate. This adhesive fixes the fabric over the apron to prevent movements during print application. The adhesive is applied when the lattice apron circulates through the lower part of the bedplate, at the return of the fabric ( 4 ). The latter is stuck by contact remaining fixed during all its run until removed at the end of the bedplate. The apron is cleaned at device ( 13 ) with brushes and water in an operation prior to the application of a new layer of adhesive.
[0039] On an upper surface of the lattice apron ( 12 ), there is located a plurality of rotary cylinders ( 15 ) for color application, in sufficient number for the colors to be applied, arranged tangentially to the lattice apron ( 12 ). A last rotary cylinder ( 16 ) is a flock adhesive applier. This cylinder ( 16 ) includes engraving corresponding to the design desired for the flocking.
[0040] The rotary cylinders ( 8 , 15 and 16 ) are paste dispensers, each including a cylinder engraved on a contour, to include several minute holes defining a design to be applied to the fabric via flocking. Each cylinder has in its interior a longitudinal pressure pitched knife (not shown) forcing the paste outwardly against the cylinder holes next to an area tangential to the fabric ( 4 ). Moreover, each cylinder interior includes an electronic pressure probe connected to an external paste feed pump (not shown). Each cylinder also has on a shaft thereof, an independent motor (not shown) with variable speed and programmable with an angular setting memory synchronized with the other mechanical components of the machine (A). All the cylinders ( 15 ) are operated to achieve matching of colors.
[0041] Thus, the conventional colorants and liquid adhesives have been replaced in the present invention by color and adhesive pastes, resulting in less diffusion during application over the fabric. This technical solution is an advantage, because the limits between color and adhesive areas are more defined, preventing the saturation effect which accompanies liquid products. Moreover, the circulation of wet fabric through the machine is prevented, requiring shorter drying times.
[0042] In light of the above, in the cylinders ( 8 , 15 ) of the pre-treatment device and the printing device, and the flock adhesive application cylinder ( 16 ), a paste is used. These cylinders have respectively, on their contour the corresponding design to be applied engraved thereon, including the plurality of small perforations through which the paste is expelled via the internal longitudinal knife. The knife is arranged next to the contact zone with the fabric, so that the paste is applied at the point of closest contact. All these cylinders have their own motoring with speed adjuster and position memory. The speed adjuster allows the cylinder rotation to be adjusted according to the circumference of the contour and hence, prevents non-matching of the applications as the fabric ( 4 ) circulates through the machine. The position memory permits each cylinder to be placed in the correct angular position, when first starting the machine or after stopping. Hence, fabric consumption is prevented in test operations, when adjusting the printing and flocking parameters. The paste is fed from inside the cylinder by the external pump. The internal electronic probe measures the amount of paste inside the cylinder. As the paste is consumed, the probe detects same, and activates the feed pump until the paste is refilled. This system assures that paste application is uniform at a specific pressure, obtaining correct dispensing of the paste over the fabric.
[0043] As the fabric leaves the printing device ( 14 ), it detaches from the lattice apron ( 12 ) which transported it in the printing bedplate, and is collected by a pin stenter fastening system, which optionally may be a clip system. Pin stenters are known in the art, wherein they are also referred to as pin tenters, or needle stentors or tentors. Such devices include a row of pins or needles on both sides of the fabric to keep the fabric taught and to continuously feed same through a machine for processing.
[0044] As best shown in FIGS. 6 , and 7 , after the printing device ( 14 ), there is a device ( 17 ) for dispensing flock over the fabric ( 4 ). The device ( 17 ) includes a closed bedplate with an air conditioning system, a fabric transporter ( 18 ), using a pin stenter or similar, and a series of non-cylindrical rotating bars ( 19 ) along the transporter ( 18 ) for shaking the fabric ( 4 ).
[0045] The air conditioning system maintains the interior flock dispenser device ( 17 ) of the interior at a constant temperature and controls humidity for the correct diffusion of flock.
[0046] Over the transporter ( 18 ), there are preferably three electrostatic flock dispensers ( 20 ), which ensure that the flock is adhered vertically over the adhesive on the fabric applied by the cylinder ( 16 ), improving the presentation of the fabric, and increasing wear resistance. As best shown in FIG. 7, each flock dispenser ( 20 ) includes an upper hopper ( 33 ) containing flock, and a pair of rotary dispensing cylinders ( 34 ) feeding flock to a flock distribution blade ( 30 ) and to a fabric sieve ( 32 ). The flock falls on the fabric sieve ( 32 ) and is uniformly dispersed on the fabric thereby. Beneath the fabric sieve ( 32 ), there is an electrostatic grid ( 29 ), spaced relative to the circulating fabric ( 4 ).
[0047] The electrostatic grid ( 29 ) charges the flock filaments with a positive electric charge, making them orientate vertically with respect to the negative charge communicated to the adhesive/fabric passing below. The positively charged flock which falls under gravity is stuck to the negatively charged adhesive in a vertical position, in search of the discharge.
[0048] At an exit end of the flock dispensing device ( 17 ) there are two aspirators ( 21 ) that suction any non-adhered flock and resend it to the dispensing hoppers ( 33 ) for recycling. That is, given that the amount of flock supplied is in excess, any surplus may be eliminated by suctioning and returning same to the flock dispensing device ( 17 ). Moreover, since the adhered flock is arranged vertically, it is more resistant than the fiber deposited in the areas without adhesive, so that cleanliness is greater.
[0049] As best shown in FIG. 8, after the flock dispensing device ( 17 ), there is an embossing or wofering device ( 22 ) including a rotating engraved cylinder ( 31 ), opposite a counter cylinder ( 11 ), with a pitched separation. Between both cylinders ( 31 and 11 ) the fabric ( 4 ) circulates under pressure.
[0050] Thus, after application of the flock, if desired, the flocked fabric is submitted to embossing. On the surface of the counter cylinder ( 11 ) there is a design in relief corresponding to the design given to the flock, the adhesive still being soft to provide determined shapes and orientations of the flock.
[0051] Afterwards, there is a second oven drier ( 24 ) for thermo-fixing the flock adhesive and printing color pastes, again relying upon a fabric transporter ( 18 ) with a pin stenter or clips to move the fabric and prevent the formation of wrinkles in the flocking. The second oven drier ( 24 ), has its length divided in different zones with temperature adjustable heaters ( 23 ).
[0052] Once the fabric ( 4 ) has left the second oven ( 24 ), the flocking is still weak due to the temperature and may suffer deformations due to treading or contact. For this purpose, the fabric is again passed through a second cooling device ( 26 ), including two opposite cylinders, through which water cooled between approximately 5° C. and 10° C. circulates. The contact of the continuous fabric with the cooled cylinders sets the adhesive and fixes the flock rigidly to the fabric.
[0053] The fabric ( 4 ) then moves towards a brushing battery ( 27 ), as shown best in FIG. 9. The brushing battery ( 27 ) includes a series of brushes applied over the flocked fabric surface, there being shaking bars arranged on a back thereof. At this stage there is a final brushing of the totally finished surface to eliminate possible remains and to check quality. Next to each one of said brushes, there is an air expansion cyclone aspirator (not shown), opposite the flocked surface for suctioning loose flock, and directing same to collection bags.
[0054] As a last stage of the machine (A) production line, there is a roller ( 28 ) and a cutter ( 35 ). Since the fabric is cold and clean, there is no problem of introducing defects by contact or similar, such that rolling may be performed directly.
[0055] This cutter ( 35 ) is used when the roller ( 28 ) reaches the desired amount of wound fabric, and a new roller ( 28 ) is necessary.
[0056] The mentioned machine stages are synchronized by electronic, mechanical and electric synchronisms, permitting the start and simultaneous operation of the necessary stages, with the due corrections for a continuous quality production.
[0057] Based on this invention, it is possible to obtain quality fabrics comparable to those made by conventional systems like weft insertion weaving with pile (e.g., Chenilla) threads, made with a Jaquard system, or velvety fabrics, with significant advantages including a lower final fabric weight due to applying flock including just to the parts of fabric which will be visible, which is not possible with such conventional fabrics/processes.
[0058] The lower fabric weight obtained with the process and machine of this invention permits products to be made that may be used in, among other things, the decoration of bed covers, etc., where the weight is important.
[0059] The invention provides the following additional significant benefits:
[0060] Product quality is consistent.
[0061] Possibility of using a large variety of base fabrics and hence, production of a greater diversity of products, as well as price variation.
[0062] Possibility of using finer fibers (microfibers), demanded by the market.
[0063] High processing speed, compared to weaving
[0064] Competitive final product due to lower of production costs.
[0065] The foregoing is considered illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. Accordingly, all suitable modifications and equivalents may be resorted to that fall within the scope of the invention and the appended claims. | Machine to simultaneously hot-press, print, flock imprint and brush, especially suitable for the production of printed and flocked fabrics, including a fabric reel, a fabric accumulator, a pretreatment device, a first continuous oven drier, a hot-pressing device, a first cooling device, a printing device including rotary rollers for applying color printing paste and flock adhesive paste, a flock dispensing device, a flock embossing device, a second continuous oven drier for thermally fixing the flock adhesive and color printing pastes, a second cooling device, a brushing battery, a roller for winding, and a cutter. | 3 |
[0001] The present invention relates to a camshaft adjuster which includes a stator and a rotor, a spring rotatably bracing the rotor against the stator.
BACKGROUND
[0002] It is generally known that camshaft adjusters are used in internal combustion engines for varying the timing of the combustion chamber valves. Adjusting the timing to the instantaneous load reduces fuel consumption and emissions. Camshaft adjusters include a stator and a rotor. The rotor is usually connected in a rotatably fixed manner to the camshaft, the rotor being situated within the stator, coaxially with respect to same. The rotor and stator include oil chambers which may be acted on by oil pressure and generate a relative movement between the stator and the rotor.
[0003] To allow a torque transmission between the components of rotor and stator and also to compensate for a drive torque of the camshaft, a spring rotatably braces the rotor against the stator. This is described, for example, in German patent specification DE 103 61 509 B4 or United States patent specification U.S. Pat. No. 6,758,178 B2. In the cited publications, a coil spring is supported on each rotor by additional components or additional machining of the rotor. These additional parts or the additional machining increase not only the manufacturing costs, but also the assembly costs of a camshaft adjuster. In addition, the installation space for the coil spring is limited in the camshaft adjuster. However, since these known spring bearings require a relatively long axial installation length, installation of the coil spring in the rotor is therefore made more difficult.
[0004] In addition, it is generally known and customary in the prior art for these camshaft adjusters to include a cover that is situated on both sides of the “stator-rotor assembly.” These covers may have further functions in addition to a strictly sealing function. Thus, for example, they may be designed with gear teeth or with locking elements in order to be used as a chain wheel or as a locking cover. Regardless of which specific embodiment the cover includes, it is always designed in one piece. It is also known to fasten the above-described spring to the cover in order to brace the rotor against the stator.
[0005] For camshaft adjusters which provide a spring in the form of a coil spring, the coil spring is suspended in the cover and then fixed. For this purpose, a collar for spring suspension is necessary in the inner diameter of the cover. Due to the spring torque, the torsion spring in the spring suspension, which is formed as a punched or milled undercut (forming a web), is pressed against the cover collar, or axially and radially secured in a pressed-in pin. These known approaches using a cover with a drawn collar also have a number of disadvantages.
SUMMARY OF THE INVENTION
[0006] If the installation space in the overall camshaft adjuster is very small, and the punched spring suspension has too small a cross section, during operation of a camshaft adjuster this may result in failure due to a rupture of the web.
[0007] In addition, the sheet metal fibers of the cover are severed at three sides due to the punched-out or milled spring suspension. As a result, the stability of the remaining web of the spring suspension in the circumferential direction is less than in a specific embodiment which is only shaped, or punched out or bent upwardly, at fewer than three sides.
[0008] It has also been shown in practice that during the punching, a cutting gap is necessary between the base of the cover and the collar. Depending on the geometric design with an excessively large material cross section on the collar, the cutting punch must also have a certain cross section in order to still allow cost-effective manufacture. For this reason, the punch generally has a square design. This means that for a radial collar thickness of 3 mm, for example, the cutting punch as well must be at least 3 mm wide. The suspended spring thus has more play on the cover than is necessary or allowed.
[0009] Furthermore, a cutting force must be supported on the remaining web during the punching. The cutting force is thus determined by geometric or material limits of counterholders. For very small installation space conditions, this may be a reason for not being able to implement some spring designs.
[0010] In particular, the grindability of such drawn covers is limited or is not economically viable. Due to the large differences in surface area between the cover area and the narrow collar area, grinding removal with high asymmetry is to be expected. In addition, an option for turning the cover area is not always the best choice from a cost-effectiveness and qualitative standpoint, for example due to chatter marks from interrupted cuts, insufficiently large clamping surfaces for tools, or too precise requirements for squareness.
[0011] It is an object of the present invention to refine a camshaft adjuster in such a way that it compensates for a drive torque of the camshaft in a cost-effective and space-saving way, and during operation meets technical and mechanical requirements in a functionally reliable way.
[0012] The camshaft adjuster according to the present invention is made up of a stator and a rotor. A spring rotatably braces the rotor against the stator, so that during operation of the camshaft adjuster a drive torque of the camshaft may be at least partially compensated for.
[0013] According to the present invention, the spring is a coil spring, for which the stator has a first recess for a first free end of the coil spring, and the rotor has a second recess for a second free end of the coil spring.
[0014] In a first specific embodiment of the camshaft adjuster according to the present invention, a polygon, for example a square, forms the second recess at an inner wall of the rotor, with which a correspondingly shaped spring winding of the second free end of the coil spring cooperates in a form-fit manner. In particular, a last spring winding of the coil spring is appropriately shaped to ensure the required form fit. If the coil spring is thus inserted into the base, i.e., into the inner wall, of the rotor, a rotatably fixed connection is established between the second free end of the coil spring and the rotor.
[0015] Another specific embodiment provides that a width across flats of the polygon in the rotor is designed to be small enough that the polygon is situated beneath a screw head of a screw which fastens at least one cover to the stator. The second free end of the coil spring is axially held in position in this way.
[0016] In a second specific embodiment of the present invention, a borehole is provided in the rotor. The borehole is situated at an angle less than or equal to 90° with respect to the pulling direction of the coil spring in the rotor, and represents the second recess into which the second free end of the coil spring is inserted. This specific embodiment generates an axial force in a self-acting manner which automatically forces the second free end of the coil spring into the installation position.
[0017] In particular, the camshaft adjuster provides at least one cover in order to prevent oil within the camshaft adjuster from escaping. The at least one cover is mounted on the stator via at least one screw.
[0018] One specific embodiment of the present invention provides that a metal sheet is mounted on the stator via the at least one screw, and which has formed an axial bulge which forms the first recess, and in which the first free end of the coil spring rests. To prevent the first free end of the coil spring from falling out of the axial bulge, a partially cut-out element, such as a window, is additionally provided on the metal sheet or cover. This specific embodiment functions as a bayonet lock for the second free end of the coil spring. In particular, another specific embodiment may be provided here, in which the metal sheet is designed in such a way that in addition to this axial fixing of the first free end of the coil spring, further spring windings of the coil spring may be axially held in position. The coil spring is thus prevented from falling out.
[0019] In another specific embodiment of the camshaft adjuster according to the present invention, the at least one screw forms an extended screw head or screw shank for the first recess, in which the first free end of the coil spring is suspended.
[0020] Another specific embodiment provides that the at least one cover forms an axial extension element for the first recess, in which the first free end of the coil spring is suspended. In this specific embodiment, for example a press-in part, which is necessary on the inner side of the cover for mechanical locking of the camshaft adjuster, is appropriately modified on the outer side to form an axial extension element.
[0021] In another preferred specific embodiment, the at least one cover is made up of an inner cover and an outer cover. The inner cover is a sealing cover for preventing oil within the camshaft adjuster from escaping. The outer cover forms a spring recess cover for the first recess, in which the first free end of the coil spring is suspended. In the present invention, instead of a cover with a drawn collar, two covers are thus used as a “package” in this specific embodiment, in contrast to the prior art. The strength or rigidity of the spring recess cover is thus advantageously increased, which as a whole ensures the functioning of the overall camshaft adjuster under all operating conditions. The sealing cover preferably includes at least one ground sealing surface as a contact surface for the “stator-rotor assembly.” The coil spring suspension is introduced into the spring recess cover as an axially punched or shaped spring suspension. This spring recess cover may provide various specific embodiments for the first recess of the first free end of the coil spring, such as a cutout, an elevated element, an upwardly bent element, a free punched out portion, or a combination thereof.
[0022] In particular, in one specific embodiment the spring recess cover may be designed in the form of a stamped closed ring; in another specific embodiment it is likewise conceivable for the spring recess cover to be at least a partial segment of a ring.
[0023] In addition, it is noted here that the inner diameter of the spring recess cover may be designed as described below. On the one hand, the inner diameter may be smaller than an outer diameter of the coil spring, thus achieving additional axial spring lock. On the other hand, the inner diameter may be greater than or equal to the outer diameter of the coil spring. This larger area may then be used as an additional spring work area. However, guiding of the coil spring is not possible then.
[0024] All of the above-described specific embodiments of the coil spring on the rotor and/or on the stator or on the at least one cover may be arbitrarily combined with one another, provided that the coil spring rotatably braces the rotor against the stator. It is likewise conceivable for spring suspensions on the rotor or on the stator, already known from the prior art, to be combinable with the above specific embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Exemplary embodiments of the present invention and their advantages are explained in greater detail below with reference to the appended figures. For the sake of clarity, the shapes in the figures are simplified and are not always illustrated true to scale.
[0026] FIGS. 1A and 1B show a perspective view and a sectional view of a first specific embodiment of the camshaft adjuster according to the present invention, in which a second free end of a coil spring cooperates with a second recess on the rotor;
[0027] FIG. 1C shows a sectional view of one refinement of the specific embodiment from FIGS. 1A and 1B ;
[0028] FIG. 2 shows a sectional view of a second specific embodiment of the present invention, in which the second free end of the coil spring is introduced into the second recess on the rotor;
[0029] FIGS. 3A and 3B show a perspective view and a sectional view of a first specific embodiment of the present invention, in which a first free end of the coil spring rests in a first recess on the stator;
[0030] FIG. 4 shows a perspective view of one refinement of the specific embodiment from FIGS. 3A and 3B ;
[0031] FIGS. 5A and 5B show a perspective view and a sectional view of another specific embodiment of the present invention, in which the first free end of the coil spring is suspended in the first recess on the stator;
[0032] FIGS. 6A and 6B show another perspective view and a sectional view of another specific embodiment of the present invention, in which the first free end of the coil spring is suspended in the first recess on the stator;
[0033] FIG. 7 shows a sectional view of a cover of the camshaft adjuster according to the present invention, which is made up of an inner cover and an outer cover;
[0034] FIGS. 8A, 8B, and 8C each show a side view and a top view of known coil springs that are used in the present invention for subsequent FIGS. 9A through 9F ; and
[0035] FIGS. 9A through 9F each show a top view and a side view of specific embodiments of the cover according to FIG. 7 , in which the outer cover is a spring recess cover, and the first free end of the coil spring cooperates with same.
DETAILED DESCRIPTION
[0036] Identical reference numerals are used for similar or functionally equivalent elements of the present invention. In addition, for the sake of clarity, only reference numerals are illustrated in the individual figures that are necessary for describing the particular figure. The illustrated specific embodiments are used only to illustrate the camshaft adjuster according to the present invention by way of example, but are not to be construed as limiting the present invention.
[0037] FIG. 1A shows a perspective view and FIG. 1B shows a sectional view of a first specific embodiment of camshaft adjuster 1 according to the present invention, which is made up of a stator 2 and a rotor 4 . A spring in the form of a coil spring 6 rotatably braces rotor 4 against stator 2 , so that a drive torque of a camshaft, not illustrated here, may be compensated for during operation of camshaft adjuster 1 . According to the present invention, stator 2 includes a first recess 8 for a first free end 10 of coil spring 6 , and rotor 4 includes a second recess 12 for a second free end 14 of coil spring 6 .
[0038] In FIGS. 1A and 1B , only the specific embodiment is described in which second free end 14 of coil spring 6 cooperates with second recess 12 of rotor 4 . The description for FIGS. 3A and 3B is to be used for the specific embodiment of first recess 8 of first free end 10 of coil spring 6 on stator 2 .
[0039] A square 16 at an inner wall 18 of rotor 4 forms second recess 12 , with which a correspondingly shaped spring winding 20 of second free end 14 of coil spring 6 cooperates in a form-fit manner. In particular, a last spring winding 20 of coil spring 6 has a corresponding angular or right-angled shape. When coil spring 6 is thus inserted into inner wall 18 of rotor 4 , a rotatably fixed connection is established between second free end 14 of coil spring 6 and rotor 4 . According to one specific embodiment of the present invention, a form-fit and rotatably fixed connection is established between coil spring 6 and rotor 4 .
[0040] FIG. 1C shows a sectional view of one refinement of the first specific embodiment from FIGS. 1A and 1B , in which a width across flats of square 16 is designed to be small enough that square 16 is situated beneath a screw head of a screw 24 which fastens a cover 26 to stator 2 . Second free end 14 of coil spring 6 is axially held in position in this way.
[0041] FIG. 2 shows a sectional view of a second specific embodiment of the present invention. A borehole 22 forms second recess 12 at an angle α less than 90° with respect to pulling direction R of coil spring 6 in rotor 4 , into which second free end 14 of coil spring 6 is introduced. This specific embodiment generates an axial force in a self-acting manner which automatically forces second free end 14 of coil spring 6 into the installation position.
[0042] FIG. 3A shows a perspective view and FIG. 3B shows a sectional view of a first specific embodiment of the present invention, in which a first free end 10 of coil spring 6 rests in a first recess 8 in stator 2 . For this purpose, camshaft adjuster 1 provides an additional metal sheet 28 which is mounted on stator 2 via at least two screws 24 , and which has formed an axial bulge 30 which forms first recess 8 , and in which first free end 10 of coil spring 6 rests. A partially cut-out element 52 is additionally provided on stator 2 to facilitate insertion of first free end 10 of coil spring 6 into axial bulge 30 .
[0043] FIG. 4 shows a perspective view of one refinement of the specific embodiment from FIGS. 3A and 3B . Here, metal sheet 28 is designed in such a way that in addition to this axial fixing of first free end 10 of coil spring 6 , further spring windings 20 of coil spring 6 are axially held in position. Coil spring 6 is thus prevented from falling out.
[0044] FIG. 5A shows a perspective view and FIG. 5B shows a sectional view of another specific embodiment of the present invention, in which first free end 10 of coil spring 6 is suspended in first recess 8 in stator 2 , in particular in such a way that at least one screw 24 forms an extended screw head 32 for first recess 8 .
[0045] FIG. 6A shows a perspective view and FIG. 6B shows a sectional view of another specific embodiment of the present invention, in which cover 26 forms an axial extension element 34 for first recess 8 , in which first free end 10 of coil spring 6 is suspended. Axial extension element 34 has a T-shaped design.
[0046] FIG. 7 shows a sectional view of a cover 26 of camshaft adjuster 1 according to the present invention, which is made up of an inner cover 36 and an outer cover 38 . The inner cover is a sealing cover 36 , and the outer cover forms a spring recess cover 38 for first recess 8 , in which first free end 10 of coil spring 6 is suspended. This illustration of the screwing direction shows the screwing direction from the side of sealing cover 36 and of spring recess cover 38 . Alternatively, a screwing direction is also possible in which the thread in spring recess cover 38 is implemented in the form of cut threads or via press-in nuts.
[0047] Detailed specific embodiments of the design of spring recess cover 38 are apparent from FIGS. 9A through 9F and are described with reference to same.
[0048] FIGS. 8A, 8B, and 8C each show a side view and a top view of known coil springs 6 used in the present invention for subsequent FIGS. 9A through 9F .
[0049] In FIG. 8A , coil spring 6 is designed in such a way that it includes an axial leg 54 . Coil spring 6 in FIG. 8B is designed in such a way that it has formed a radial leg 54 . In contrast, in FIG. 8C , coil spring 6 is formed from a combination from FIGS. 8A and 8B ; i.e., coil spring 6 includes a leg 54 which is both axial and radial.
[0050] FIGS. 9A through 9F each show a top view and a side view of specific embodiments of cover 26 according to FIG. 7 , in which the outer cover is a spring recess cover 36 , and first free end 10 of coil spring 6 is suspended therein. The leadthroughs or threads for fastening are not illustrated for the sake of simplicity.
[0051] In FIG. 9A , spring recess cover 36 for first recess 8 of first free end 10 of coil spring 6 has a cutout 40 in the form of a hole. The inner diameter of spring recess cover 36 here is preferably smaller than an outer diameter of coil spring 6 , so that an additional axial spring lock is achieved. In addition, in this specific embodiment a coil spring 6 which includes an axial leg 54 according to FIG. 8A is preferably used.
[0052] Spring recess cover 36 in FIG. 9B has formed an elevated element 42 , i.e., an elevated slot, in which first free end 10 of coil spring 6 is suspended. The inner diameter of axial spring retainer and the selection of coil spring 6 correspond to FIG. 9A .
[0053] In FIG. 9C , spring recess cover 36 for first recess 8 of first free end 10 of coil spring 6 includes an upwardly bent element 44 , such as an upwardly bent tab shown here. A coil spring 6 which includes a radial leg 54 according to FIG. 8 b is preferably used in this specific embodiment. The axial spring lock is preferably achieved here only via upwardly bent element 44 . However, it is also conceivable to reinforce the axial spring lock by using a coil spring 6 which includes an axial and radial leg 54 according to FIG. 8C .
[0054] Spring recess cover 36 in FIG. 9D has a free punched out portion 46 for first recess 8 of first free end 10 of coil spring 6 (not illustrated here). In this specific embodiment, coil spring 6 once again is a coil spring 6 which includes a radial leg 54 according to FIG. 8 b . An axial spring lock is not necessary in this specific embodiment.
[0055] In FIG. 9E , spring recess cover 36 for first recess 8 of first free end 10 of coil spring 6 (not illustrated here) includes, in addition to a free punched out
[0056] portion 46 already described with reference to FIG. 9D , an upwardly bent element 44 according to FIG. 9C . Other combinations of the above-described specific embodiments of spring recess cover 36 for first recess 8 of first free end 10 of coil spring 6 are also conceivable.
[0057] In FIGS. 9A through 9E , spring recess cover 36 is a stamped closed ring 48 . However, as shown in FIG. 9F , it is also conceivable for spring recess cover 36 to merely be at least a partial segment 50 of a ring 48 (see FIGS. 9A through 9E ), which likewise has a cutout 40 for first recess 8 of first free end 10 of coil spring 6 . However, it is also conceivable for partial segment 50 to include an elevated element 42 , an upwardly bent element 44 , a free punched out portion 46 , or a combination thereof.
LIST OR REFERENCE NUMERALS
[0000]
1 camshaft adjuster
2 stator
4 rotor
6 spring, coil spring
8 first recess
10 first free end
12 second recess
14 second free end
16 polygon
18 inner wall
20 spring winding
22 borehole
24 screw
26 cover
28 metal sheet
30 axial bulge
32 screw head or screw shank
34 axial extension element
36 inner cover, sealing cover
38 outer cover, spring recess cover
40 cutout
42 elevated element
44 upwardly bent element
46 free punched out portion
48 ring
50 partial segment
52 cut-out element
54 leg
R pulling direction
α angle | A camshaft adjuster ( 1 ) including a stator ( 2 ) and a rotor ( 4 ), a spring ( 6 ) tenses the rotor ( 4 ) rotationally counter to the stator ( 2 ). According to the invention, the spring is a helical spring ( 6 ), the stator ( 2 ) includes a first recess ( 8 ) of a first free end ( 10 ) of the helical spring ( 6 ) and the rotor ( 4 ) includes a second recess ( 12 ) for a second free end ( 14 ) of the helical spring ( 6 ). | 5 |
FIELD OF THE INVENTION
[0001] This invention provides a novel method and apparatus for preventing the friction induced rotation of non-rotating stabilizers which are attached to a drilling tool to control the direction and orientation of drilling. The invention can be utilized to prevent rotation at any combination of hole angle, curvature rate and bit load. The present invention provides a more efficient method of operating rotary steerable directional tools.
BACKGROUND
[0002] Most rotary steerable systems utilize non-rotating stabilizers to control the trajectory of the hole. The rotating friction between the non-rotating stabilizer and the shaft that turns the bit on conventional systems causes the non-rotating stabilizer to rotate in a clockwise direction. With conventionally surfaced stabilizers, the procession rate is related to the ratio of the rotational friction force between the shaft and the fixed stabilizer to the axial drag force between the fixed stabilizer and the borehole wall. The frictional rotation rate decreases as the hole angle, curvature rate, and/or bit weight increases. However, rotation rates may become excessive at low hole angles, low curvature rates and/or low bit weights. The worst conditions are most likely to occur at the kick off point in a vertical hole. This problem prevents the use of conventional rotary steerable systems on many directional drilling applications.
[0003] For example, Table 1 shows the expected frictional rotation rates for a 12 ft non-rotating stabilizer that includes a conventional smooth surfaced adjustable stabilizer, a fixed stabilizer and which utilizes low friction sealed bearings between the shaft and the non-rotating unit.
TABLE 1 CONVENTIONAL NON-ROTATING STABILIZER Hole Curvature Bit Lateral/axial Frictional Angle Rate Weight Slide friction Rotation rate deg. deg/100 ft kips Ratio deg/axial ft 30.0 6 25 1 14.5 30.0 3 25 1 17.1 30.0 2 25 1 18.4 0.5 3 25 1 37.4 0.5 2 25 1 48.1 0.5 3 10 1 55.5 0.5 2 10 1 68.6
[0004] As suggested by the last column, the adjustable stabilizer blades must be continuously adjusted to compensate for the friction-induced rotation of the non-rotating unit. Even with a hole angle of 30 degrees the expected frictional rotation rates would be a problem. With a 0.5 degree hole angle, the rotation rates are unacceptable.
SUMMARY OF THE INVENTION
[0005] Applicant solves the frictional rotation problem by making the stabilizer surface act like a drag bit and by increasing the contact forces between the stabilizer and the bore wall formation. Rotation is prevented whenever the threshold torque required to rotate the drag bit like contacts exceed the rotational driving torque. The design is so effective that it can prevent frictional rotation by only applying the design concept to the fixed stabilizer.
DESCRIPTION OF THE DRAWINGS
[0006] Preferred embodiments of the invention will be described below in reference to the appended drawings wherein,
[0007] FIGS. 1A-1D illustrate the relationship between rotational drive torque, bearing forces and frictional rotation rate as observed by the present inventor;
[0008] FIG. 2 illustrates a fixed stabilizer as mounted on a drilling tool according to a preferred embodiment;
[0009] FIGS. 3 A-B illustrate the fixed stabilizer according to a preferred embodiment;
[0010] FIGS. 4 A-B illustrate the forces on a PDC cutter which models drag behavior of the fixed stabilizer according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0011] Referring to the accompanying Figures, a preferred embodiment of the invention is described as follows.
[0012] Referring to FIGS. 1A-1D , the present inventor determined that the mechanics of frictional rotation are defined generally by the following equations:
RDT = bd · ff · SBF 2 + 2 · st ( 1 )
[0013] Where:
RDT = Rotational driving torque in lbs. bd = Shaft bearing diameter in. ff = Bearing friction factor * SBF = Sum of all the bearing forces lbs. st = Rotating seal torque in lbs
[0014] The present invention is specifically applicable to drilling tools including two to four bearings. However, the invention may be applied to a drilling tool with a different number of bearings as long as the summation of the lateral forces on the bearings (SBF) is taken into account. The rotational driving torque comes from the frictional torque in the Kalsi seals and the lateral contact forces in the bearings between the shaft and the (non-adjustable stabilizer) (NAS). The resisting forces are generated by the lateral contact forces between the stabilizers and the hole. Whenever the resisting forces are larger than the frictional forces rotation is prevented.
[0015] FIG. 2 illustrates the placement of fixed stabilizer blades 1 , 1 ! on a non-rotating stabilizer according to the present invention. Reference number 2 corresponds to an adjustable stabilizer to position the drilling tool in the bore hole.
[0016] The present inventor noted that the calculated cases for Table 1 (conventionally surfaced stabilizer) assumed that the axial sliding friction factor and the rotating friction factor were equal. If the sliding surface of the stabilizer blade were modified to increase the rotating friction factor, the rotation rate would be reduced.
[0017] Table 2 shows the effect of utilizing a blade surface that provides a rotational friction factor that is 3 times the axial sliding friction factor. The desired effect is enhanced by aligning the edges of the ridges parallel to the axis of the bore hole and making the ridges sharp.
TABLE 2 NON-ROTATING STABILIZER WITH DIRECTIONAL FRICTION Hole Curvature Bit Lateral/axial Frictional Angle Rate Weight Slide friction Rotation rate deg. deg/100 ft Kips Ratio deg/axial ft 30.0 6 25 3 4.8 30.0 3 25 3 5.7 30.0 2 25 3 6.1 0.5 3 25 3 12.5 0.5 2 25 3 16.0 0.5 3 10 3 18.5 0.5 2 10 3 22.9
[0018] This improvement makes the frictional rotational rates acceptable in 30 degree holes but still presents a significant problem in 0.5 degree holes, especially at reduced bit weight and curvature rate.
[0019] In the present invention, the contact surface of the stabilizer blade is modified to inhibit lateral movement. The preferred modification places axial ridges on the surface of fixed stabilizer blades. The lateral forces on the stabilizer push the ridges into the bore wall, thereby preventing lateral rotation of the drilling assembly whenever the resisting shear forces in the formation wall exceed the rotational friction force.
[0020] Referring to FIG. 3A , each stabilizer fin has 6 sharp drag bit shaped cutters 3 a - 3 f . The cutters are equally spaced from the tool center. The cutters are curved along the axial direction. Under low loads only a single cutter will contact the wall of the hole. Referring to FIG. 3B , the stabilizer fins are supported on load springs. The allowable radial travel is set to provide an under gauge diameter (relative to the bore hole) when the blades are fully collapsed and an over gauge diameter when fully extended. The trailing edge will be 30° (angle A) below the tangential surface.
[0021] The cutters act like polycrystalline diamond compact (PDC) cutters on a PDC bit. The rotational mechanics of this design can be modeled using technology developed for the drill bit industry. FIGS. 4A-4B illustrate known configurations for PDC cutters. An excellent source of useful information was published by Glowka of Sandia Nat'l Labs in the Society of Petroleum Engineers Journal of Petroleum Technology in August 1989 pgs 797-849.
[0022] Glowka used a variety of single PDC cutters to measure the mechanics of drilling in three kinds of rock. The test included flat faced cutters as well as sharp edge cutters. Most of the tests measured the axial cutter loads and the penetration forces as a function of the depth of cut.
[0023] They developed the following empirical relationships for cutting dry rock at the surface.
FDB=FA·(0.90+2.2·D) FDT=FA·(0.65−0.58·D) FDS=FA·(0.63+0.88·D)
[0027] where
FDB = Cutter drag force in Berea Sandstone lbs. FDT = Cutter drag force in Tennessee Marble lbs. FDS = Cutter drag force in Sierra White Granite lbs. FA = Downward force on the dull cutter lbs. D = Depth of cut in.
[0028] The tests that used sharp cutters required larger cutter drag forces than observed with the dull cutter tests. They also ran tests with drilling fluid. These tests showed that the drilling fluid acted as a lubricant and reduced the cutter drag forces by 10 percent.
[0029] The inventor notes that the cutter drag forces are greater in softer rocks. Using the performance in granite should underestimate the cutter drag forces in all oilfield formations. Combining all these factors gives the following safe estimate for the rotational resistance of the stabilizer design of the invention:
RT = FS ( 0.63 ) ( 0.9 ) sd 2 ( 2 )
[0030] Where:
RT = Rotation resisting torque in lbs. FS = Total lateral loads on all of the stabilizer blades lbs. sd = stabilizer diameter in.
[0031] By using a bit cutter like contact, the mechanics are changed from a two dimensional sliding problem to establishing a threshold resisting load that prevents any rotation whenever it exceeds the driving torque RDT defined above in equation (1).
[0032] Referring back to FIG. 3B , the fixed stabilizer adjusts from 8 ⅜ in. outer diameter to 8 ⅝ in. outer diameter for drilling 8 ½ in. holes. The fixed stabilizer load springs apply 50 to 60 pound loads across the travel limits. The shaft uses three low friction bearings. Both the cutter like contacts and the spring assisted fixed stabilizer blades are needed to completely eliminate frictional rotation. The rotational torque in this situation is modified from equation (2) above to further include the sum of the spring forces.
RT s = sd 2 ( FS + Σ F spring ) ( 0.63 ) ( 0.9 ) . ( 3 )
[0033] Where:
RT s = Rotation resisting torque with spring loaded contacts in lbs. FS = Total lateral loads on all of the stabilizer blades lbs. sd = stabilizer diameter in. ΣFspring = Sum of all of the spring forces lbs.
[0034] Table 3 shows the expected performance of using cutter type contacts without spring loaded stabilizer blades.
TABLE 3 NON-ROTATING STABILIZER WITH ROTATION AVOIDANCE CUTTERS ON THE FIXED STABILIZER Rotational Rotational Avoidance Hole Curvature Bit Driving Resisting Design Angle Rate Weight Torque Torque Design deg. deg/100 ft kips In lbs In lbs Factor 30.0 6 25 145 1349 9.3 30.0 3 25 131 902 6.9 30.0 2 25 126 750 5.9 0.5 3 25 130 375 2.9 0.5 2 25 126 227 1.8 0.5 1 25 120 73 0.6 0.5 3 10 128 27 0.2 0.5 2 10 124 23 0.2 0.5 1 10 120 14 0.1 0.5 3 5 129 110 0.9 0.5 2 5 125 73 0.6 0.5 1 5 120 37 0.3
[0035] This design easily prevents rotation at both 30 degree and 0.5 degree hole with bit weights of 25,000 lbs and curvature rates of 2 deg/100 ft or more. However, the last five cases in the table would not stop frictional rotation. As shown in Table 4, adding 50 to 60 lb. springs to each of the stabilizer blades completely eliminates any chance of frictional rotation. Five blades are contemplated for the preferred embodiment. At a minimum, the present invention can minimize rotation to 1-3° of roation per foot drilled, even for a verticle hole.
TABLE 4 NON-ROTATING STABILIZER WITH ROTATION AVOIDANCE CUTTERS AND 50/60 POUND SPRINGS ON THE FIVE FIXED STABILIZER BLADES Rotational Rotational Avoidance Hole Curvature Bit Driving Resisting Design Angle Rate Weight Torque Torque Design deg. deg/100 ft kips In lbs In lbs Factor 30.0 6 25 145 2020 14.0 30.0 3 25 131 1567 11.9 30.0 2 25 126 1413 11.2 0.5 3 25 130 1040 8.0 0.5 2 25 126 891 7.1 0.5 1 25 120 736 6.1 0.5 3 10 128 699 5.5 0.5 2 10 124 691 5.6 0.5 1 10 120 679 5.7 0.5 3 5 129 779 6.0 0.5 2 5 125 740 5.9 0.5 1 5 120 700 5.8
[0036] The combination of cutter like contacts and spring loaded blades provides a rotational resistance force that is at least 5 times greater than the frictional driving force under all conditions.
[0037] While a preferred embodiment has been described above, one skilled in the art would recognize that the invention can be modified and still fall within the scope of the appended claims. For instance, the load spring can be replaced by alternative mechanism to exert a lateral force against the wall such as a hydraulic system. | A method and apparatus prevents rotation of a stabilizer which rotates due to friction-induced forces of bearing seals disposed in a shaft. The apparatus includes a stabilizer having a ridged edge where the stabilizer is mounted to a drilling tool using a deformable member. The deformable member assists in creating friction of the stabilizer edge against a drilled bore hole wall and thereby reduces friction-induced rotation. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2001-138727, filed May 9, 2001, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a switch box for a vehicle door apparatus having a powered door lock function.
[0004] 2. Description of the Related Art
[0005] [0005]FIGS. 1 and 2 show the arrangement of part of a vehicle door lock device having a powered door lock function (see Jpn. Pat. Appln. KOKAI Publication No. 8-326387). Referring to FIGS. 1 and 2, a recess 2 is formed in the lower portion of the front surface of a synthetic-resin body 1 of the door lock device. A latch 3 and ratchet 4 are pivotally supported in the recess 2 by shafts 5 and 6 , respectively.
[0006] The latch 3 is biased counterclockwise in FIG. 1 by a spring (not shown). Upon a door closing operation, when the latch 3 engages with a striker 7 fixed to the car body, it rotates counterclockwise. Hence, the latch 3 rotates to its full-latch state through a state (a so-called half-latch state) where it engages with its half-latch stepped portion 8 .
[0007] A switch 34 is provided to abut against the side surface of the latch 3 . The switch 34 detects the full-latch state of the latch 3 which engages with the striker 7 fixed to the car body side when the door is closed.
[0008] The switch 34 has an electrical switch mechanism which is ON when the latch is in the full-latch state. As shown in FIG. 1, most of the switch 34 , excluding one end of its pin abutting against the side surface of the latch 3 , is housed in an actuator housing chamber 20 which houses a powered actuator unit 17 (to be described later).
[0009] The actuator housing chamber 20 is surrounded by a base case 18 and a cover case (not shown). The base case 18 is integrally formed with the upper portion of the body 1 . The cover case is fixed to the base case 18 .
[0010] A lock lever (not shown) is axially supported by the latch shaft 5 and is switched between a lock position and unlock position. The actuator unit 17 in the actuator housing chamber 20 switches this lock lever between the lock position and unlock position.
[0011] [0011]FIG. 2 is a view schematically showing the actuator unit 17 housed in the actuator housing chamber 20 together with the switch 34 . A gear 22 is fixed to the rotating shaft of a motor 21 . A gear disk 23 meshes with the gear 22 .
[0012] The gear disk 23 has a small-diameter gear 24 coaxial with it. A sector gear 25 rotatably axially supported by a shaft 26 meshes with the small-diameter gear 24 .
[0013] The sector gear 25 is held at a neutral position at the center by a spring (not shown). When the motor 21 rotates in the forward or reverse direction, the sector gear 25 rotates clockwise or counterclockwise.
[0014] A projection 28 is formed on the distal end of a change lever 27 fixed to the shaft 26 . The projection 28 engages with a wide recess 29 of the sector gear 25 with a lost motion linkage.
[0015] One end of the shaft 26 projects outward through the shaft hole of the cover case, and an output gear is fixed to this projecting portion. The output gear meshes with a gear portion formed on the lock lever.
[0016] The gear 22 fixed to the rotating shaft of the motor 21 rotates in the forward or reverse direction to rotate the gear disk 23 . Then, the small-diameter gear 24 integrally formed with the gear disk 23 rotates the sector gear 25 within a predetermined range from the neutral position at the center.
[0017] Thus, the projection 28 of the change lever 27 engaging with the large-width recess 29 with the lost motion linkage engages with the sector gear 25 over the lost motion linkage and is rotated by it. Then, an output gear 31 fixed to the other end of the shaft 26 of the change lever 27 is rotated to pivot a lock gear 14 through its gear portion 32 .
[0018] Therefore, the forward/reverse rotation of the motor 21 is transmitted to the lock lever (not shown) through a mechanism in the actuator unit 17 . Thus, the lock lever is switched from the lock position to the unlock position or vice versa. After this, power supply to the motor 21 is ended and the rotational torque of the motor 21 disappears. Then, the sector gear 25 is automatically restored to the neutral position at the center by the elasticity of the spring.
[0019] As described above, the switch 34 is housed in the actuator housing chamber 20 together with the actuator unit 17 . The distal end of the projecting pin of the switch 34 abuts against the side surface of the latch 3 .
[0020] In the switch 34 , one end of the pin biased by the spring projects to abut against the side surface of the latch 3 , as described above. The other end of the pin is connected to an electrical contact piece which is ON when the latch 3 is in the full-latch state.
[0021] Since a vehicle door lock device is attached and fixed to the inner side of the steel plate of a vehicle door, it is adversely affected by the atmospheric temperature more easily than various types of components provided in the vehicle compartment.
[0022] The switch 34 is housed in the actuator housing chamber 20 together with other actuator unit 17 and the like. However, since the switch 34 particularly has an electric contact or the like, it may result in an operation failure due to dew condensation or the like.
BRIEF SUMMARY OF THE INVENTION
[0023] It is an object of the present invention to provide a switch box for a vehicle door lock device, in which the adverse influence of dew condensation and the like caused by a temperature change is eliminated as much as possible so the operating state of a latch can be reliably detected under any condition.
[0024] A switch box for a vehicle door lock device for a vehicle door lock device, which is integrally housed in a lock body case and engages with and is fixed to a striker of a vehicle door, according to one aspect of the present invention is characterized by comprising: a slide pin which has one end abutting against a side surface of a latch that engages with and is fixed to the striker of a vehicle, and which slides in response to a pivot motion of the latch when biased by a spring; a slider which is connected and fixed to the other end of the slide pin and on which an elastic slide contact is disposed; a pair of terminals which are short-circuited to be connected to each other by the slide contact depending on a slide position of the slider; and a switch box cover which substantially hermetically covers most of the slide pin, excluding one end thereof abutting against the side surface of the latch, the spring, the slider, and the terminals in the lock body case, and the switch box cover has a through hole for ventilation at that position thereof which corresponds to a lower side of one side surface thereof when the switch box cover is attached to the vehicle door. The adverse influence of dew condensation and the like caused by a temperature change is eliminated as much as possible, so the operating state of the latch can be reliably detected under any condition.
[0025] Preferred manners of the switch box for a vehicle door lock device described above are as follows. The following manners may be used alone each, or may be appropriately combined.
[0026] (1) A path extending from the through hole for ventilation to an interior of the switch box is bent. The possibility that water may enter the switch box directly by any chance can be minimized.
[0027] (2) The switch box cover further has a through hole for drainage at that position thereof which corresponds to a lowermost end of one side surface of the switch box cover when the switch box cover is attached to the vehicle door. Water in the switch box can be drained immediately.
[0028] Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0029] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
[0030] [0030]FIG. 1 is a cross-sectional plan view showing the arrangement of mainly a latch, ratchet, and car body striker in a conventional door lock device;
[0031] [0031]FIG. 2 is a cross-sectional plan view showing the arrangement of mainly an actuator unit in the conventional door lock device;
[0032] [0032]FIG. 3 is a perspective view showing the arrangement of a synthetic-resin body in a vehicle door lock device according to an embodiment of the present invention;
[0033] [0033]FIG. 4 is a perspective view showing the arrangement of a switch cover, slide pin, and slider;
[0034] [0034]FIG. 5 is a view for explaining a path extending from a vent hole to the interior of a switch box (a portion covered by the switch cover);
[0035] [0035]FIG. 6 is a perspective view showing the respective members that form the switch box;
[0036] [0036]FIG. 7 is a perspective view showing how the slider and slide pin are attached to the lower portion of the switch box; and
[0037] [0037]FIG. 8 is a perspective view showing how the switch cover is attached to the lower portion of the switch box.
DETAILED DESCRIPTION OF THE INVENTION
[0038] A vehicle door lock device according to an embodiment of the present invention will be described with reference to the accompanying drawings.
[0039] [0039]FIG. 3 is a view showing the arrangement of a synthetic-resin body 51 in the vehicle door lock device. As shown in FIG. 3, a switch box lower portion 52 is formed on the inner surface of the synthetic resin body 51 to be integral with it. A notch 53 is formed in part of the side wall of the switch box lower portion 52 . The notch 53 forms a vent maze (to be described later).
[0040] [0040]FIG. 4 is a view showing the arrangement of a switch cover 54 , slide pin 55 , slider 56 , and the like. The switch cover 54 is fitted in the switch box lower portion 52 to form a switch box. The slide pin 55 and slider 56 are sealed in the switch box.
[0041] Referring to FIG. 4, one distal end of the slide pin 55 provided in the body 51 forms a hemispherical shape and abuts against the side surface of a latch (not shown). A coiled spring 57 is mounted on the slide pin 55 . The other distal end of the slide pin 55 forms a stepped portion. This stepped portion is fitted in a stepped groove 56 a of the slider 56 . Hence, the slide pin 55 and slider 56 integrally slide in the switch box.
[0042] The slider 56 is formed of an insulating member. A slide contact 58 is attached and fixed to one side surface of the slider 56 . The slide contact 58 has a pair of open legs formed by bending an elastic metal plate.
[0043] The switch cover 54 has a thin structure. Thus, part of the side wall of the switch cover 54 which abuts against the notch 53 forms a recess 59 with respect to the surrounding wall surface. The recess 59 has a vent hole 60 at its one end. The vent hole 60 extends to that upper surface of the cover which corresponds to the lower side in FIG. 4.
[0044] Assume that the switch box is formed by covering the switch box lower portion 52 with the switch cover 54 such that the inner surface of the side wall of the switch cover 54 abuts against the outer surface of the side wall of the switch box lower portion 52 . In this case, the bent vent maze formed of the vent hole 60 , recess 59 , and notch 53 realizes ventilation between the interior and the outer side of the switch box.
[0045] In addition, similarly to the vent hole 60 , a drain hole 64 is formed at that position in the switch cover 54 which is in the vicinity of the lowermost end of the switch box when the door lock device is attached to the vehicle door. The drain 64 extends to the upper surface of the cover.
[0046] A path extending from the vent hole 60 to the interior of the switch box (portion covered by the switch cover) will be described with reference to FIG. 5. The vent hole 60 extending to the upper surface of the switch cover 54 is formed at the end of the recess 59 . Thus, the recess 59 is ventilated by the vent hole 60 extending to the upper surface of the switch cover 54 . The interior of the switch box communicates with the recess 59 through the notch 53 . In this manner, ventilation is ensured in the switch box. The path extending from the vent hole 60 to the interior of the switch box is bent twice, as is apparent from FIG. 5. Therefore, direct entering of water from the vent hole 60 into the switch box can be avoided as much as possible. That portion of the switch cover 54 which is provided with the slide pin 55 communicates with the recess 59 through the notch 53 . That portion of the switch cover 54 which is provided with the slide pin 55 has the drain hole 64 . Thus, water in the switch box can be discharged immediately.
[0047] A protrusion 61 is formed on the inner side of the upper surface of the switch cover 54 . The protrusion 61 fits in a groove formed in the lower surface of the slider 56 to define the slide direction of the slider 56 . A stopper 62 formed of a protrusion and a pair of terminal retaining protrusions 63 are also formed on the inner side of the upper surface of the switch cover 54 . The stopper 62 regulates the slide range of the slider 56 . The pair of terminal retaining protrusions 63 are parallel to each other to sandwich the protrusion 61 , and press terminals (to be described later) against the inner bottom surface of the switch box lower portion 52 .
[0048] [0048]FIG. 6 is an exploded perspective view showing the respective members that are attached to the switch box lower portion 52 to form the switch box.
[0049] Terminal grooves are formed in the inner surface of the switch box lower portion 52 shown in FIG. 3. A pair of terminals 65 A and 65 B formed by bending are fitted in the terminal grooves from below in FIG. 6. The slider 56 and the slide pin 55 are integrally placed above the pair of terminals 65 A and 65 B, as shown in FIG. 7. The slider 56 has the slide contact 58 . The spring 57 is mounted on the slide pin 55 .
[0050] The switch cover 54 is attached and fixed to the switch box lower portion 52 through a waterproof packing 66 by threadable engagement of, e.g., three set screws 67 . Hence, the switch box as shown in FIG. 8 is completed.
[0051] One projecting end of the slide pin 55 in the switch box abuts against the side surface of the latch 3 (not shown) upon a biasing operation of the spring 57 , as shown in FIG. 7. Thus, the slide pin 55 slides the slider 56 to a position corresponding to the pivoting state of the latch 3 . At a slide position where the latch 3 becomes full-latched, the slide contact 58 attached to the slider 56 short-circuits the pair of terminals 65 A and 65 B.
[0052] Therefore, whether or not the latch 3 is in the full-latch state can be known by, e.g., detecting electrical connection between the terminals 65 A and 65 B from the outside.
[0053] In the above arrangement, the switch cover 54 is attached to the switch box lower portion 52 by using the waterproof packing 66 as well. Thus, hermeticity in the switch box is maintained. Also, water and the like can be prevented from entering the switch box from the attaching surface of the switch cover 54 .
[0054] With an ordinary hermetic structure, when a sharp temperature change or the like occurs, dew condensation may occur in it. According to the present invention, even in such a case, ventilation between the interior and the outer side of the switch box is maintained through the vent hole 60 , as shown in FIG. 8. Thus, no large temperature difference occurs. This minimizes the possibility of dew condensation in the switch box. Consequently, the operating state of the latch can be detected reliably.
[0055] Particularly, the vent path is formed in a bent manner of the vent hole 60 and recess 59 of the switch cover 54 , and the notch 53 of the switch box lower portion 52 . This minimizes the possibility of direct water entering into the switch box.
[0056] The drain hole 64 is formed at that position of the switch cover 54 which corresponds to the lowermost end when the door lock device according to this embodiment is attached to the vehicle door, as shown in FIG. 8. Hence, even if water should enter the switch box, it can be discharged quickly.
[0057] The shapes and the like of the respective components of the present invention are not limited to this embodiment, but can obviously be appropriately modified in accordance with their mutual connection, engaging relationship, and the like.
[0058] The present invention is not limited to the embodiment described above, but can be modified and practiced in various manners within a range not departing from the spirit and scope of the invention.
[0059] The above embodiments include inventions of various stages, and various types of inventions can be extracted through appropriate combinations of a plurality of disclosed constituent elements. For example, assume that even when several constituent elements are eliminated from all constituent elements shown in the embodiment, at least one of problems described referring to the problems to be solved by the invention can be solved, and at least one of the effects described referring to the effect of the invention can be obtained. In this case, an arrangement from which these several constituent elements are eliminated can be extracted as an invention.
[0060] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A switch box for a vehicle door lock device comprises a slide pin which has one end abutting against a side surface of a latch that engages with and is fixed to the striker and slides in response to a pivot motion of the latch, a slider which is connected and fixed to the other end of the slide pin and on which an elastic slide contact is disposed, a pair of terminals which are short-circuited to be connected to each other by the slide contact depending on a slide position of the slider, and a switch box cover substantially covering them in the lock body case, and the switch box cover has a through hole for ventilation at that position thereof which corresponds to a lower side of one side surface thereof when the switch box cover is attached to the vehicle door. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to improvements in one-piece metal door frames of the type having a pair of opposed jambs and a connecting header, which frames incorporate a central soffit, a pair of flanking stops, rabbets flanking said stops, and trim faces flanking said rabbets, and improvements in methods of assembling same.
As is known to the trade, the major components of such frames, which are jambs and headers, are customarily shipped to an assembly plant (near the site of proposed use in construction) to be assembled and further transported to the job site. Also, as known to the trade, cooperating metal tabs and slots are provided in the appropriate ends of the jambs and header to facilitate forming the frame corners which are then welded to make the junction stronger. In the prior art method the corners are squared by measurement, a weld is made on the joint, the jambs might or might not be braced, and a load of frames is trucked to the construction job site.
The resulting frame assembly is often out of square when it leaves the assembly plant or becomes so after handling en route to or at the job site.
The problem of dealing with imperfectly aligned frames has been customarily dealt with on the job site as a building construction problem, and the usual strategems and devices used at the job site are directed primarily at preventing further deformation of the frame after it is positioned in a doorway; e.g., from grout, twisted studs and shifting of doorway wall opening elements.
Accordingly, various devices for use at the job site have been made to correct defects, and to prevent further deviation caused by on-site stresses such as pressure from poured concrete, and to compensate for out of square door openings.
Some success at squaring the frame and keeping the frame members in the same plane after installation has been achieved at the job site, but truing of the frame after the frame leaves the assembly plant is difficult and of limited success.
Also, factory jambs ordinarily have a camber (the curve that a long section of formed thin steel assumes when responding to the stresses created by forming with a press break o by roll forming) as a result of the break form or roll form step at the factory, the latter condition either not being known or not understood or treated properly at the local assembly plant.
BRIEF DESCRIPTION OF THE INVENTION
The improvement in the method of assembling thin metal frames includes the step of precisely positioning the two jambs and the header (component parts of the frame) with a spacer bar before the tabs are fixed (as by bending and hammering closed), and removing the camber from the jambs. An integral jig is combined with the frame wherein a first element of a middle spreader and a foot spreader are attached on the door opening (first) side of the frame, the frame is turned over and, in subsequent steps, second elements of a middle spreader and foot spreader are installed on the off (second) side. In the assembly of a thin steel frame according to the invention, the frame becomes an integral part of its own setting jig. The apparatus is further described hereafter.
Squaring/Decambering/Retaining Apparatus
In combination with a one-piece, thin-metal door frame having an inverted U-shape with two vertical jambs, wherein the header is at the top and the open end of the U is at the foot, and further having means on the face of the frame defining a soffit, two stops flanking the soffit, two rabbets flanking the stops and two trim faces flanking the rabbets; apparatus for decambering, and shimming, the frame is provided. The apparatus has a middle spreader means having a beam extending between the jambs at a location intermediate the header and the foot; elongate first braces extending from each end of the beam perpendicular to the beam length, the first braces having means for releasably engaging a first rabbet and an associated trim face of each jamb on the door opening side of the frame; an auxiliary brace detachably affixed to the beam and bearing on the second rabbet on the off side of the frame on each of the jambs; and a pair of cooperating foot spreader bars releasably attached to the jambs at the open end, the bars being spaced from the middle spreader bar.
Additionally, the apparatus described may incorporate means for leveling the foot spreader bars (and consequently the entire frame) comprising at least two cross members spanning the foot spreader bars, a threaded bolt rotatably carried by each of the cross braces and having two ends, one of which is adapted to engage the floor beneath the foot and the other of which is provided with means for engaging a turning tool. The apparatus may further comprise a support beam, one end of which engages the middle spreader and the other end of which releasably engages the header.
The Shimming/Fastening Apparatus
Also, a one-piece metal door frame as described is combined with apparatus for shimming and anchoring said frame comprising a girder rigidly affixed to two of the inside surfaces of the frame; means defining a tapped bore in the girder; an axially hollow tube having external thread means rotatably engaged in the tapped bore in the girder and means for axially engaging a turning tool; a screw extending through the hollow tube for engagement with a wall area around an existing door opening, the screw having a head larger than the inside diameter of the tube; an opening in the soffit of the frame providing axial access to the tube and screw; and means for closing and concealing the opening in the soffit after use.
The Method
It has been discovered that removing camber from the frame at the assembly plant works a great improvement, and that the instant method of performing the squaring and decambering operations at the factory and preserving the relationship until installation is markedly superior to prior art methods.
In a method of assembling, squaring and maintaining the correct, positional attitude of the jambs and header in a metal door frame of the type having a soffit and successively flanking stops, rabbets and trim faces, the improvement is the step comprising removing the camber in the frame at the assembly plant, and in a preferred embodiment the steps of inserting a middle spreader having elongate first and second braces to cause the first braces to bear on the opposed rabbets of the door opening side of the jambs of the frame and the second braces to bear on the opposed rabbets of the jambs on the off side of the frame, whereby the camber is removed.
The steps of squaring the frame and removing camber therefrom are performed, and apparatus adapted to maintain the frame in square and camber-free condition is installed at the assembly plant and retained on the frame while the frame is installed for use in a suitable building door rough opening.
BRIEF DESCRIPTION OF THE DRAWINGS
Turning now to the drawings in which a presently preferred embodiment of the apparatus is depicted:
FIG. 1 is a perspective view of a door frame with integral jig made according to the method of this invention;
FIG. 2, a plan view, in section, taken along the
is lines 2--2 in FIG. 1;
FIG. 3 is a elevation view, in section, taken along the lines 3--3 of the device of FIG. 2;
FIG. 4 is a sectional view of the device of FIG. 1 taken along the lines 4-4;
FIG. 5 is a fragmentary view of the device of FIG. 4 taken along the lines 5--5;
FIG. 6 is a schematic view of an optional embodiment wherein an optional truss head support is used to support a double frame;
FIG. 7 is a view of the jambs and header during a step in the process of assembling the same according to this invention;
FIG. 8 is a view of the same jambs and header in a subsequent step of this process;
FIG. 9 is a perspective view of a device, enlarged, used in the step illustrated in FIG. 8;
FIG. 10 is a partial view, in elevation, of the header and jambs with a temporary jig in place; and
FIG. 11 is a section of FIG. 10 taken along the lines 11--11, with a squaring (minimum width) jig added to the view.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The Apparatus--Squaring/Decambering
In FIG. 1 a completed thin steel frame 1 with integral jig members 1a, 1b in a door opening setting is depicted. The frame 1 includes soffit 2, flanking stops 3, 4, flanking rabbets 5, 6, flanking trim faces 7, 8 and associated returns 9, 10. The odd numbered stops, rabbets, trim faces and returns are on the door opening, or first, side of the frame and the even numbered stops, rabbets, trim faces and returns are on the second, or off-side, of the frame.
As best seen in FIGS. 1 and 4 (wherein the frame is isolated in cross section), the middle spreader beam 11 terminates at each end in perpendicularly disposed first braces 12, extending from each end of the beam 11 and embracing the rabbet 5 and trim face 7 of the jambs 20. The middle spreader beam is temporarily attached to the jambs by means of screws 45 which engage both rabbets 5 and trim face 7 of the jambs. The screws 45 are tightened first on the rabbets to decamber the frame; then the trim faces are secured by screws 45. A cooperating pair of foot spreader bars 30, 31 have perpendicular tabs 32, 33 respectively which in this embodiment are affixed to rabbets 5 and 6 respectively by means of self-tapping screws 34. Auxiliary braces 14 are fastened to the beam 11 by means of screws 16, further details of which can be better seen in FIGS. 4 and 5 wherein the metal screw 16 engages hole 18 in beam 11. Gusset 19 braces legs 15a and 15b.
As best seen in FIGS. 2 and 3 the foot spreader means is equipped with a leveling means 36 wherein two cross braces 37 (which may be carried above or below bars 30,31) carry a threaded bolt 38 which at one end has a foot 40 which swivels around the end 41 of the bolt 38. The other end 42 has a slot to receive a screwdriver for turning the bolt 38. The height of the foot 40 is adjusted by turning the bolt 38, and locked in place by nut 39. The cross members 37 may be attached by any suitable means (here screws 43) to the foot spreader bars 30, 31.
The Apparatus--Self Shimming Anchor
Referring specifically to FIG. 4 the details of the self-shimming apparatus are clearly displayed. A girder 51 is in this embodiment welded to the inside surface 7a of trim face 7, the inside surface 99 of return 9, the inside surface 100 of return 10 and inside surface 8a of trim face 8 at the leg 52 of the girder 51. The girder 51 has a tapped bore adapted to receive the external threads 54 of tube 55. Tube 55 is provided with a swivel foot 40 inserted on the tube and contained by means of flared end 56 and lock nut 59. Screw 70 has a head 71 larger than the axial bore 72 of tube 55. Any numbers of anchoring sub-assemblies 50 desired may be employed; however, the presently preferred number is 4 on each jamb.
The Method of Assembly of Squaring/Decambering Apparatus
In the presently preferred embodiment the following steps are followed in assembling the combination door frame and jig at the assembly plant, in the process of which the frame is reliably squared and decambered, which condition is preserved through shipment and eventual installation in a suitable door opening: A. Provide unassembled door frame components including two jambs 20 and header 21 B. First Side Operation
1. Position frame 1 with door opening (first) side up
2. Set temporary door width spacing jig 85 to engage soffit 2 adjacent header to set minimum tolerance on door opening width.
3. Set interlock tabs (not shown) to engage jambs 20 with header 21
4. Clamp on temporary corner squaring jigs 90 to rabbets 5 by means of C-shaped vise grip clamps 95
5. Affix semi-permanent middle spreader bar 80 first to rabbet 5 and then to trim face 7 (second)
6. Affix semi-permanent foot spreader bar 30/31 to rabbets 5 on first side of jambs
7. Check all measurements
8. Weld header to jambs on first side
9. Remove temporary corner squaring jigs 90 and spacing jig 85
10. Grind welds and paint.
C. Off-Side Operation
1. Turn frame over (off side is now facing up)
2. Engage temporary spacing jig 80 to enclose trim face 8 of jambs near mid-point of jambs length
3. Clamp on temporary corner squaring jigs 90 to rabbets 6 by means of C-shaped vise grip clamps 95
4. Bolt extension 15 to middle spreader bar to contact off-side rabbets 6
5. Affix semi-permanent foot spreader bar 30/31 to off-side rabbets 6
6. Check all measurements
7. Weld header 21 to jambs 20 on off side
8. Remove temporary corner squaring jigs 90
9. Grind welds and paint.
The squaring jig 90 has a shim pad 91, the purpose of which is to provide clearance for door opening width minimum tolerance spacing jig 85. As shown in FIGS. 10 and 11 the jig 85 fits against the header 21 and engages the soffit 2 and rabbets 5, 6 of each jamb by means of legs 86, 87 extending from bar 88. The shim pads 91 adjust for the space taken by legs 86 when the squaring jig 90 is fitted into the corners made by header 21 and jambs 20.
The resulting apparatus is relatively lightweight, easily portable and proof against deformation until ready for use. Optionally, in a larger frame, header support can be furnished by means of trusses 22 terminating in support means 23, as seen in FIG. 6.
Method of Installation
The apparatus shown in FIG. 1 is ready for installation at the job site, in a typical instance wherein the material surrounding the wall opening is a wood stud wall opening surround W, which opening has been roughly framed to the size of the door frame, with some tolerance. If the door frame opening is somewhat out of square or the studs are twisted the condition can be somewhat corrected and the frame can be securely fastened to the surround W by means of the shim and anchoring subassembly 50 which is shown in detail in FIG. 4. The foot 40 is advanced toward the wall opening surround W by removing access plug 58 and advancing tube 55 by means of a socket wrench (not shown) applied to bolt head 57 to cause the foot 40 to contact the surround W. The self-tapping screw 70 is inserted in the axial opening in tube 55 and screwed into the surround. The access cover 58 is replaced. The gap 60, if any, between the return and the face 61 of surround W is closed by a bead of caulking compound (not shown) or other methods known to the trade. The integral jig is left in place until any construction activities that could affect the square and camber-free condition of the door frame have been completed. The jig is then removed and the door hung. Then the door frame is painted and the access plugs 58 become virtually unnoticeable.
For the convenience of the reader a list of numbers used on various parts is listed hereafter:
______________________________________1. frame 37. cross members1a. integral jig member 38. bolt1b. integral jig member 39. lock nut2. soffit 40. swivel foot3. stop 41. end4. stop 42. slot5. rabbet 43. screw (girder)6. rabbet 45. screw7. trim face 50. anchoring sub- assembly7a. inside surface of trim face 51. girder8. trim face 52. leg8a. inside of trim face 53. tapped bore9. return 54. external threads10. return 55. tube11. beam 56. flared end12. first braces 57. bolt head14. auxiliary braces 58. access plug15a. base leg 59. lock nut15b. extension leg 60. gap15c. brace leg 61. face of W16. self tapping screw 70. screw17. slot 71. head18. hole 72. axial bore19. gusset 80. temporary middle spacing jig20. jambs 85. temporary header spacing jig21. header 86. leg22. truss 87. leg23. support means 88. bar30. foot spreader bars 90. temporary corner squaring jigs31. foot spreader bars 91. shim pad32. perpendicular tabs 95. C clamp33. perpendicular tabs 99. inside surface of return34. screws 100. inside surface of return36. levelling mean 140. foot W surround______________________________________ | Apparatus and method for squaring and decambering at the assembly plant, and shimming at the job site, a thin metal door frame wherein the frame becomes an integral part of its own setting jig until installation, after which the semi-permanent setting jig is removed. Temporary jigs are used in the method to set the minimum door width tolerance and to square the frame elements. | 4 |
RELATED PATENTS AND PATENT APPLICATIONS
[0001] This Patent Application is based upon and claims the benefit of U.S. Provisional Application No. 60/606,136, filed Sep. 1, 2004, entitled “Means and Apparatus for a Scaleable Congestion Free Switching System with Intelligent Control III,” the entirety of which is incorporated herein by reference.
[0002] The disclosed system and operating method are related to subject matter disclosed in the following patents and patent applications that are incorporated herein by reference in their entirety:
U.S. Pat. No. 5,996,020 entitled, “A Multiple Level Minimum Logic Network”, naming Coke S. Reed as inventor; U.S. Pat. No. 6,289,021 entitled, “A Scaleable Low Latency Switch for Usage in an Interconnect Structure”, naming John Hesse as inventor; U.S. patent application Ser. No. 09/693,359 entitled, “Multiple Path Wormhole Interconnect”, naming John Hesse as inventor; U.S. patent application Ser. No. 09/693,357 entitled, “Scalable Wormhole-Routing Concentrator”, naming John Hesse and Coke Reed as inventors; U.S. patent application Ser. No. 09/693,603 entitled, “Scaleable Interconnect Structure for Parallel Computing and Parallel Memory Access”, naming John Hesse and Coke Reed as inventors; U.S. patent application Ser. No. 09/693,358 entitled, “Scalable Interconnect Structure Utilizing Quality-Of-Service Handling”, naming Coke Reed and John Hesse as inventors; U.S. patent application Ser. No. 09/692,073 entitled, “Scalable Method and Apparatus for Increasing Throughput in Multiple Level Minimum Logic Networks Using a Plurality of Control Lines”, naming Coke Reed and John Hesse as inventors; U.S. patent application Ser. No. 09/919,462, entitled, “Means and Apparatus for a Scaleable Congestion Free Switching System with Intelligent Control”, naming John Hesse and Coke Reed as inventors; U.S. patent application Ser. No. 10/123,328 entitled, “A Controlled Shared Memory Smart Switch System”, naming Coke S. Reed and David Murphy as inventors; and U.S. patent application Ser. No. 10/289,902 entitled, “Means and Apparatus for a Scaleable Congestion Free Switching System with Intelligent Control II”, naming and Coke Reed and David Murphy as inventors.
FIELD OF THE INVENTION
[0013] The present invention relates to a method and means of controlling an interconnect structure applicable to voice and video communication systems and to data/Internet connections. More particularly, the present invention extends the concepts introduced in the related patent No. 8 entitled “Means and Apparatus for a Scaleable Congestion Free Switching System with Intelligent Control”.
[0014] This invention shows how to use the incorporated inventions to handle a wide variety of traffic conditions and non-connection protocols, including Internet Protocol and Ethernet. Moreover, new protocols and systems will come on line because of advances in technology and architectures. In particular, the present invention and the incorporated inventions very much broaden the horizon of possibilities. Therefore, in addition to describing systems to handle the existing packet formats, this patent describes systems that will handle future packet formats as well. Several packet formats may enter the switching system at the same time. The system may treat the various types of packets in different ways. In addition to teaching new ways to control and switch the packets, the present invention teaches how to handle packets at the input and output interfaces of the system.
SUMMARY OF THE INVENTION
[0015] There can be no doubt that the volume of communication traffic will increase dramatically over the next twenty years. The next generation of switching systems must be scalable and intelligent. The next generation of switches must be reliable and able to carry more data at lower cost. The incorporated inventions clearly point the way to the future of switching. The switches of the future must be able to handle data that is sent in the present formats as well as handle packets that are sent in new formats that are made practical by the switching breakthrough described in this and the incorporated patents. The present invention describes an intelligent packet switching system that can simultaneously handle packets of various types. The systems explained in the invention are designed to have a large number of input and output ports with high bandwidth per port, to have low latency, to be reliable, and to offer cost effective solutions. The existing transparent switches are backbone circuit (connection) switches. What is needed is an intelligent transparent packet switch. This patent describes the first such device. The devices described in patents No. 8, No. 10 and this patent can be used in an extremely wide variety of applications. They can replace the existing backbone switches, thus offering far more flexibility to the entire system. They can serve as the next generation of very high bandwidth routers. In general, they can serve as the building blocks of the entire next generation of data-moving platforms.
[0016] A single switching system of the present invention can simultaneously receive a variety of packet formats, including:
electronic packet transmissions; optical wave division multiplexed data (WDM) with a single frame consisting of a plurality of packets to be sent to a common output line, with each packet traveling on a separate wavelength; WDM packets where the header of an individual packet travels on a wavelength different from the remainder of the packet (i.e. the payload) and the payload either travels on a single wavelength or is subdivided into a plurality of sub-packets with each sub-packet carried on a separate wavelength; and a single-wavelength system, which is a subset of format (3).
[0021] The techniques employed here are very general, and it will be clear to one reasonably skilled in the art that these techniques can be applied to other forms of electronic and optical data. Each of the above packet formats can arrive at a system of the type described in patents No. 8 and No. 10. In the patent No. 8 and No. 10 descriptions, the optical packet is converted to electronics before insertion into the switch. In one embodiment of the present invention, the arriving electronic packets are switched electronically. In a first embodiment, the packets of format (2) are all converted to electronics and switched electronically, then switched back to optics (OEO). In a second embodiment, the packets of format (2) are switched optically in case the packets are all targeted for the same output port, but are switched electronically in case some of the packets in the frame are targeted for different output ports. In an embodiment described here, the packets of formats (3) and (4) are switched optically. In one embodiment, each output line of the switch is designed to carry only one of the three types of packets. Nevertheless, for each type, there is at least one output line from the system that is capable of forwarding that type of packet downstream. An important illustrative embodiment concerns the optical switching of packets of format (3).
[0022] The main steps of intelligent transparent packet switching are:
The headers of the arriving packets are detected, processed, and sent to one or more logic units. The electronic logic unit (or units) controls a de-concentrating component of the system. The de-concentrating unit receives packets on N input lines and outputs packets on K output lines so that the minimum dark space interval between two consecutive packets on a de-concentrating unit output line will be greater than the minimum dark space between two consecutive packets on the input lines. Typically, the number K of lines out of this de-concentrating component is of the form 2 J .N, where J is an integer. The packets are realigned in the K transmission lines. This realignment shifts packets back on the data lines a variable distance, but the sequential order of the packets on each line is left unchanged. The headers of the realigned packets are then read and sent to one or more logic units. A logic unit compares the headers of packets that are targeted for the same output line. Two or more packets to be compared may arrive from different input ports, and this comparison may take quality of service (QoS) into account in conjunction with current traffic at the output port. The comparison of information associated with packets destined for the same output port and action based on that comparison form an important feature of the present invention and of the invention described in patent No. 8. This feature provides a high level of intelligent control for systems described in patents No. 8, No. 10, and in the present patent. The control systems utilized in this patent and in patents No. 8 and No. 10 define a new, higher level of performance not found in other systems. After making their comparisons, the logic units determine how long to delay each packet in order to prevent a collision. Accordingly, the units cause the packets to be re-sequenced in the K data lines. The nodes of one or more optical packet switches are set by a logic unit, or the packets may pass through a self-routing packet switch, such as an MLML switch taught in patent No. 1. Packets are sent through a switch that may be constructed using a wide range of technologies, including optics and electronics. After a second variable-delay adjustment, packets in lines leaving the optical packet switch are concentrated into fewer data lines. Typically, there are N data lines entering the packet switching and control system; there are 2 J .N or more lines internal to the system; and there are N lines leaving the switching and control system.
[0032] The packets may be amplified and cleaned up prior to sending them down output lines. The format of packets leaving the switch may or may not be the same as the format of packets entering the switch. Additionally, there may be amplification and cleaning of the packets inside the packet switch. An in-depth description of each of these steps is given later in the “Detailed Description” section of the patent.
[0033] In the embodiments of the invention described herein, there are N incoming lines entering the switch. Each input line goes through J de-concentration switches, so that the heavy traffic entering an input line into a de-concentration unit (similar to a time-division demultiplexer) exits through one of K=2 J lightly loaded lines. The purpose of this process is to insure a sufficiently large “dark gap” between any pair of successive packets exiting the same path of the de-concentration unit. This large gap advantageously permits the use of slower, less costly switches in the remainder of the packet's journey through the system. There are a total of N.2 J lines leaving the N de-concentrators. For ease of illustration, the drawings assume that J=2, so that K=2 J =4. These lines may be denoted by the sequence {L kn }, where 1≦k≦K=2 J and o≦n≦N-1. Thus, the lines exiting the de-concentrator unit DC n would be denoted by L 1n , L 2n , . . . L Kn . The number MD 1 is defined as the time period (or “distance”) between the beginnings of the timing bits of two adjacent packets in the incoming lines. The number MD 2 is defined as MD 1 ·2 J , which is the minimal time period between the beginnings of the timing bits of two adjacent packets in one of the lines leaving the de-concentrator. The term “timing bit” refers to the leading edge of the envelope of the optical packet, assuming there is a detectable dark gap between incoming packets. An optical or electronic line contains a system-wide reference signal of short pulses with a period of MD 2 .
[0034] The timing bit is read from incoming packets at input point PD. The packet is then put through a delay loop while the timing bit is sent to logic units that read the timing bit and send control signals to the switches in the de-concentrator and in the realignment modules. The logic functions in such a way that the 1×2 switches in the de-concentrator unit are set in a timely and orderly fashion prior to packet arrival, that is, switches are set/reset during the large dark gap between successive packets. This method has an additional advantage of causing the lines leaving the de-concentrator to be equally heavily loaded.
[0035] The 1×2 switches in the de-concentrator and in the re-sequencer can be constructed using lithium niobate gates, silicon optical amplifiers (SOA), or other type of optical gates of sufficient speed. In case the switches cause losses in the signal, there will be a need for amplification along the lines. These amplifiers are appropriately placed in order to amplify signals after they pass through a given number of gates. (These amplifiers are not always illustrated in the drawings.) There may also be a need for units that clean up the signal as it passes through the system, advantageously maintaining an adequate signal-to-noise ratio. The switch at the root of the de-concentrator needs to be faster than the switches further down the tree. The switches at the second level of the de-concentration tree can operate at a lower rate, and the switches at the next level can be still slower, and so forth. It is advantageous to have only one very fast switch per input connection because fast switches tend to be more expensive and use more power.
[0036] Packets entering the switch from upstream are generally out of synch with respect to each other and other input lines. It is the purpose of the realignment unit to build global synchronization. A system-wide timing signal is used for this global realignment. Control lines, signaling lines, data lines, and other non-packet transmission lines and devices may be optical, electronic, or may employ a combination of the two technologies. In some embodiments of the present invention, there may be multiple synchronous copies of this reference signal. The global alignment unit consists of a group of switches and delay loops. Packets first pass through a 1×2 root switch that sends packets “up” or “down,” that is, on alternate branches of the unit. Packets traveling up pass through a delay loop of length MD 2 /2. Following this loop, the packets enter an optical variable-delay unit, VDL, consisting of a tree of switches and loops that can delay a packet a minimum of o time units to a maximum of MD 2 time units. Packets passing through the bottom of the root switch enter an identical variable-delay unit VDL. Therefore, the packet alignment system is capable of delaying the packets a minimum of zero to a maximum approaching 3·MD 2 /2.
[0037] The packets leave the alignment unit in such a way that a packet on the top line of the 2 J lightly loaded lines has its center positioned midway between a system-wide, periodic timing pulse and a point traveling at distance MD 1 behind the pulse. Packets traveling on the line one down from the top line have their centers halfway between a point traveling MD 1 behind the pulse and a point traveling 2·MD 1 behind the pulse. This continues until the packets traveling on the bottom line of the 2 J lines has its center halfway between a referenced pulse and a point traveling at a distance MD 1 ahead of that pulse.
[0038] The decision whether or not to send a packet up or down through the first loop is made so that the packets entering either system VDL need to be delayed an amount between MD 2 /4 to 3·MD 2 /4. The purpose of this first loop is to avoid the problem of one packet being delayed an amount close to MD 2 and a following packet being delayed an amount close to zero, thus causing a collision.
[0039] The set of all packets that leave the system alignment units in the time interval between two successive pulses of the reference signal can be formed into groups. Let G 1 denote the collection of all packets in this interval that exit from the top line L 1n of some system alignment unit PA n . Let G 2 denote the collection of all packets in the interval that exit from the set of lines L 2n , which are located one below the top line of the alignment units. Continue in this manner so that G K denotes the collection of all packets in the interval that exit from the set of bottom lines L Kn of the alignment units. Note that for each k in the sequence, G k contains N or fewer packets, and that all the packets in G k are aligned with respect to each other. Furthermore, if 1≦k<K, then all the packets in G k precede the packets in G k+1 by an amount determined by the length of a packet plus the length of the gap between consecutive packets.
[0040] After alignment, the packet enters a packet header reader, HR, which has an optical tap that connects to an optical-to-electronic converter (O/E). The packet then enters a large optical delay loop that delays it a sufficient amount of time for the control system to determine what to do with it. The delay loop may contain a plural number of packets and serves as a FIFO (first-in, first-out buffer). There is an input port controller (IPC) in the system control unit for each input port; the IPC reads the packet header to determine its priority and output port. The packet switch is a crossbar-type switch with N inputs, N outputs, and N 2 nodes. A requirement for the operation of a crossbar is that no more than one input can be connected to a given output at the same time. It is the function of the control system to honor this constraint while taking into account any QoS requirements and any contention among a plurality of input ports that want to send to the same output in the same time interval. The control system achieves these objectives in a scalable manner by means of what can be thought of as an “analog” of the packet switch in conjunction with a set of output-port traffic managers. During the time the packets are in the optical FIFO, each IPC sends a surrogate of the actual packet (a “request”) to the appropriate virtual output port, termed a “request processor”. Each request processor (RP) controls and schedules all traffic for its associated output port. For each cycle, an RP may receive zero, one, or multiple requests; it examines the timing and priority fields of each request and decides when each of the competing IPCs will get to use the crossbar for its respective packets. Typically, each IPC will have future time slots that are booked for packets that entered the FIFO earlier and other time slots that are currently available. The request packet from the IPC informs the RP which slots are available for its use. The RP keeps track of current and future time slots that are still available, that is, upcoming time slots that are open for the associated output port. The RP processes the set of requests from one or more IPCs along with its set of available time slots; it then sends to each requesting IPC an “answer” indicating when the packet must enter the switch. In this process, input port controllers (IPC) do not communicate directly with each other; similarly, request processors (RP) do not communicate directly with each other. An IPC communicates solely with an RP to which it wants to send a packet; an RP communicates solely with requesting IPCs, but only in response to a request to send to the port under its control. Communication from IPCs to RPs is by means of a scalable request switch (RS) of the type disclosed in patents No. 1 through No. 7. Response packets are communicated by a similar answer switch (AS). Control systems are disclosed in the inventions taught in patents No. 8 and No. 10.
[0041] The above steps are performed and completed while the subject packet is in the optical FIFO. The RP informs the IPC of the time slot in which to send the packet into the crossbar (packet switch). Accordingly, as the IPC knows when each packet will exit the FIFO, it easily computes how much longer the packet is delayed after exiting the FIFO so that it enters the crossbar exactly on schedule. Upon exiting the FIFO, the packet enters an optical variable-delay unit (consisting of an optical demux) that feeds into a set of delay loops whose lengths are integer multiples of the packet cycle time. The packet is switched through the appropriate delay loop and enters the crossbar at the time specified by the RP, which desirably prevents collisions. In some cases, an output port may be overloaded, and thus, one or more packets must be discarded; in this case, the packet is discarded before entering the crossbar. When QoS is implemented, the request processor uses priority in determining what to throw away.
[0042] Packets exit the crossbar at the output port determined from its header. If a de-concentration step was performed at the front end, packets destined for the same output port enter a concentrator (MUX) that combines them into a single downstream line. In some embodiments, a packet re-alignment unit makes relatively small adjustments to the packets prior to entering the MUX; thus, the minimum inter-packet dark gap is maintained downstream.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] In the FIGURES, optical signal paths are generally indicated by “λ” and are drawn with smooth curves when the direction changes; electronic-only paths are drawn with sharp angles.
[0044] FIG. 1A is an illustration of an electronic data packet 100 . FIG. 1B is an illustration of a number of optical data packets 110 in a frame, with each packet having its own wavelength. FIG. 1C is an illustration of an optical data packet 120 , which uses one or more wavelengths for the header ( 102 , 104 , 106 ) and one or more different wavelengths for the payload 108 . (This format is used in the main embodiment of the present patent.) FIG. 1D illustrates a request packet 130 sent by an input port controller in the system logic control unit to the request processor unit in the system logic control unit. FIG. 1E illustrates an answer packet 140 sent back to an input port controller by a request processor. FIG. 1F illustrates a re-sequence packet 150 sent by an input port controller to re-sequence an individual packet. FIG. 1G illustrates I/O packet 160 that is used for a variety of internal signaling functions among input processors, request processors, and the external control and interface unit (ECIU) 254 .
[0045] FIG. 2A is a block diagram of a packet switch that is suitable for intelligently switching packets in the form of FIG. 1C . FIG. 2B illustrates an embodiment of the packet switching system in which a de-concentrator unit is not employed. FIG. 2C is an embodiment that employs optical lines and components only for packet transmission; electronic lines and components are employed elsewhere whenever possible. Optical feedback “taps” provide precise timing information related to the flow of optical packets through the system. FIG. 2D illustrates an alternate embodiment that employs the system of FIG. 2C as its “switching core”.
[0046] FIG. 3 is a diagram of an optical packet detector with an amplification unit and an optical fixed delay loop (FDL) that serves as an optical FIFO.
[0047] FIG. 4A is a diagram of a de-concentrator unit which increases the amount of “dark time” between exiting packets. FIG. 4B is a diagram that shows packets being de-concentrated from one line to four, advantageously permitting the use of lower cost optical switching components.
[0048] FIG. 5A is a diagram of a set of packet alignment units that accommodate asynchronous packet arrival. FIG. 5B illustrates the use of a reference signal for aligning packets. FIG. 5C illustrates in more detail how a series of delay loops are used to align packets on one of the K lines entering an alignment unit. FIG. 5D illustrates a packet alignment unit with a packet detector for each input line. The switches described in the alignment and the re-sequencing units for the principle embodiment of the invention are lithium niobate gates or SOA (silicon optical amplifier) devices; an alternate embodiment employs tunable lasers or some other type of optical demux. FIG. 5E illustrates an alternate packet alignment unit design. FIG. 5F illustrates a packet alignment unit, similar to that shown in FIG. 5C , which is directly controlled by electronic signals from an input port controller.
[0049] FIG. 6 is a diagram of a header reader unit with four input lines.
[0050] FIG. 7A is a block diagram of the system logic control unit, which operates in a scalable, parallel fashion. It collects information from all incoming packets, determines each packet's output port, and, importantly, determines how long to delay each packet before sending it into the packet switch, thus preventing packet collisions. FIG. 7B is a block diagram of an alternate embodiment of a system logic control unit that uses electronic signaling lines wherever possible and employs an optical feedback capability for ongoing performance management and system tuning.
[0051] FIG. 8 is a diagram of a packet re-sequencing unit in which each packet is delayed an amount determined by the system control logic. Thus, the set of arriving packets are individually delayed and re-sequenced before being sent through the optical crossbar switch, desirably such that no packet collides with any other packet in its journey through the system.
[0052] FIG. 9A is a diagram of a crossbar-type packet switch that is suitable for use in the intelligent switching system. FIG. 9B is a diagram of a crossbar-type packet switch where each IPC sets its connection to an output port.
[0053] FIG. 10 is a diagram of a packet alignment unit (with a packet detector unit at each input line) that applies a small timing adjustment to each packet to align it for the final concentrator operation.
[0054] FIG. 11 is a diagram of a packet concentrator unit, where a plurality of optical input connections is merged into a single output for downstream transmission.
DETAILED DESCRIPTION
[0055] FIGS. 1A, 1B , and 1 C illustrate the formats of optical packets that arrive from upstream. The switching system forwards packets downstream according to fields in the header. FIGS. 1D, 1E , 1 F, and 1 G illustrate electronic packets used internally in the system for inter-unit communication and control. The following table gives a description of the various fields in these packets.
TABLE 1 AVT Field indicating the set of all time slots available to the input port controller for injecting a given packet into a packet switch. AVT field 114 of request packet 130 is sent by an input port controller 704 in system logic control unit 260 or 280 to the request processor 710 that governs all traffic flow through its associated output port via line 218; it is used to determine what re-sequencing of the packet, if any, is necessary. DS A sequence of switching settings 126 used by the resequencing unit to change the order (and thus the time) in which a packet enters a packet switch. ICN The identifying number (input port address) 112 for an input port controller in the system logic control unit. Used by a request processor to return answer packet 140 to the input port controller that sent the request. IOMSG The payload of message 160, which can be sent from one IPC, or request processor, or external control unit to another. The content of payload 162 is dependent on the particular message being sent and is described in detail here. It typically contains subfields, including packet length, packet ID, and other fields pertaining to the type of message. LN The relative line number 124 for a packet after the deconcentration process. PAY The payload 108 of the packet, which may be divided into a plurality of sub-packets and may be carried using a plurality of wavelengths. QoS Quality of service field 106 used by a request processor in making its decisions related to the value of the packet and type of service it receives. TB Leading timing bit 102, or leading edge of the optical power envelope, that indicates the presence of a packet and/or its precise time of arrival. TOP Target output port number (address) 104 for a packet. TS Time slot 116 selected by the request processor for injecting a given packet into a packet switch. This field may also be used to indicate that a packet is to be discarded.
[0056] A block diagram of an intelligent switching system is illustrated in FIG. 2A . Components of the system 200 are shown selectively coupled by a plurality of interconnect lines. Packets enter the system through lines 202 . Packets of the forms illustrated in FIGS. 1A, 1B , and 1 C are well suited for switching by this system in applications where optical dispersion in not a significant factor. In the first embodiment described herein, it is assumed that the packet is of the form of FIG. 1C . The system includes a plurality of module types, including:
packet detectors (PD) 222 ; packet de-concentrators (DC) 224 ; packet alignment units (PA) 226 and 234 ( 284 in FIG. 2C ); header readers (HR) 228 ; packet re-sequencing units (RS) 230 ; packet switches (PS) 232 ; packet concentrators (PC) 236 ; system logic control unit (SLC) 260 ( 280 in FIG. 2C ) that globally manages and controls the flow of all traffic through the system; and an external control and interface unit, (ECIU) 254 that communicates with all internal processing devices in the system, coordinates and updates many details of their functions, and supports external operation, administration and control of the entire system.
[0066] A packet enters the system on line 202 . It passes through packet detector 222 , which detects if (and precisely when) the leading edge of a packet has entered the system. This timing signal is sent to de-concentration unit 224 via line 242 and, in one embodiment, also to packet alignment unit 226 via line 244 . The packet continues through the switching system on its journey to output line 218 on the following path:
via interconnect line 204 to packet de-concentration unit 224 (which is similar in function to a time-division demultiplexer); through interconnect line 206 to packet alignment unit 226 , which provides internal system-wide synchronization to facilitate subsequent processing, via line 208 to header reader and delay unit 228 ; through interconnect line 210 to packet re-sequencing unit 230 ; via line 212 to packet switch 232 ; through line 214 to a second alignment unit 234 , which makes small timing adjustments so that the packet is aligned suitably for the next concentration step; through line 216 to packet concentrator 236 (similar to a time-division multiplexer), and finally; the packet exits the system via line 218 and is sent downstream on its journey to its eventual destination.
[0075] The packet de-concentration units 224 and the packet alignment units 226 and 234 do not use the data content of the packet; instead, they use the timing of the “envelope” of the arriving packet. A header reader unit 228 employs an optical tap to send a copy of the packet header 180 to the system logic control unit, where it is converted to electronic form. Control system 260 employs means and apparatus to read and process header information for subsequent management of all packets and their flow through the switching system components. Fixed-delay loop 602 in the header reader acts as an optical packet buffer (an optical FIFO) that delays a packet for a sufficient amount of time for control system 260 / 280 to complete all operations that determine the subsequent path of the packet. Packet re-sequencing units 230 and packet switches 232 are controlled by the system logic control unit (SLC) 260 / 280 . The system control unit sends control information (which is based on current traffic rates, packet priority, and target output port status) to re-sequencing units 230 and to switches 232 . Understanding of the operation of the intelligent switching system is achieved by understanding each of its component units and their collective functions. The component units will be described in the order in which they receive packets and control signals.
[0076] Alternate embodiments of the system are illustrated in FIGS. 2B and 2C discussed in the section entitled “Alternate Embodiments”.
[0077] FIG. 3 is a block diagram of packet detector 222 , optical amplifier 304 , and fixed-delay loop (FDL) 276 . The packet detector receives input on line 202 in the form of serially arriving optical packets, which exit the detector on lines 204 . The leading edge (or timing bit) of the packet is picked off by an optical tap 302 and copies of it are sent to the de-concentration unit and to the packet alignment unit on lines 242 and lines 244 , respectively. It is possible for the packet detector to send the header (or timing information) to the de-concentrator unit, to the packet alignment unit, or to both units in either electronic or optical form. In another embodiment, line 244 is omitted and the packet alignment unit has its own packet detector. In the present embodiment, the packet detector sends the header information in optical form. In one embodiment tap 302 drops only a small portion of the signal into lines 242 and (possibly) 244 ; it may be necessary to amplify the signals on these lines. In one embodiment, this could be accomplished by employing an erbium doped fiber amplifier or similar optical amplifier 304 in lines 242 and 244 ; these lines could be pumped by a single laser (not shown).
[0078] It is convenient for the header to be of a specific wavelength λ o so that device 302 can passively strip off a portion of the light of wavelength λ o from the packet. In an alternate embodiment, it may be convenient for each bit of the header to be a different wavelength (but requires that more wavelengths be broadcast). In the case where the header has multiple wavelengths, λ o is the wavelength of the timing bit.
[0079] The time of arrival of the packet is the only control information that is used by the de-concentration unit. In order to delay the packets for the proper amount of time, and thus synchronizing their arrival with the control information, the packet detector contains a delay loop 276 . Accordingly, the packet detector sends a signal, which indicates the precise arrival time of the packet at the de-concentration unit. This signal is the timing bit in the header of packet M; it is this bit that governs the timing of the control bit in line 242 . In other embodiments, there is a plurality of lines 242 from the packet detector to the de-concentrating unit. Each of these lines carries a timing signal to various switches that are internal to the de-concentration unit. It is important that the signal on line 242 arrive precisely at the right time. In an alternative embodiment, the header (which includes the timing signal) is sent directly from the packet detector to the de-concentrator. Depending on the technology, it may be necessary that the de-concentrator have an optical to electronic conversion unit.
[0080] Refer to FIG. 4A for a schematic diagram of a packet de-concentration unit (DC) 224 . This unit receives packets on input line 204 and outputs them on a plurality of lines 206 . The unit receives timing information on line 242 . As illustrated in FIG. 4B , there is a time ΔM that indicates the length of time that it takes a packet M to pass a point on the fiber. The packet width ΔM is constant for all packets. There is minimum gap time ΔG, which is the time that it takes for the shortest gap between packets to pass a point on the fiber. The intelligent switch system 200 sends packets downstream on output lines 218 in a manner preserving the minimum “dark gap” between successive packets. When an upstream connection is sending at less than 100% traffic rate, the dark gap between successive packets is ΔG plus an integer multiple of (ΔG+ΔM). It is assumed that the intelligent switch 200 receives packets from other switches that use this format. In case the intelligent switch receives packets in another format, it may be necessary that there exist a packet format conversion unit that precedes the intelligent switch, 200 .
[0081] The de-concentration unit of FIG. 4A contains a plurality of 1×2 switches arranged in a tree structure. Lithium niobate gates and silicon optical amplifiers (SOA) are suitable for use in this application. Other technologies may be used for these gates as well. There is a single, high-speed 1×2 switch 402 at the root of the tree and a pair of slower speed 1×2 switches 404 at the second level of the tree. The tree illustrated in FIG. 4A is a binary tree with two levels. For various applications, the tree can have a number of levels different from two, and the tree can have a branching basis distinct from two. In the model embodiment of FIG. 2A , the binary tree of two levels enables the de-concentrator to receive packets on one line and output packets on four lines. This set of lines exiting a de-concentrator unit DC n (or other unit type), where o≦n≦N-1, will be referred to as an “internal line set”, which is labeled L 1n , L 2n , L 3n and L 4n in the drawings for the model embodiment. The individual nodes in the tree structure are switched by a de-concentrator control unit 406 . The control unit receives timing input on line 242 and sends control signals to node switch 402 through line 408 and to node switches 404 through lines 410 .
[0082] Referring to FIGS. 3 and 4 A, packet detector 222 sends a signal down line 242 indicating the time of entry of a packet M into the detector. While packet M passes through delay loop 276 , the control signal in line 242 arrives at the de-concentrator control unit 406 so that the control signal sent via line 408 arrives at the proper time for switch 402 to change state after packet M has passed through switch 402 , but before another packet arrives at switch 402 . Alternately stated, switch 402 changes states during the time interval ΔG (refer to FIG. 4B ). Similarly, the control signals on lines 410 arrive at switches 404 so that these switches change states between entering packets. Node 402 is a high-speed, 1×2 optical switch that is capable of toggling in the brief time period ΔG, which is the minimum separation between incoming packets. Notice that the gap between packets entering switch 404 is at least of length ΔM+2·ΔG. The cost of switch 404 as well as the power that it uses is a function of its switching speed. Therefore, the switch 404 is less expensive than switch 402 . The minimum length of the blank space ΔB between packets on a line 206 is advantageously increased to at least 4·ΔG+3·×M. Any switch that directs packets on lines 206 can be slower yet.
[0083] The purpose of the de-concentrator unit is to create ΔB, a large, regular gap between packets. Accordingly, slower and lower-cost switches are employed in the remainder of a packet's journey through the system. FIG. 4B shows a series of consecutive packets passing through the de-concentrator unit. As soon as a packet passes through the de-concentrator, the switch that it passes through changes state. In this way, first node 402 toggles with every packet, and second nodes 404 toggle with every other packet. The logic in the unit is simple; timing signal 242 arrives at a node at the beginning of the dark gap. Upon receiving this signal, control logic 406 immediately toggles node 402 , and slightly later, toggles the appropriate second node 404 . In both cases, the switches change state immediately after a packet clears the switch.
[0084] Refer to FIG. 5A for a block diagram of packet alignment units (PA). The system has N alignment units 226 , one for each port. Each PA is responsible for aligning a set of packets in reference to a system-global timing signal 262 as the packets arrive on internal lines 206 from the corresponding de-concentrator unit 224 . FIG. 5B illustrates the application of global reference signal 262 . Four packets, depicted as A, B, C, and D in the top half of the figure, arrive on internal lines 206 and are situated with respect to reference signal 262 as depicted in the top half of the figure. They are realigned and fine-tuned with respect to this signal and exit the alignment unit as illustrated in the lower half of the figure.
[0085] FIG. 5C is a diagram of packet alignment unit 226 that incorporates optical variable-delay devices along each path. The packet logic unit (PLU) 510 uses a timing signal from packet detector 222 sent to it on line 244 . FIG. 5D is a diagram of an alignment unit with internal packet detector 522 . For simplicity of illustration, only one of the four sets of delay loops (VDL) 520 is illustrated in detail; the others are identical in structure and function. An advantage of the FIG. 5C embodiment is that it requires only one header reader and one packet detector on a packet's end-to-end path. In this design, PLU 510 keeps track of the state of the de-concentrator switches in order to know on what line a packet is arriving. This is possible because the de-concentrator always switches in a predetermined pattern that is known by the alignment unit. An advantage of the embodiment illustrated in FIG. 5D is that PLU 512 may be simpler and there is less likelihood for jitter in the timing.
[0086] The FIG. 5D embodiment is presented here. Packets arrive at PA 226 on line 206 . The packet-timing signal is obtained from internal packet detector PD 522 and sent to PLU 512 . System-wide reference signal 262 connects to the PLU. Fixed delay loop 530 provides the PLU with enough time to determine how long to delay each of the four (or fewer) packets that arrive in a given cycle determined by MD 2 . Based on the relative arrival time and the global timing signal, PLU 512 calculates how long to delay each packet so as to produce the relative alignment of exiting packets shown in FIG. 5A and sets nodes 524 accordingly. Variable delay unit 520 includes a serially connected set of optical delay loops 526 that can be switched in or out of the packet's path. When 1×2 switch 524 is set “low”, a packet moves on zero-relative-delay path 528 ; when the node is set “high”, the packet is delayed according to the length of each loop. In a model embodiment, the set of lengths of the loops are powers of 2 in this fashion: 1, 2, 4, 8, . . . , 2 n-1 . Importantly, the total amount of delay obtained from VDL 520 ranges from zero to the sum of the set, which is (2 n -1) time units. A delay of one time unit is the smallest timing adjustment needed to satisfy internal system function and to meet external (downstream) timing requirements. The longest delay is approximately the time associated with four consecutive packets and the gaps between them. In summary, sets of packets on the internal line sets arrive asynchronously at their respective variable delay units 522 . After processing by the alignment unit, all packets on all lines in the intelligent switching system are globally aligned with respect to reference signal 262 .
[0087] In another configuration (not illustrated), all four input lines for a unit could be managed by a single 4×32 switch. Using tunable lasers (or other demux-type node) for internal switching, the intelligent switching system could be constructed using three sets of the selected switch: one set for the alignment units, one set for the re-sequencing units, and one set for the packet switches. An alternate design for a packet alignment unit is illustrated in FIG. 5E and is discussed in the section entitled “Alternate Embodiments”. FIG. 5F is a packet alignment unit, 284 , that is similar in function to PA 520 , except that unit 284 is controlled directly by electronic signals over lines 288 from input port controllers 724 (see FIGS. 2C and 7B ).
[0088] FIG. 6 illustrates a header reader and packet delay unit 228 . Each unit contains a plurality of header readers and delay loops, one for each line 208 in its internal line set. Header reader 240 obtains an optical copy of the entire packet or, minimally, packet header 180 for immediate use by control system 260 . A packet M enters on line 208 and exits on line 210 after passing through fixed delay loop 602 . This loop is an optical FIFO (first-in, first-out buffer) that delays all packets for a time interval sufficient for control system 260 to perform all scheduling operations for a packet prior to its exiting the FIFO. An optical copy of the header information is sent via lines 246 to system control unit 260 . Since all packets in the system have already been globally aligned (synchronized), they arrive at the header readers at times precisely determined by the global reference signal. During a given cycle determined by MD 2 , sets of packets arrive at the header readers in the order G 1 , G 2 , . . . , G K (G n as previously defined), with a fixed time gap between each group. Header information 180 is read and sent to system control unit 260 in corresponding time-division-multiplexed groups H 1 , H 2 , . . . , H K , where H n is the set of header records from G n . The header of a packet M includes the following data fields:
a timing bit (TB) 102 (or leading edge of the optical envelope) that is used to indicate that a packet is present and also to indicate the precise time of arrival of the packet; a QoS field 106 that is used by the system logic control unit (SLC) to assign a packet priority (PP) to the packet; and information that can be used to ascertain a target output port (TOP) 104 for the packet.
[0092] These three fields, TB, QoS, and TOP, are used by SLC to generate and apply its control signals. SLC immediately converts the packet header from optical to electronic form (unless O/E conversion has already been performed) and obtains the content of header fields. In case each of the heater bits is on a separate wavelength, each header bit can be dropped using a chromatic filter or similar device. Otherwise, single-wavelength, serial O/E conversion can be employed. The packet header may contain other fields that are used by various embodiments of the intelligent switch. In particular, they may contain multicast bits.
[0093] FIG. 7A is a schematic diagram illustrating the system logic control unit, SLC 260 . A central idea in the present patent and in patents No. 8 and No. 10 is the scalable, intelligent control of all packets entering the switch fabric, taking into account current traffic rates and QoS requirements. The following is a summary of the means and apparatus for scalable control of a switching system taught in detail in these patents. A scalable control unit 706 (in conjunction with IPCs) schedules the timing of all packets entering switch(es) 232 . In an application where scheduling strategy is based, at least in part, on QoS values, IPC 704 receives and processes header fields (including the QoS field) from all packets entering the system during each cycle. SLC 260 employs a scalable means and apparatus to determine at which time slot a given packet can enter optical packet switch 232 without colliding with any other packet. (A collision occurs when two or more packets are sent to a single output port at the same time.) A basic reason that the system management is so effective is that there is a logic unit (called a request processor RP) associated with each output port. RP considers all of the packets previously scheduled and currently wanting to use the output port and, given their priorities and timing, it schedules when each packet enters the packet switch, desirably preventing collisions. In order for RP 710 to be informed of all incoming packets scheduled for its port, it is necessary to route each request packet to the appropriate RP. The interconnect structures defined in patents No. 1 to No. 7 are self-routing and allow for multiple packets to be routed to the same target. Therefore, they are used here as request switch 708 for effective routing of the request packets to the desired request processors and also used as answer switch 712 for routing the answer packets from the request processors back to the input port controller that issued the request.
[0094] As illustrated in FIG. 7A , optical header information enters the system logic control unit 260 via lines 246 , where it is converted to electronics by O/E converters 702 and then sent via lines 722 to its corresponding input port controller (IPC) 704 . The IPC performs line-card functions including header lookup and other traffic management functions. For each header received and parsed, the input port controller builds a request packet 130 and sends it via line 716 to the request system 706 , which is similar in construction and function to those taught in patents No. 8 and 10. Sets of headers arrive at system control unit 260 in cycles determined by the global reference signal and in the order H 1 , H 2 , . . . , H K . For each k such that 1≦k≦K, the packets associated with the headers in H k are in G k and thus are on the set of lines L kn (o≦n≦N-1). Moreover, these packets are destined for packet switch PS k 232 . During each request/approval cycle, an input port controller submits a single request for only one switch and receives a single answer from a request processor. The switch number and the packet ID are identified by knowing which set of headers is being processed. Input port controllers are also aware of the time at which each packet will exit the FIFO and enter the re-sequencing unit. In the request packet, an input port controller gives a list, AVT 114 , of all available times for inserting the associated packet into the proper packet switch 232 . The AVT times are based on the packet being sent either straight through the re-sequencing unit or else through a set of delay loops within this unit. When an answer packet 140 for a request is received, the input port controller updates its AVT list and sends re-sequencing command 150 via line 248 to the re-sequencing unit at the appropriate time. The re-sequencing command is sent to and arrives at RS 230 just prior to the packet's exit from the FIFO 602 in the header reader; thus, the logic in the re-sequencing unit has time to set the appropriate switches. The RP updates its internal AVT based on packets it scheduled in the current cycle.
[0095] Each request processor 710 controls the flow of packets into the packet switches. Based on information such as QoS and load on the target output port, a request processor selects an available time slot and returns it as TS 122 in an answer packet 140 (via the answer switch AS 712 and line 718 ) to the input port controller that sent the request. In some cases, it may be necessary to discard the packet. In one embodiment, during each request cycle, request packets are received for only one packet switch 232 . Upon receipt of an answer packet by an input port controller, the IPC knows when to send its packet into the packet switch, and thus knows the required delay for the packet. When a packet is approved by a request processor, it also sends switch-setting information for the packet via line 720 to the switch controller SC 714 , either directly or via an input port controller. SC collects switch setting information from all of the request processors and organizes it by switch injection time. Just prior to a set of packets arriving at switches 232 , SC sends the appropriate switch-setting information on lines 250 to set the crossbar nodes 902 .
[0096] Referring to FIGS. 6 and 7 A, in an alternate embodiment, O/E converter 702 is located in header reader 240 (rather than in SLC 260 ). In this embodiment, lines 246 carry electronic signals. This embodiment advantageously reduces the amount of optical plumbing in the system, replacing it with low-cost, high-speed serial communications technology.
[0097] SLC 260 determines the delay time per packet for all packets, where one time unit MD 2 consists of the time associated with one packet plus its minimum inter-packet gap on a “de-concentrated” line. The outcome of the SLC is the determination of how much time each packet must wait before it can enter packet switch 232 , desirably avoiding collisions, while taking into account current traffic rates and QoS demands. Input port controller 704 is the final device in this process of determining the delay for a packet that has arrived at its associated input port. Importantly, the packet is moving through the FIFO during the time it takes to determine its delay value. Immediately before the packet exits FIFO 602 , the input port controller informs the re-sequencing unit how long to delay the packet. Alternately stated, re-sequencing unit 230 can be thought of as a set of fixed delay lines terminating at the same point. For example, packets may enter the system in the order A, B, C, D, E, and F, and exit in an arbitrary sequence, such as C, F, B, D, A, and E In this example, packet A is delayed eight periods longer than packet F.
[0098] Referring to FIGS. 7A and 7B , the external control and interface unit (ECIU) 254 serves at least two functions. First, it has two-way communication with all processing element in the system, including IPCs 704 ( FIG. 7A ) or 724 ( FIG. 7B ), and RPs 710 . Second, it is the interface between the system and the external world, for purposes including administration, operation, maintenance, performance measurements, and diagnoses.
[0099] Refer to FIG. 8 for a schematic diagram of packet re-sequencing unit 230 . When a re-sequencing packet is received from SLC 260 on line 248 , it is processed by the control unit CTL 810 . Immediately prior to a packet arriving on line 210 , re-sequencing packet 150 informs CTL 810 of the line number and the desired delay. CTL sets switches in demux 812 , which may be implemented as a binary tree of 1×2 nodes in an arrangement such as indicated in FIG. 4A or by another suitable optical demux design. Demux 812 has a plurality of outputs. Output 814 causes the packet to be discarded, which could occur when the packet's output port is overloaded with traffic and the packet has a low QoS value. Output 816 connects on line 212 to the crossbar without delay. The length of each delay loop 818 is MD 2 . Accordingly, other outputs of the demux unit delay packets in integer multiples of MD 2 .
[0100] FIG. 9A illustrates a crossbar packet switch 232 suitable for use in the intelligent switching system 200 . Crossbar packet switch 232 receives packets on lines 212 , sends packets out on line 214 , and receives switch setting information on lines 250 . The crossbar nominally contains N 2 nodes. Node 902 makes an optical connection from an input line to an output line. According to the operation of control system 260 , an input connects to zero or lo one output line, and one output is connected to zero or one input line. In the embodiment being described, the system contains K packet switches 232 , one switch for each line that exits a de-concentrator unit. Packet switch PS k 232 receives and switches all packets arriving on the set of lines L kn , where 1≦k≦K and o≦n≦N-1. In the illustrations for the system 200 , K=4 and thus, PS 1 switches packets from the set of lines L 1n , PS 2 switches packets from the set of lines L 2n , PS 3 switches packets from the set of lines L 3n , and PS 4 switches packets from the set of lines L 4n . In other embodiments of the switching system, the number of packet switches may be a number different from K. Suitable switches may be of several types:
optical crossbar switches; crossbar-like N×N switches in which each input port is capable of choosing one of N wavelengths to send its data and each output port is tuned to accept only one of the wavelengths, with each output port accepting a different wavelength; or optical MLML switches as described in the referenced patents.
[0104] MLML switches may be self-routing or may be optical slaves to electronic MLML networks within the switch controller 714 (as described in patent No. 2). In case an MLML switch is employed, it is useful to attach optical delay lines of various lengths to the outputs of the innermost rings. The delay lines for all of the nodes at a single angle are equal. In this way, all of the packets are realigned after emerging from the system composed of the MLML lo network and these delay lines.
[0105] FIG. 9B illustrates a crossbar packet switch 278 where input-to-output connections are set by means of a signal connected to each input port of the crossbar. It receives packets on lines 212 , sends packets out on line 214 , and receives switch setting information directly from the input port's associated IPC on line 726 (see FIGS. 7B and 2C ). The crossbar nominally contains N 2 nodes. Node 902 makes an optical connection from an input line to an output line. According to the operation of control system 280 , an input connects to zero or one output line.
[0106] FIG. 10 illustrates an additional packet alignment unit 234 . This unit is similar in construction and function to the alignment unit 226 illustrated in FIG. 5A . Each input line 214 contains a packet detector unit 222 , which sends each incoming packet through a delay loop while sending a timing signal to the corresponding alignment unit 226 . Whereas first alignment unit 226 could be somewhat course in aligning the packets, the purpose of final alignment unit 234 is to perform a finer alignment that is required prior to the concentration process.
[0107] FIG. 11 is a schematic diagram of a packet concentrator unit 236 . Four optical lines 216 enter the unit and combine signals until all packets exit on a single fiber. Since the packets have been aligned with respect to a global reference signal, no two input lines send packets into the concentrator at the same time. Importantly, a minimum dark space ΔG is always maintained between packets sent downstream. Packets exit the concentrator and the switching system on lines 218 . A final optical amplifier, such as shown in FIG. 2C , may be needed here.
Alternate Embodiments
[0108] If packets entering the system on lines 202 were spaced sufficiently far apart or if low-cost high-speed 1×2 switches are available, then the de-concentration unit 224 is not be required. An embodiment of the invention with this property is illustrated in FIG. 2B . In FIG. 2B there are N lines entering the intelligent switching system, N lines internal to the system, and N lines exiting the system. Since the de-concentration step has been eliminated, this embodiment does not contain the following units that are illustrated in FIG. 2A :
[0109] the de-concentrator unit 224 ;
[0110] the additional packet alignment unit 234 ; and
[0111] the packet concentrator unit 236 .
[0112] Thus, packets exit this system directly from the packet switch 232 on lines 220 .
[0113] Another embodiment, 205 , of the invention, shown in FIG. 2B , packets sent to the system on lines 202 are timed with a world-wide global clock. Thus, packets arriving on each input line would be evenly spaced on that line, and this spacing would be uniform on each of the N input lines. In an ideal situation of this type, once the switch settings in the packet alignment units 284 are determined for aligning the initial set of packets on the N input lines, these setting would remain the same for all future arriving packets. In one embodiment, however, the arrival of the packets is monitored and some minor adjustments to the alignment switches is made, if only on an infrequent basis.
[0114] FIG. 5E illustrates a packet alignment unit 226 that uses optical demux 514 such that a packet passes through one of a plurality of optical delay lines 504 before exiting. Accordingly, the optical packet is delayed over a range determined by the longest delay line, with timing increments related to the number of delay loops in the chosen line.
[0115] In another embodiment, the design given in FIGS. 2C, 7B and 9 B uses electronics whenever possible, thus reducing the amount of optical fibers, connectors, and other optical devices. System 270 incorporates these features:
All inter-unit signaling components and control units, including cabling, connectors, and circuit board components, employ low-cost, high-speed OTS (off the shelf) electronic transmission technologies wherever practical or economically warranted. There is only one fixed-delay loop FDL 276 per end-to-end path through the system, and O/E conversion of optical header contents to electronic form is performed early, and only once per packet, at OE unit 272 . Packet header content is sent on electronic communication line 282 to the system logic control system (SLC) 280 . SLC receives immediate notification of packet arrival and determines all timing, aligning, and re-sequencing settings for all packets. There is only one packet alignment device, 284 , per path, which is similar in function to variable delay unit 520 , except that control signal 288 is generated by input processor control unit (IPC) 724 , taking into account factors already mentioned as well as end-to-end timing measurements for all paths and components the packet may use. Re-sequencing of packets is performed by re-sequencing unit (RS) 230 , which is similar in function to the re-sequencing unit of FIG. 8 . FIG. 9B illustrates optical crossbar switch 278 . The switch is controlled directly by the set of IPCs. An IPC uses signal line 726 to control the single input port associated with that IPC. It sets one node, 902 , on input line 212 to make an optical connection to one output line 214 . (When there is no packet, no connection is made.) IPC 724 can command its associated test-packet generator (TP) 296 to generate an optical test packet and inject it into the front end for testing the end-to-end operation of any optical path originating at its input port, and thus, obtain precise timing information for any such path. A command to the test-packet generator is sent over line 274 from the input port controller. Optical packet feedback tap (OFB) 292 , located at an input port of the packet switch, informs IPC 724 the of successful transmission and precise arrival time of a packet through the series of 1×2 switches and delay lines between the system input from line 202 and the input into the data switch from line 212 . Optical encoder (OE) 272 provides the precise time of arrival of a packet (including a test packet) entering the system. Signals from OFB and OE provide precise timing measurements of a packet that passes through the system, advantageously providing the control system and the IPC with information needed for fine tuning of timing during operation, and eliminating the need for additional alignment steps. Faults and failures in the optical plumbing can be identified in this manner as well. Test packets generated by optical packet generator 296 provide timing information during system setup, maintenance, and normal operation. OFB 292 signals the control system over electronic line 294 . The signal shows of the successful end-to-end transmission and precise timing of normal packet traffic through the system, thus permitting fine-tuning of timing and alignment during normal operation. This process allows the system to adjust for temperature effects on optical fibers that occur during ongoing system operation, as well as make adjustments for other effects. OFB 298 is located at the final output of the switch, which advantageously informs the system logic control system of the successful switching and precise timing of a packet through the entire system, including packet switch 278 . In one use of OFB 298 , a “target” IPC (IPC T ) sends an I/O message 160 to a “sending” IPC (IPC S ), requesting that IPC S generate an optical test packet (TP) and send it to the output address of IPC T . IPC S uses OFB 292 to determine time, t IN , when TP enters the switch. IPC S sends an I/O message to IPC T , which includes the time (t IN ) that TP entered the data switch (along with other information to identify S, T, the nature of the message, and the expected time packet TP will arrive at output T). IPC T uses OFB 298 to determine the precise time, tout, that TP exited the switch; it then determines the delay between ports S and T: t ST =t OUT −t IN . This timing measurement is sent back to IPC S so that it can make fine-tuning adjustments when sending a packet to IPC T . Alternately, processor T can simply send the timing value back to IPC S by means of an I/O message. IPC S uses this value to determine t ST . In the case where S=T, IPC S uses its connections to input OFB S 292 and output OFB S 298 to measures t SS . In an operation where the target address T is cycled through all port numbers, IPC S generates and updates an internal timing table for all outputs. By these means and methods, the timings and delays of all components in the system can be measured. An IPC uses this information to determine how to set packet alignment units in order to make fine-tuning adjustments. An IPC can generate a suite of test packets sent into a plurality of input ports to check overall system performance and to measure the timing parameters of individual components, fibers, and connections. It may initiate this process autonomously as part of its normal operation, or it may be commanded by the ECIU. The ECIU can command an input processor (S) to send a test packet to a target processor (T) to initiate the sequence just described; the result, t ST , is sent back to the control system for ongoing maintenance and operations purposes. Other uses of OFB include component failure detection, and other operational and maintenance functions in conjunction with ECIU 254 . Optical amplifier (OA) 286 amplifies the signal for purposes that include increasing signal strength for downstream transmission and improving the optical signal to noise ratio. Optical amplifiers are placed at a plurality of locations along the optical paths to appropriately maintain signal amplitude and signal to noise levels.
[0130] Referring to FIGS. 2A, 2B , 2 C, 7 A and 7 B, external control and interface unit (ECIU) 254 has connections to all IPCs and RPs in the system. ECIU has a plurality of connections 256 to input ports of request switch 708 and a plurality of connections 258 from output ports of request switch 708 , and thus can send an I/O packet to any RP and receive one from any IPC. Similarly, ECIU has a plurality of input and output connections to answer switch 712 , and thus can send an I/O packet to any IPC and receive an I/O packet from any RP. Uses of this connection capability include:
setting up and changing parameters for the operation of IPCs; setting up and changing algorithms for the operation of IPCs; receiving notification of normal operation and traffic conditions from IPCs and RPs on a timely or periodic basis; setting up and changing parameters for the operation of RPs; setting up and changing algorithms for the operation of RPs; receiving traffic-flow information from RPs during operation; receiving timely and urgent notification of exceptional operation or traffic conditions from IPCs and RPs, e.g. failure of a component such as a 1×2 optical switch, an optical fiber or connection, or an electronic line, connection or component; ECIU can command a specific IPC to generate test packets for testing, initialization, diagnosis, troubleshooting, and fine-tuning operations; any RP can send an I/O packet P to any IPC (where packet P is not an answer packet 140 ); any IPC, S, can send an I/O packet P to a target IPC, T, by sending the packet through an RP, which forwards P to IPC T; similarly, any RP can send an I/O packet to another RP by sending it to an IPC, which forwards P to the target RP.
[0141] One use for IPC-to-IPC communications is to generate an optical test packet and use it to gather timing information for paths from one port to another. One use for RP-to-IPC communication (in addition to its primary answer-packet function) is to inform an IPC of exceptional conditions such as excess traffic for the output address associated with the RP. In general, an IPC has greater processing capabilities than an RP. An IPC analyzes the traffic information and can inform the ECIU, which has yet greater processing and analysis capabilities and can use the information in managing the system. ECIU functions include operator interface, maintenance, diagnosis and troubleshooting, collecting and analyzing traffic data, putting ports online and offline, and managing user requirements such as QoS service for different traffic types and different ports. By these means and methods, any processing element in the system has a high-speed connection to any other, which is an advantage of the parallel, scalable nature of all communications in the system.
[0142] System 270 ( FIG. 2C ) can be employed in a system 290 ( FIG. 2D ) similar to the system 205 shown in FIG. 2B , where input 202 connects upstream and output 220 connects downstream. In an alternate embodiment of this type, system 270 can be employed as the “switching core”, using packet de-concentrators 224 and concentrators 236 in a fashion similar to their use in system 200 as shown in FIG. 2A . In this embodiment lines 206 from the de-concentrator are the input to system 270 and lines 216 are the output from system 270 , connecting directly to packet concentrators 236 . Advantageously, the system 200 packet alignment unit 234 is not needed because SLC 280 uses optical feedback 292 in conjunction with a single packet alignment unit 284 to fine-tune the timing of packets so that a second alignment/adjustment step is unnecessary.
[0143] In yet other embodiments of systems 200 and 205 , test-packet generator 296 , optical feedbacks 292 and 298 , and SLC 280 can be suitably incorporated for purposes and uses mentioned above, including system installation, setup, reconfiguration, operation, management, system analysis, diagnosis, and repair functions.
[0144] Other embodiments of the invention could combine the ideas taught in this patent with the ideas taught in referenced patents No. 8 and No. 10. For example, some of the input or output lines of the system could be electronic. In another embodiment, some of the data is switched optically, while other data is switched electronically. One skilled in the art will be able to see other variation of this scenario by combining ideas in the referenced patents. | A switching system for routing information packets that can simultaneously receive a variety of packet formats. The packet formats include electronic packet transmissions, optical wave division multiplexed data (WDM) with a single frame consisting of a plurality of packets to be sent to a common output line, with each packet traveling on a separate wavelength, WDM packets where the header of an individual packet travels on a wavelength different from the remainder of the packet (i.e. the payload) and the payload either travels on a single wavelength or is subdivided into a plurality of sub-packets with each sub-packet carried on a separate wavelength, and the like. The system includes input devices, a scheduling unit, a switching unit; and variable delay line units. A deconcentrator in the packet switching system creates a minimum gap between packets. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a novel process for adjusting the amine load upon an absorption column intended for the disulfuration of gas, taking into account the absorption rate of the gas to be eliminated on the amine. It also concerns a device which reduces to practice the process and in particular the photometric cell that allows measurements.
2. Description of the Prior Art
Scrubbing using amine, of gas containing hydrogen sulfide is well known to the man skilled in the art. According to this process, the gas to be scrubbed is injected into the bottom of an absorption column, in which it is contacted at counter-current with an amine solution. The scrubbed gas is recovered at the head of the column and the amine loaded with hydrogen sulfide exits at the bottom of the column, in order to be regenerated and reinjected into the absorption column.
The problem that arises is that of controlling the amine flow-rate taking into account operating conditions. It is possible, as disclosed in French Pat. No. 2,141,413, to control the mass flow-rate of the amine solution to the mass flow-rate of the gas to be scrubbed. It is also possible, as disclosed in U.S. Pat. No. 3,288,706 to analyze the gas at the output of the absorption column (once scrubbed) or the saturated amine at the bottom of the column.
These different control and adjustment methods present the principal drawback of being based upon parameters that are external to the column, namely:
in particular for the first above-mentioned patent, the process is based on elements existing prior to the reaction per se and thus is not able to take into account the behavior per se of the reaction;
for the second above-mentioned patent, the process is based on observing subsequently the result of the reaction and thus on reacting with a lapse of time.
These parameters do not take into account an eventual loss of adjustment or an overload on the column, due to a discrepancy of the measurements with respect to the absorption reactions and/or to a lack of precision and to the variable response time of the equipment.
SUMMARY OF THE INVENTION
The present invention aims overcoming these drawbacks. In order to do this, it foresees a process for controlling the amine load, wherein the said control is performed as a function of the residual content in the amine of the gas to be eliminated, the sample being drawn off in the liquid phase inside the column.
The invention also provides an installation for reducing to practice this process and comprising: a device for the continuous drawing off of the amine sample, a circuit for introducing the amine and a system for controlling the amine flow-rate.
The analyzing circuit acts upon the amine load circuit as a function of the rate of absorption of the gas to be eliminated on the amine.
Another characteristic of the invention is that the analyser comprises a photometer, the measuring cell of which is capable of withstanding high pressures and temperatures with a very short and adjustable optical trajectory. It is thus possible to analyze the amine upon which is absorbed the hydrogen sulfide within the core itself of the column.
The advantages obtained due to this invention are of considerable importance. In the first place, the in situ measuring of the H 2 S absorption rate on the amine allows control of the amine load at the exact moment when the reaction deviates from a predetermined rate. In particular, in this way all risks of flare are prevented, or at least their frequency is reduced. Furthermore, a quasi-perfect stability of operating is obtained, thereby producing a saving in energy on the pumping of the load, on the one hand, and on the regenerating of the amine, on the other hand.
According to one characteristic of the invention, it is possible to complete this adjustment or control by associating thereto a recording of the temperatures throughout the length of the absorber and to associate an adjustment a priori through an electronic device for the economic management or control of the process.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become more apparent from reading the following embodiment, given by way of non-limiting illustration with reference to the appended drawings in which:
FIG. 1 partially represents a desulfuration installation produced according to the invention; and
FIG. 2 is a detailed cross-section of a photometer cell for use in the apparatus of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 represents an installation for the desulfurization of gases comprising an absorber 2, load or evacuation pipes 1, 3, 4 and 10, an amine load pump 5, a regeneration unit 6, a tapping device 11 and a control system constituted by the analyzer 13, the addition module 18 and regulator 19, a flow-rate meter 16 and an automatic valve 17.
With reference to FIG. 1 the gas to be scrubbed 25 containing hydrogen sulfide and possibly other acid compounds arrives through the pipe 1 and enters the bottom of an absorber 2 in which it is contacted at counter-current with a concentrated hot amine solution 26 introduced through pipe 10. The scrubbed gas issues at the head of the absorber through the pipe 3 and the amine solution, having fixed the acid compounds, is brought through the intermediary of the pipe 4 to a regeneration unit 6. Once the amine has been regenerated, it is re-pumped by the load pump 5 in order to be thereafter reinjected into the absorber.
For the control of the amine flow-rate, a tapping 11 is performed, issuing into the liquid phase 21 at the level 22 of one of the baffle plates of the absorber. The sample is then brought through the intermediary of a pipe in which a safety system with respect to the pressure towards the analyser 13 has been foreseen. The said analyser comprises a photometer, the cell of which is adapted to withstand very high pressures and temperatures and allows the taking of measurements upon very short and adjustable optical trajectories. The measurement, after adjustable amplification, of the saturation rate of the amine is compared to a previously determined reference 14 and modifies by increasing or decreasing it, an outflow reference 15, due to an addition module 18. The output signal of the module 18 is piloting the reference point of the control-loop of the flow-rate constituted by the flow-rate meter 16, the regulator 19 and the automatic valve 17.
Furthermore, so as to confirm the evolution of the measurement given by the analyser 13, it is possible to perform a follow-up of the temperatures taken on one or several baffle plates, still in the liquid phase, thereby allowing visualization of the displacement of the absorption front within the column.
Another embodiment for the control of the amine flow-rate consists in acting not upon the valve 17 but upon the speed of the pump 5, for example, by controlling the steam admission of a driving turbine or the speed of an electric motor through any suitable means.
The resulting device, such as described herein-above, can only be envisaged with a measuring system, especially adapted to withstand high pressures and temperatures and which allows very short optical trajectories, since large quantities of hydrogen sulfide absorbed on the amine, and not traces, have to be analyzed. Furthermore, the optical trajectory must be easily adjustable in order to be able to adapt the sensitivity of the analysis to the characteristics of the column. FIG. 2 represents a preferred embodiment of a photometric cell that meets these requirements.
With reference to FIG. 2, the photometer cell is symmetrical with respect to a plane passing through the axis XX' and perpendicular to the optical axis YY'. It also presents a revolution symmetry around the axis YY'. The cell comprises two quartz cylinders 102 and 202, their diameters corresponding to the internal diameters of two bodies 108 and 208, themselves packed and welded within the internal cylindrical recess of a main body 100. On each of these bodies 108 and 208, is screwed a socket 107 (respectively 207) by wedging against the corresponding quartz cylinder a joint or seal 105 (respectively 205) and a joint 106 (respectively 206) having a bevelled form. The tip of the bevelled portion of the said joint 106 (respectively 206) is wedged between the quartz and the end of the body 108 (respectively 208) that is cut in a bevelled form in the opposite direction. Similarly, the tip of the bevelled portion of the joint 105 (respectively 205) is wedged between the quartz and the other end of the joint 106 (respectively 206) that is shaped in a bevelled form in the opposite direction. These joints 105 and 106 (respectively 205 and 206) are made of polytetrafluoroethylene (PTFE) and ensure the sealing to pressure. Since the two quartz cylinders are positioned in such a manner as to obtain the desired optical trajectory (interquartz distance), their positions are fixed through tightening of the sockets 107 and 207 upon the bodies 108 and 208 after introduction of a wedge of a suitable thickness through one of the orifices 110 or 111. This sealing is completed by a ring made of polytetrafluoroethylene 104 (respectively 204) that is applied against the bottom of the quartz cylinder 101 (respectively 201) through screwing of the base 103 (respectively 203) upon the main body. This screwing is rendered fool-proof by blocking in counter-bolt 109 against the base 103.
A perfect sealing to pressure and to temperature is thus obtained with as short an optical trajectory as desired. The product to be analyzed enters through the hole 110 having axis XX' and provided in the main body, passes between the two quartz cylinders that determine the optical trajectory and exits through the hole 111 also of axis XX'.
The present invention is in no way limited to the single embodiment described herein-above and can, on the contrary encompass all variants.
In particular, it is possible to envisage insulating the photometric installation, in the case of leakages or adjustment of the cell. In order to do this, it is possible to utilize a system of valves that short-circuit the inlet and the outlet of the photometer and of which the action will be actuated automatically, for example, upon the appearance of a leakage. | A process and apparatus for adjusting the amine load upon an absorption column for the desulfuration of gases uses a photometric cell allowing measurements of absorption to be taken, wherein the process comprises performing the said adjustment as a function of the residual content in the amine of the gas to be eliminated, the sample being drawn off in liquid phase from inside the column. The application of said process to the processing of natural acid gases is disclosed together with an embodiment of a photometer cell. | 2 |
REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 13/420,497, filed Mar. 14, 2012, now U.S. Pat. No. 8,632,779, issued Jan. 21, 2014, which is a divisional of U.S. application Ser. No. 12/826,160, filed Jun. 29, 2010, now U.S. Pat. No. 8,163,288, issued Apr. 24, 2012, which is a continuation of U.S. application Ser. No. 11/909,258, filed Jun. 12, 2008, now U.S. Pat. No. 7,767,211 issued Aug. 3, 2010, which claims priority to International Application No. PCT/GB2006/000826, filed Mar. 8, 2006, which claims priority to United Kingdom Application No. GB0505949.8, filed Mar. 23, 2005, the disclosures of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The invention relates to antigenic polypeptides expressed by pathogenic microbes, vaccines and immunogenic compositions comprising the antigenic polypeptides and therapeutic antibodies directed to the antigenic polypeptides.
BACKGROUND
A problem facing current medical development is the evolution of antibiotic resistant strains of a number of significant pathogenic microbes. An example of a pathogenic organism which has developed resistance to antibiotics is Staphylococcus aureus. S. aureus is a bacterium whose normal habitat is the epithelial lining of the nose in about 20-40% of normal healthy people and is also commonly found on people's skin usually without causing harm. However, in certain circumstances, particularly when skin is damaged, this germ can cause infection. This is a particular problem in hospitals where patients may have surgical procedures and/or be taking immunosuppressive drugs. These patients are much more vulnerable to infection with S. aureus because of the treatment they have received. Resistant strains of S. aureus have arisen in recent years. Methicillin resistant strains are prevalent and many of these resistant strains are also resistant to several other antibiotics. Currently there is no effective vaccination procedure for S. aureus.
The present invention is concerned with the identification of potential vaccine components and therapies against which the problem of directly resistant pathogen strains is avoided or reduced.
Amongst the approximately 4100 genes in the soil gram-positive bacterium Bacillus subtilis chromosome, 271 are indispensable (“essential”) for growth and among them, 23 have undefined roles in the physiology of the organism (gcp, obg, ppaC-yybQ-, trmU, yacA, yacM, ydiB, ydiC, yjbN, ykqC, ylaN, yloQ, ylqF, ymdA, yneS, yphC, yqeH, yqeI, yqjK, yrvO, ysxC, ytaG, ywlC) (Kunst et al. 1997). Homologs of the proteins encoded by these genes can be found in the various strains sequenced thus far of another gram-positive bacterium, the human pathogen Staphylococcus aureus . Amongst them, the Gcp and YneS orthologs are predicted membrane proteins, while the rest are predicted cytoplasmic proteins. Nonetheless, Obg has been shown to be partially bound to membranes in B. subtilis (Kobayashi et al. 2001).
SUMMARY
The inventors have isolated certain polypeptides that are essential components for growth of the pathogens Bacillus subtilis and Staphylococcus aureus and have raised antisera against these polypeptides. Antisera raised against the Bacillus subtilis polypeptides was found to result in extremely potent killing of Staphylococcus aureus . This effect could not have been predicted. The present findings facilitate the development of vaccines, immunogenic compositions and antibody therapies that mitigate some of the problems of current therapies such as antibiotic resistance.
The present disclosure provides antigenic polypeptides that are essential for growth of the gram-positive bacteria Bacillus subtilis and Staphylococcus aureus and which are useful in the treatment or prevention of microbial infections.
According to a first aspect, there is provided an antigenic polypeptide, or part thereof, encoded by an isolated nucleic acid sequence selected from the group consisting of:
i) a nucleic acid sequence as shown in FIGS. 1 to 6 (SEQ ID NO: 1-7); ii) a nucleic acid sequence as in (i) which encodes a polypeptide expressed by a pathogenic organism; iii) a nucleic acid sequence which hybridizes to a sequence identified in (i) or (ii) above; and iv) a nucleic acid sequence that is degenerate as a result of the genetic code to the nucleic acid sequence defined in (i), (ii) or (iii)
for use as a medicament.
In one aspect, the medicament is a vaccine or immunogenic composition.
The nucleic acid encoding an antigenic polypeptide of the first aspect of the disclosure may anneal under stringent hybridization conditions to a nucleic acid sequence shown in FIGS. 1 to 6 (SEQ ID NO: 1-7) or to its complementary strand. Stringent hybridization/washing conditions are well known in the art. For example, nucleic acid hybrids that are stable after washing in 0.1×SSC, 0.1% SDS at 60° C. It is well known in the art that optimal hybridization conditions can be calculated if the sequence of the nucleic acid is known. For example, hybridization conditions can be determined by the GC content of the nucleic acid subject to hybridization. Please see Sambrook et at (1989) Molecular Cloning; A Laboratory Approach. A common formula for calculating the stringency conditions required to achieve hybridization between nucleic acid molecules of a specified homology is:
T m =81.5° C.+16.6 Log [Na + ]+0.41[% G+C]−0.63(% formamide).
The nucleic acid encoding the antigenic polypeptide of the first aspect of the invention may comprise a sequence set out in FIGS. 1 to 6 (SEQ ID NO: 1-7) or a sequence which is at least 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, for example 98%, or 99%, identical to a nucleic acid sequence set out in FIGS. 1 to 6 (SEQ ID NO: 1-7) at the nucleic acid residue level.
“Identity”, as known in the art, is the relationship between two or more polypeptide sequences or two or more polynucleotide sequences, as determined by comparing the sequences. In the art, identity also means the degree of sequence relatedness between polypeptide or polynucleotide sequences, as the case may be, as determined by the match between strings of such sequences. Identity can be readily calculated ( Computational Molecular Biology , Lesk, A. M. ed., Oxford University Press, New York, 1988; Biocomputing: Informatics and Genome Projects , Smith, D. W., ed., Academic Press, New York, 1993; Computer Analysis of Sequence Data , Part I, Griffin, A. M., AND Griffin, H. G., eds., Humana Press, New Jersey, 1994; Sequence Analysis in Molecular Biology , von Heinje, G., Academic Press, 1987; and Sequence Analysis Primer , Gribskov, M. and Devereux, J., eds., M Stockton Press, New York, 1991). While there exist a number of methods to measure identity between two polynucleotide or two polypeptide sequences, the term is well-known to skilled artisans ( Sequence Analysis in Molecular Biology , von Heinje, G., Academic Press, 1987; Sequence Analysis Primer , Gribskov, M. and Devereux, J., eds., M Stockton Press, New York, 1991; and Carillo, H., and Lipman, D., SIAM J. Applied Math., 48: 1073 (1988). Methods commonly employed to determine identity between sequences include, but are not limited to those disclosed in Carillo, H., and Lipman, D., SIAM J. Applied Math., 48: 1073 (1988). Preferred methods to determine identity are designed to give the largest match between the sequences tested. Methods to determine identity are codified in computer programs. Preferred computer program methods to determine identity between two sequences include, but are not limited to, GCG program package (Devereux, J., et al., Nucleic Acids Research 12(1): 387 (1984)), BLASTP, BLASTN, and FASTA (Atschul, S. F. et al., J. Molec. Biol. 215: 403 (1990)).
The nucleic acid encoding an antigenic polypeptide disclosed herein may comprise a fragment of a sequence according which is at least 30 bases long, for example, 40, 50, 60, 70, 80 or 90 bases in length.
The nucleic acid sequence encoding the antigenic polypeptide of the first aspect of the invention may be genomic DNA, cDNA or RNA, for example mRNA.
The antigenic polypeptide of the first aspect of the invention may be a cell membrane protein, for example an integral membrane protein or a cytoplasmic protein.
Preferably, the antigenic polypeptide of the first aspect of the invention is expressed by a pathogenic organism, for example, a bacterium, virus or yeast. Preferably the pathogenic organism is a bacterium. The bacterium may be a gram-positive or gram-negative bacterium, preferably a gram-positive bacterium. The bacterium may be selected from the group consisting of: Bacillus subtillis, Staphylococcus aureus; Staphylococcus epidermidis; Enterococcus faecalis; Mycobacterium tuberculsis; Streptococcus group B; Streptoccocus pneumoniae; Helicobacter pylori; Neisseria gonorrhea; Streptococcus group A; Borrelia burgdorferi; Coccidiodes immitis; Histoplasma sapsulatum; Neisseria meningitidis type B; Shigella flexneri; Escherichia coli; Haemophilus influenzae; Listeria monocytogenes, Bacillus anthracis, Corynebacterium diptheriae, Clostridium tetani, Mycoplasma spp. and Treponema pallidum . Preferably the bacterium is of the genus Staphylococcus spp. Preferably still the bacterium is Staphylococcus aureus.
In a preferred embodiment of the invention, the antigenic polypeptide is associated with infective pathogenicity of an organism as defined herein.
In a further preferred aspect of the invention the antigenic polypeptide comprises all, or part of, an amino acid sequence shown in FIGS. 7 to 12 (SEQ ID NO: 8-14). As used herein “part of” may include a polypeptide fragment which may be at least 10, 15, 20 or 30 amino acids long. The antigenic polypeptide may comprise a non-protein antigen, for example a polysaccharide antigen.
As used herein, the term “polypeptide” means, in general terms, a plurality of amino acid residues joined together by peptide bonds. It is used interchangeably and means the same as peptide, protein, oligopeptide, or oligomer. The term “polypeptide” is also intended to include fragments, analogues and derivatives of a polypeptide wherein the fragment, analogue or derivative retains essentially the same biological activity or function as a reference protein.
According to a second aspect of the invention there is provided a vector comprising a nucleic acid sequence encoding a polypeptide disclosed herein.
The vector of the second aspect of the invention may be a plasmid, cosmid or phage. The vector may include a transcription control sequence (promoter sequence) which mediates cell specific expression, for example, a cell specific, inducible or constitutive promoter sequence. The vector may be an expression vector adapted for prokaryotic or eukaryotic gene expression, for example, the vector may include one or more selectable markers and/or autonomous replication sequences which facilitate the maintenance of the vector in either a eukaryotic cell or prokaryotic host (Sambrook et al. (1989) Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y. and references therein; Marston, F (1987) DNA Cloning Techniques: A Practical Approach Vol III IRL Press, Oxford UK; DNA Cloning: F M Ausubel et al, Current Protocols in Molecular Biology, John Wiley & Sons, Inc. (1994). Vectors which are maintained autonomously are referred to as episomal vectors.
Promoter is an art recognized term and may include enhancer elements which are cis acting nucleic acid sequences often found 5′ to the transcription initiation site of a gene (enhancers can also be found 3′ to a gene sequence or even located in intronic sequences and is therefore position independent). Enhancer activity is responsive to trans acting transcription factors (polypeptides) which have been shown to bind specifically to enhancer elements. The binding/activity of transcription factors (see Eukaryotic Transcription Factors, by David S Latchman, Academic Press Ltd, San Diego) is responsive to a number of environmental cues which include intermediary metabolites (eg glucose, lipids), environmental effectors (e.g. light, heat).
Promoter elements also include so called TATA box and RNA polymerase initiation selection (RIS) sequences which function to select a site of transcription initiation. These sequences also bind polypeptides which function, inter alia, to facilitate transcription initiation selection by RNA polymerase.
The vector of the second aspect of the invention may include a transcription termination or polyadenylation sequences. This may also include an internal ribosome entry sites (IRES). The vector may include a nucleic acid sequence that is arranged in a bicistronic or multi-cistronic expression cassette.
According to a third aspect of the invention there is provided a method for the production of a recombinant antigenic polypeptide disclosed herein comprising:
(i) providing a cell transformed/transfected with a vector according to the second aspect of the invention; (ii) growing said cell in conditions suitable for the production of said polypeptides; and (iii) purifying said polypeptide from said cell, or its growth environment.
In a preferred aspect of the method of the third aspect, the vector encodes, and thus said recombinant polypeptide is provided with, a secretion signal to facilitate purification of said polypeptide.
According to a fourth aspect of the invention there is provided a cell or cell-line transformed or transfected with the vector according to the second aspect of the invention. In a preferred embodiment, said cell is a prokaryotic cell, for example, yeast or a bacterium such as E. coli.
Alternatively said cell is a eukaryotic cell, for example a fungal, insect, amphibian, mammalian, for example, COS, CHO cells, Bowes Melanoma and other suitable human cells, or plant cell.
According to a fifth aspect of the invention there is provided a vaccine or immunogenic composition comprising at least one antigenic polypeptide, or part thereof, according to the first aspect of the invention. Preferably said vaccine or immunogenic composition further comprises a carrier and/or adjuvant. As used herein “part thereof” may include a fragment or subunit of the antigenic polypeptide wherein the fragment or subunit is sufficient to induce an antigenic response in a recipient.
The vaccine or immunogenic composition according to the fifth aspect may be a subunit vaccine or immunogenic composition in which the immunogenic part of the vaccine or immunogenic composition is a fragment or subunit of the antigenic polypeptide according to the first aspect of the invention.
The terms adjuvant and carrier are construed in the following manner. Some polypeptide or peptide antigens contain B-cell epitopes but no T cell epitopes. Immune responses can be greatly enhanced by the inclusion of a T cell epitope in the polypeptide/peptide or by the conjugation of the polypeptide/peptide to an immunogenic carrier protein such as key hole limpet haemocyanin or tetanus toxoid which contain multiple T cell epitopes. The conjugate is taken up by antigen presenting cells, processed and presented by human leukocyte antigens (HLA's) class II molecules. This allows T cell help to be given by T cell's specific for carrier derived epitopes to the B cell which is specific for the original antigenic polypeptide/peptide. This can lead to increase in antibody production, secretion and isotype switching.
An adjuvant is a substance or procedure which augments specific immune responses to antigens by modulating the activity of immune cells. Examples of adjuvants include, by example only, agonistic antibodies to co-stimulatory molecules, Freunds adjuvant, muramyl dipeptides, and liposomes. An adjuvant is therefore an immunomodulator. A carrier is an immunogenic molecule which, when bound to a second molecule augments immune responses to the latter.
In yet a further aspect of the invention there is provided a method to immunize an animal against a pathogenic microbe comprising administering to said animal at least one polypeptide, or part thereof, according to the first aspect of the invention. Preferably, the polypeptide is in the form of a vaccine or immunogenic composition according to the fifth aspect of the invention. In a preferred method of the invention the animal is human.
Preferably the antigenic polypeptide of the first aspect, or the vaccine or immunogenic composition of the fifth aspect, of the invention can be delivered by direct injection either intravenously, intramuscularly, subcutaneously. Further still, the vaccine or antigenic polypeptide, may be taken orally. The polypeptide or vaccine may be administered in a pharmaceutically acceptable carrier, such as the various aqueous and lipid media, such as sterile saline, utilized for preparing injectables to be administered intramuscularly and subcutaneously. Conventional suspending and dispersing agents can be employed. Other means of administration, such as implants, for example a sustained low dose releasing bio-observable pellet, will be apparent to the skilled artisan.
The vaccine may be against the bacterial species Staphylococcus aureus S. epidermidis, Streptococcus pneumoniae, Streptococcus pyogenes, B. anthracis , and/or Listeria monocytogenes.
It will also be apparent that vaccines or antigenic polypeptides are effective at preventing or alleviating conditions in animals other than humans, for example and not by way of limitation, family pets (e.g. domestic animals such as cats and dogs), livestock (e.g. cattle, sheep, pigs) and horses.
A further aspect of the invention provides a pharmaceutical composition comprising an effective amount of at least one of the polypeptides of the invention, or a vaccine or immunogenic composition of the invention. These polypeptides may also include a pharmaceutically acceptable carrier or diluent.
According to a further aspect of the invention there is provided an antibody, or at least an effective binding part thereof, which binds at least one antigenic polypeptide, or part thereof, according to the invention.
As antibodies can be modified in a number of ways, the term “antibody” should be construed as covering any binding member or substance having a binding domain with the required specificity for the antigenic polypeptide. Thus, this term covers antibody fragments, derivatives, functional equivalents and homologues of antibodies, including any polypeptide comprising an immunoglobulin binding domain, whether natural or wholly or partially synthetic. Chimeric molecules comprising an immunoglobulin binding domain, or equivalent, fused to another polypeptide are therefore included. Cloning and expression of chimeric antibodies are described in EP-A-0120694 and EP-A-0125023.
In a preferred aspect of the invention said antibody is a polyclonal or monoclonal antibody.
In a further preferred aspect of the invention said antibody is a chimeric antibody produced by recombinant methods to contain the variable region of said antibody with an invariant or constant region of a human antibody.
In a further preferred aspect of the invention, said antibody is humanized by recombinant methods to combine the complementarity determining regions of said antibody with both the constant (C) regions and the framework regions from the variable (V) regions of a human antibody.
Preferably said antibody is provided with a marker including a conventional label or tag, for example a radioactive and/or fluorescent and/or epitope label or tag.
Preferably said humanized monoclonal antibody to said polypeptide is produced as a fusion polypeptide in an expression vector suitably adapted for transfection or transformation of prokaryotic or eukaryotic cells.
Antibodies, also known as immunoglobulins, are protein molecules which have specificity for foreign molecules (antigens). Immunoglobulins (Ig) are a class of structurally related proteins consisting of two pairs of polypeptide chains, one pair of light (L) (low molecular weight) chain (κ or λ), and one pair of heavy (H) chains (γ, α, μ, δ and ε), all four linked together by disulphide bonds. Both H and L chains have regions that contribute to the binding of antigen and that are highly variable from one Ig molecule to another. In addition, H and L chains contain regions that are non-variable or constant.
The L chains consist of two domains. The carboxy-terminal domain is essentially identical among L chains of a given type and is referred to as the “constant” (C) region. The amino terminal domain varies from L chain to L chain and contributes to the binding site of the antibody. Because of its variability, it is referred to as the “variable” (V) region.
The H chains of Ig molecules are of several classes, α, μ, σ, α, and γ (of which there are several sub-classes). An assembled Ig molecule consisting of one or more units of two identical H and L chains derives its name from the H chain that it possesses. Thus, there are five Ig isotypes: IgA, IgM, IgD, IgE and IgG (with four sub-classes based on the differences in the H chains, i.e., IgG1, IgG2, IgG3 and IgG4). Further detail regarding antibody structure and their various functions can be found in, Using Antibodies: A Laboratory Manual, Cold Spring Harbor Laboratory Press.
Chimeric antibodies are recombinant antibodies in which all of the V-regions of a mouse or rat antibody are combined with human antibody C-regions. Humanized antibodies are recombinant hybrid antibodies which fuse the complementarity determining regions from a rodent antibody V-region with the framework regions from the human antibody V-regions. The C-regions from the human antibody are also used. The complementarity determining regions (CDRs) are the regions within the N-terminal domain of both the heavy and light chain of the antibody to where the majority of the variation of the V-region is restricted. These regions form loops at the surface of the antibody molecule. These loops provide the binding surface between the antibody and antigen.
Antibodies from non-human animals provoke an immune response to the foreign antibody and its removal from the circulation. Both chimeric and humanized antibodies have reduced antigenicity when injected to a human subject because there is a reduced amount of rodent (i.e. foreign) antibody within the recombinant hybrid antibody, while the human antibody regions do not illicit an immune response. This results in a weaker immune response and a decrease in the clearance of the antibody. This is clearly desirable when using therapeutic antibodies in the treatment of human diseases. Humanized antibodies are designed to have less “foreign” antibody regions and are therefore thought to be less immunogenic than chimeric antibodies.
In a further preferred embodiment of the invention said antibodies are antibodies whose activity is mediated by complement, for example the activity of the antibody may be activated by complement.
In another aspect of the invention there is provided a vector comprising a nucleic acid sequence encoding the humanized or chimeric antibodies according to the invention.
In a yet further aspect of the invention, there is provided a cell or cell line which comprises the vector encoding the humanized or chimeric antibody according to the invention. The cell or cell line may be transformed or transfected with the vector encoding the humanized or chimeric antibody according to the invention.
In a yet further aspect of the invention there is provided a hybridoma cell line which produces a monoclonal antibody as hereinbefore described.
In a further aspect of the invention there is provided a method of producing monoclonal antibodies according to the invention using hybridoma cell lines according to the invention.
In a yet further aspect of the invention there is provided a method for the production of the humanized or chimeric antibody according to the invention comprising:
(i) providing a cell transformed or transfected with a vector which comprises a nucleic acid molecule encoding the humanized or chimeric antibody according to the invention; (ii) growing said cell in conditions suitable for the production of said antibody; and (iii) purifying said antibody from said cell, or its growth environment.
In a further aspect of the invention there is provided a method for preparing a hybridoma cell-line according to the invention comprising the steps of:
i) immunizing an immunocompetent mammal with an immunogen comprising at least one polypeptide having an amino acid sequence as represented in FIGS. 7 to 12 (SEQ ID NO: 8-14), or fragments thereof; ii) fusing lymphocytes of the immunized immunocompetent mammal with myeloma cells to form hybridoma cells; iii) screening monoclonal antibodies produced by the hybridoma cells of step (ii) for binding activity to the amino acid sequences of (i); iv) culturing the hybridoma cells to proliferate and/or to secrete said monoclonal antibody; and v) recovering the monoclonal antibody from the culture supernatant.
The immunocompetent mammal may be a mouse, rat or rabbit.
The production of monoclonal antibodies using hybridoma cells is well-known in the art. The methods used to produce monoclonal antibodies are disclosed by Kohler and Milstein in Nature 256, 495-497 (1975) and also by Donillard and Hoffman, “Basic Facts about Hybridomas” in Compendium of Immunology V.II ed. by Schwartz, 1981, which are incorporated by reference.
In a further aspect of the invention there is provided the use of an antigenic polypeptide according to the first aspect of the invention in the manufacture of a medicament for the treatment or prophylaxis of a microbial infection or a microbe related disorder.
Preferably, the microbial infection is a bacterial infection caused by a bacterial pathogen derived from a bacterial species selected from the group consisting of: Staphylococcus spp e.g. Staphylococcus aureus, Staphylococcus pyrogenes, Staphylococcus epidermidis; Enterococcus spp e.g. Enterococcus faecalis; Lysteria spp; Pseudomonas spp; Mycobacterium spp e.g. Mycobacterium tuberculsis; Enterobacter spp; Campylobacter spp; Salmonella spp; Streptococcus spp, e.g. Streptococcus group A or B, Streptoccocus pneumoniae; Helicobacter spp, e.g. Helicobacter pylori; Neisseria spp e.g. Neisseria gonorrhea, Neisseria meningitidis; Borrelia burgdorferi spp; Shigella spp, e.g. Shigella flexneri; Escherichia coli spp; Haemophilus spp, e.g. Haemophilus influenza; Chlamydia spp e.g. Chlamydia trachomatis, Chlamydia pneumoniae, Chlamydia psittaci; Francisella tularensis; Bacillus spp, e.g. Bacillus anthracis; Clostridia spp, e.g. Clostridium botulinum; Yersinia spp, e.g. Yersinia pestis; Treponema spp; and Burkholderia spp, e.g. Burkholderia mallei and B. pseudomallei.
The bacteria related disorder may be a Staphylococcus aureus -associated disorder. A Staphylococcus aureus -associated disorder may include, for example, septicaemia; tuberculosis; bacteria-associated food poisoning; blood infections; peritonitis; endocarditis; osteomyelitis; sepsis; skin disorders, meningitis; pneumonia; stomach ulcers; gonorrhoea; strep throat; streptococcal-associated toxic shock; necrotizing fasciitis; impetigo; histoplasmosis; Lyme disease; gastro-enteritis; dysentery; and shigellosis
In a further aspect of the invention there is provided the use of antibodies according to the invention in the manufacture of a medicament for the treatment of a microbial infection.
In a further aspect of the invention there is provided a method of treating a patient comprising administering to the patient an antigenic polypeptide according to the first aspect of the invention, or a vaccine or immunogenic composition according to the fifth aspect of the invention, or an antibody according to the invention.
Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, means “including but not limited to”, and is not intended to (and does not) exclude other moieties, additives, components, integers or steps.
Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.
An embodiment of the invention will now be described by example only and with reference to the following materials, methods and figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the DNA sequence of the yphC polypeptide from Bacillus subtilis (SEQ ID NO: 1);
FIG. 2 shows the DNA sequence of the ysxC polypeptide from Bacillus subtilis (SEQ ID NO: 2);
FIG. 3 shows the DNA sequence of the ywlC polypeptide from Bacillus subtilis (SEQ ID NO: 3);
FIG. 4 shows the DNA sequence of the yneS ortholog peptide 731 from Staphylococcus aureus (SEQ ID NO: 4);
FIG. 5 shows the DNA sequence of the yneS ortholog peptide 733 from Staphylococcus aureus (SEQ ID NO: 5);
FIG. 6 shows (a) the DNA sequence encoding the gcp region putatively exposed outside of the membrane (SEQ ID NO: 6); and (b) the full DNA sequence of the gcp ortholog polypeptide, both from Staphylococcus aureus (SEQ ID NO: 7);
FIGS. 7 to 11 show the amino acid sequences (SEQ ID NO: 8-12) corresponding to the DNA sequences shown in FIGS. 1 to 5 (SEQ ID NO: 1-5) respectively;
FIGS. 12( a ) and ( b ) show the amino acid sequences (SEQ ID NO: 13 and 14) corresponding to the DNA sequences shown in FIGS. 6 ( a ) and ( b ) (SEQ ID NO: 6 and 7) respectively;
FIGS. 13 and 14 show hydropathy plots of the membrane proteins yneS and gcp. The calculation of the hydropathy plots of the proteins stated above and the corresponding graphic representation to predict the transmembrane topology model was determined according to the ConPredII Method and was carried in the server http://bioinfo.si.hirosaki-u.ac.jp/˜ConPred2/;
FIG. 15 shows graphs showing that heat treatment of sera from a human patient (□), from a non-immunized rabbit (◯) or from sera raised against the A. thaliana cyclophilin protein (Δ) did not induce death of S. aureus SJF741. No killing of S. aureus SJF741 was observed either when using native sera from a patient convalescent from S. aureus infection (▪) (Panel A) and from a non-immunized rabbit (●) (Panel B). When native sera raised against the A. thaliana cyclophilin protein (▴) (Panel C), against the B. subtilis proteins Obg (▾) and YdiB ( ) (Panel D) and against the S. aureus protein SA1387 (♦) (Panel E) a minor decrease in the number of S. aureus SJF741 during the first 6 hours was observed, which was followed by subsequent recovery.
FIG. 16 shows graphs showing that native sera raised against the B. subtilis proteins YsxC (●), YphC (▪), and YwlC (▴) (Panels A and B) killed S. aureus SJF471 dramatically, a 5 log decrease within 2 to 4 hours. A similar effect was observed when using native sera raised against the S. aureus peptides YneS-731 (▾) and YneS 733 (♦) and the S. aureus protein Gcp ( ) (Panels C-E). In contrast, heat treating the sera raised against the B. subtilis YsxC protein (◯) or the S. aureus peptides YneS-731 (∇) and YneS-733 (⋄) (Panels A, C, D) abolished the killing abilities of these sera, which were able to kill S. aureus SJF741 in the native form (not heat-treated), as indicated above. Hence, the killing abilities of the sera are due to a heat labile component, which is inactivated in the heat treated sample. No experiments using heat treated sera raised against the B. subtilis proteins YphC (▪) and YwlC (▴) or against the S. aureus gcp protein ( ) are shown in this figure, and the experiments with the corresponding native sera (Panels B and E), as indicated above, illustrate the S. aureus killing capability of these sera.
DETAILED DESCRIPTION
Materials and Methods
Strains
The chromosomal DNA used for PCR amplification of the gene sequences of interest were B. subtilis subsp. subtilis str. 168, S. aureus NCTC 8325, S. aureus N315 and S. aureus COL. An erythromycin resistant sodA::lacZ transcriptional fusion derivative of S. aureus SH1000 ( S. aureus SJF741), was the strain used in the assays (Horsburgh et al. 2002).
DNA, Protein and Peptide Sequences Used as Antigens.
The gene and protein sequences of the genes mentioned can be found at: B. subtilis subsp. subtilis str. 168: GenBank Accession AL009126;
S. aureus 8325 (this is a non-annotated sequence; equivalent annotated sequences of S. aureus containing the genes of interest can be found below): Iandolo et al., 2002; Novick, 1967;
Other S. aureus Strains:
S. aureus subsp aureus str. N315: Kuroda, 2001;
S. aureus strain subsp. aureus COL: The Center for Genomic Research; NCBI Taxonomy Database, Taxonomy ID 93062
NOTE: Different strains of S. aureus have different locus names for the same genes due to phage insertions within the sequence. In this document, the locus names used for the S. aureus genes correspond to those in the S. aureus N315 sequence.
Antigen Preparation
The genes encoding selected proteins from Bacillus subtilis 168 (Obg, YdiB, YphC ( FIG. 1 ; SEQ ID NO: 1), YsxC ( FIG. 2 ; SEQ ID NO: 2), YwlC ( FIG. 3 ; SEQ ID NO: 3), and S. aureus N315 (SA1387, Gcp/SA1854 ( FIG. 6 ; SEQ ID NO: 6 and 7)) were amplified by PCR. The resulting products were cloned in plasmid pETBlue-1, and the genes overexpressed in Escherichia coli Tuner™ (DE3) pLacI Competent Cells (Novagen) according to the manufacturer's instructions. The overexpressed proteins were purified in a 3-step scheme based on anion exchange, hydrophobic and gel filtration chromatography. The level of protein overexpression was confirmed by SDS-PAGE, and the purity had an average of 90%. In addition, selected peptides within the S. aureus N315 protein SA1187 (YneS-731 ( FIG. 4 ; SEQ ID NO: 4) and YneS-733 ( FIG. 5 ; SEQ ID NO: 5)) were synthesized on a Milligen 9050 Peptide Synthesizer using F-moc chemistry. The F-moc amino acids (Novobiochem/Merck) were activated immediately before coupling using equimolar amounts of HCTU or HBTU in the presence of a 10% molar excess of HOBt. In both cases, a cysteine was incorporated at the C-terminus of the peptide to enable linkage to carrier protein by assembling the peptide on Fmoc-L-Cys(Trt)-PEG-PS resin (Applied Biosystems). Peptides were purified using a C18 Vydac column (22×250 mm) using gradients of acetonitrile in 0.1% TFA. Peptides were verified by mass spectrometry. The purified peptides were conjugated to KLH (Sigma) (carrier protein) to enhance immunogenicity of the hapten in the rabbit. Conjugation was performed in 10× PBS using MBS (Sigma).
Sera
Sera were obtained from the Antibody Resource Center at the University of Sheffield from: i) rabbits immunized against proteins from B. subtilis (Obg, YdiB, YphC, YwlC and YsxC and S. aureus (Gcp, SA1387); ii) rabbits immunized against KLH-conjugated peptides selected within the S. aureus protein SA1187 (YneS-731, YneS-733); iii) rabbits immunized against a KLH-conjugated peptide from the cyclophilin protein from Arabidopsis thaliana ; iv) naive (non-immune) rabbit serum; and v) human serum from a patient convalescent from a S. aureus infection.
The immunization process was performed as follows. For each rabbit 200 to 500 μg of antigen (in a maximum volume of 250 ul of Phosphate Buffer Saline, PBS) were mixed with an equal volume of complete Freund's adjuvant. The solution was filtered through a 23G needle until an emulsion formed which did not separate on standing. Each rabbit was inoculated with a maximum of 500 μl subcutaneously. On day 22, 43 and 64 the injection was repeated but using incomplete Freund's adjuvant. Sample bleeds were collected on day 53 and after day 64. Injection dates were flexible within a range of 3 to 6 weeks. When a suitable titer was detected in the test serum, a final boost followed by bleed out 10 days later was performed.
Sera were stored frozen being thawed and filtered through 0.2 μm pore diameter filters (Minisart High Flow, Sartorius) immediately before use in killing experiments.
Using western blot analysis (data not shown) it was shown that antibodies against the B. subtilis YdiB recognize a band of the size corresponding to the YdiB homolog in S. aureus , suggesting the species cross-reactivity of these antibodies.
Media and Growth Conditions
To prepare the inoculum for the serum experiments, S. aureus SJF741 was grown at 37° C. in Brain Heart Infusion medium (BHI; Oxoid) supplemented with erythromycin (Sigma) to a final concentration of 5 μg/ml (BHI-Ery).
Preparation of the Inoculum
A single colony of S. aureus SJF741 freshly grown on BHI-Ery plates from the laboratory frozen stock was inoculated in 30 ml universals containing 5 ml of BHI-Ery and incubated overnight (between 12 to 16 hours) at 37° C. in an orbital shaker (250 rpm). A 10-fold dilution in Phosphate Saline Buffer (PBS) of the resulting culture was prepared immediately before inoculation into serum.
Serum Experiments
Aliquots of 200 μl from the various sera in 1.5 ml microfuge tubes were inoculated with the PBS dilution of S. aureus SJF741 (See Preparation of the inoculum) to a final cell density of 1×10 6 to 1×10 7 cells/ml, followed by incubation in a rotary shaker at 37° C. 10 ul samples were taken periodically from these serum cultures, serially diluted, and 10 ul from each dilution plated on BHI-Ery plates, which were subsequently incubated at 37° C. overnight. In addition, another 10 ul sample from each serum culture was directly plated on BHI-Ery plates. Only the dilutions rendering between 1 to 40 colonies were enumerated and the number of viable cells (colony forming units, CFU) per ml determined.
Results
To evaluate the staphylococcal killing abilities of the various sera, S. aureus was challenged with the various rabbit anti-sera and survival over time was evaluated. The results showed that S. aureus was dramatically killed within 2 to 3 hours of contact with sera ( FIG. 16 ) containing antibodies against Gcp and YneS, as well as to other surface proteins. In contrast, antibodies against cytoplasmic proteins from B. subtilis (Obg and YdiB), to a membrane protein from Arabidopsis thaliana (cyclophilin), and to various normal rabbit sera did not show the bactericidal phenotype ( FIG. 15 ). Strikingly, sera from rabbits immunized against other presumed cytoplasmic proteins from B. subtilis (YsxC and YphC and YwlC) also revealed a killing phenotype similar to the one observed for Gcp and YneS (731 and 733) antibodies. This was unexpected since YsxC, YphC and YwlC are presumed cytoplasmic proteins and, therefore, are not surface exposed and so the antisera would not be expected to recognize them.
This work suggests the location of YsxC in the membrane fraction of S. aureus . This work has further demonstrated that the killing effect is mediated through a heat-labile component (inactivated by heat treatment, See Material and Methods) present in serum, likely to correspond to some of the components of the complement ( FIG. 16 ).
REFERENCES
Horsburgh et al., J. Bacteriol. 184(9):5457-67 (2002)
Iandolo et al., Gene 289 109-118 (2002).
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Ikeda et al., Nucleic Acids Res., 31, 406-409 (2003).
Karavolos et al., Microbiology October; 149(Pt 10):2749-58 (2003).
Kobayashi et al., Mol Microbiol. September; 41(5):1037-51 (2001).
Kobayashi et al. Proc Natl Acad Sci USA 100(8):4678-83 (2003).
Kunst et al., Nature, November 20; 390(6657):249-56 (1997).
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Lao and Shimizu In Valafar, F. (ed.), Proceedings of the 2001 International Conference on Mathematics and Engineering Techniques in Medicine and Biological Sciences ( METMBS ' 01), CSREA Press, USA, pp. 119-125 (2001).
Lao et al., Bioinformatics, 18, 562-566 (2002).
Lao et al., In Silico Biol., 2, 485-494 (2002).
Moszer et al., Nucleic Acids Res. 30(1):62-5 (2002).
Novick, R. P. Virology 33:155-156 (1967).
Xia et al., Comput. Biol. Chem., 28, 51-60 (2004).
Zalacain et al., J Mol Microbiol Biotechnol. 6(2):109-26 (2003). | The invention relates to antigenic polypeptides expressed by pathogenic microbes, vaccines comprising said polypeptides; therapeutic antibodies directed to said polypeptides and methods to manufacture said polypeptides, vaccines and antibodies. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority of a provisional application under 35 U.S.C. §119(e), namely U.S. Patent Application Ser. No. 61/470,043 filed on Mar. 31, 2011, which is incorporated by reference in its entirety herein.
BACKGROUND
1. Field of the Disclosure
Embodiments disclosed herein relate generally to marine riser buoyancy modules. In particular, embodiments disclosed herein relate to a riser buoyancy module system providing buoyancy to a riser and platform while providing a conduit for a number of intelligent downhole services.
2. Background Art
Offshore oil and natural gas drilling and production, particularly in deep water, relies on substantially vertical conduits called “marine risers” to convey fluids and slurries between the seabed and the surface, including but not limited to, drilling risers, production risers, export risers, steel catenary risers (“SCRs”), and flexible composite flowlines.
Some marine risers, such as SCRs, may include a single conduit, while other risers, such as drilling risers, may include a larger diameter main conduit with a plurality of attached, smaller diameter auxiliary lines, including but not limited to, choke and kill lines, “boost” lines, and hydraulic supply and control lines. In some cases, electrical or fiber optic control umbilicals may also be attached to the main conduit of the marine riser.
Typically a marine riser may be at least partially supported by floatation of one form or another, including for example evacuated buoyancy “cans” or buoyancy modules made from, for example, syntactic foam material. Buoyancy modules may be arranged circumferentially around the main conduit of a marine riser. Marine drilling risers, for example, typically have syntactic foam buoyancy modules, each including two “clamshell” longitudinal half-cylinder buoyancy elements that are clamped around the main conduit, and which have molded-in grooves, recesses and holes to accommodate attachment hardware and auxiliary lines.
To compensate for stress and fatigue along a length of the riser, a wall thickness of the riser in certain areas is often increased to strengthen the riser, causing it to be heavier and more expensive. In addition, a riser monitoring system (“RMS”) may be installed onto the riser to monitor stress points along a length thereof. These installations are typically separate umbilicals laid on the seafloor from an existing subsea umbilical termination assembly (“SUTA”) and require additional SUTAs and flying leads to run over and attach to the riser monitoring sensors. The flying leads are often equipped with floatation devices and secured to the riser to prevent the flying leads from being crushed on the sea floor. However, this system may be prone to snagging a line on a subsea object, thus rendering the system inoperable. In addition, these additional systems that connect to the riser monitoring systems increase the clutter on the sea floor. Further, the riser monitor sensors are permanently installed items, and thus, often are unable to be serviced. Still further, acoustic Doppler current profile (“ADCP”) systems may be required to record current along a length of the riser. ADCP systems may require free standing buoys connected by expensive electrical umbilicals along with additional umbilicals, terminations, sleds and flying leads, which lie along the sea floor taking up valuable real estate and costing top dollar for the installation of the systems.
Accordingly, there exists a need for a riser system capable of combining and securing a number of monitoring systems while providing a base line of buoyancy to the entire riser and platform.
SUMMARY OF THE DISCLOSURE
In one aspect, embodiments disclosed herein relate to a marine riser including one or more buoyancy modules running along a length of the marine riser, wherein the one or more buoyancy modules are molded such that an umbilical may be secured along a length of the one or more buoyancy modules.
In other aspects, embodiments disclosed herein relate to a buoyancy module installed on a riser, the module including an outer buoyant shell, one or more inner chambers within the outer buoyant shell, and a supply valve configured to allow air and water to enter the one or more inner chambers.
In other aspects, embodiments disclosed herein relate to a method including installing one or more buoyancy modules along a length of a subsea riser and providing communication to one or more downhole components installed on the one or more buoyancy modules through an umbilical running along a length of the one or more buoyancy modules.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a riser system in accordance with one or more embodiments of the present disclosure.
FIG. 2 shows a buoyancy module in accordance with one or more embodiments of the present disclosure.
FIGS. 3A and 3B show cross-sectional views of the buoyancy module of FIG. 2 .
DETAILED DESCRIPTION
In one aspect, embodiments disclosed herein relate to a riser buoyancy module system providing buoyancy to a riser and platform while providing a conduit for a number of “intelligent” downhole services. Referring to FIG. 1 , a riser buoyancy module system 50 in accordance with embodiments of the present disclosure is shown. A riser system 50 extends from an offshore platform 20 and has a string of multiple buoyancy modules attached thereto. The buoyancy modules are assembled around or coupled to the main riser and run along a length thereof from the surface down to the seafloor.
A buoyancy module 100 is shown in FIG. 2 . The buoyancy modules 100 may include an outer buoyant shell 101 . In certain embodiments the outer buoyant shell 101 may be rotationally molded high density polypropylene (“HDPE”). Those skilled in the art will appreciate that other buoyant materials or configurations may be used for the buoyancy modules. For example, any type of buoyant syntactic foam material may be used in accordance with embodiments disclosed herein. Other configurations of buoyancy modules used may include “cans” which may be generally toroidal (i.e., doughnut-shaped) and slipped over the main riser, or may have evacuated buoyancy “cans” of other forms (e.g., closed-end cylinders) arranged in a circumferential array around the main riser conduit. Similarly, in certain embodiments, buoyancy cans may be connected to the surface by conduits so that water may be evacuated from the cans by high-pressure gas (such as compressed air or nitrogen) or by a buoyant slurry comprising, for example, glass microspheres.
Referring to FIG. 2 , a perspective view of a buoyancy module 100 in accordance with embodiments of the present disclosure is shown. In one embodiment, the buoyancy module 100 may be about 14 feet long and may be capable of providing about 2,200 pounds of buoyancy (i.e., upward force) per module. In other embodiments, the buoyancy module 100 may be between about 5 feet and 20 feet long. Those skilled in the art will appreciate that the size of the buoyancy module may be varied to achieve different buoyancy.
Referring to FIGS. 3A and 3B , cross-sectional views of the buoyancy module 100 in accordance with one or more embodiments of the present disclosure is shown. A center section 102 disposed within the outer shell 101 of the module 100 may be hollow and is centered within the shell 101 with two or more fins 104 running along a length of the center section 102 . The hollow central channel of the center section 102 may be installed onto a riser. In other embodiments, the buoyancy module may include one or more inner chambers arranged internally in a number of various configurations. For example, the modules may have chambers (not shown) for both permanent syntactic foam and void space for air or water. The multiple chambers may be connected and monitored with metering valves or other equipment.
The buoyancy module 100 may also include a molded groove 107 formed in an outer surface of the buoyant shell 101 , which runs along an entire length of the module 100 . An umbilical 106 or other conduit may be run along a length of the buoyancy modules 100 in the molded groove 106 . While only one molded groove 107 is shown, those skilled in the art will appreciate that any number of molded grooves may be included in the outer surface of the buoyant shell 101 for running multiple umbilicals 106 or conduits. In alternate embodiments, grooves for umbilicals may be formed in an inner surface of the buoyant shell 101 of the module 100 . Likewise, in alternate embodiments, channels or other passageways may be formed within a wall of the buoyant shell 101 of the module 100 . Various diameters and sizes of grooves or channels may be formed to accommodate various umbilical diameters. For example, a larger umbilical diameter may be required for additional individual communication lines running to multiple downhole components installed on the module 100 .
Referring to FIGS. 2 , 3 A, and 3 B together, in certain embodiments, the buoyancy module 100 may include an electrical actuated vent and air supply valve 108 configured to allow air to vent from or purge one or more chambers in the buoyancy module 100 . Likewise, the valve 108 may allow water to fill the one or more chambers of the buoyancy module 100 . For example, the buoyancy module 100 may have one or more orifices (not shown) in an outer surface to provide a fluid pathway from the one or more inner chambers to outside the module 100 . Check valves or other one-way flow devices may be installed in the one or more orifices to prevent water outside the buoyancy modules 100 from entering the one or more chambers. Air or other fluids may be pumped into the buoyancy modules 100 through a solenoid valve (not shown) or other valve, thereby forcing a fluid within the buoyancy modules 100 out through the one or more orifices. In this manner, a buoyancy of the modules 100 may be controlled. The umbilical 106 may include individual lines (not shown) for air supply, power cable, and fiber optics that run along the molded groove with break out cables that run to the modules and their individual components. In addition, the buoyancy module 100 may include riser monitoring sensors 110 disposed in an outer surface thereof configured to monitor and indicate stress points along a length of the riser. The sensors 110 may be removable and/or serviceable by a remotely operated vehicle (“ROV”).
A control system located at the surface is configured to communicate with the riser monitor sensors 110 to monitor a location of the stress concentration points and “touchdown” (i.e., where the riser first touches down on the seafloor) of the riser and may move water within the buoyancy modules by flooding and purging different buoyancy modules along a length of the riser, thereby moving the stress points and touchdown points. In response to indications of high stress points in specific points along the riser length, the buoyancy modules may include one or more pumps configured to displace water from within or into one or more inner chambers of the modules. For example, if a stress point is found at a particular location along a length of the main riser, the buoyancy of one or more modules disposed along the length thereof may be adjusted by filling or purging inner chambers of the modules as required, relieving the stress in the riser. In other embodiments, positioning of the riser may be adjusted by manipulating the buoyancy of one or more of the modules along the length of the riser. Still further, in alternate embodiments, the weight of the riser on the platform may be decreased by increasing the buoyancy of the modules to allow additional payload to be stored on the platform. In certain embodiments, automation software may be used to read and record the touchdown points, currents, and stresses on the risers. The information collected may be used to purge and flood various modules as required to move the touch down point and stress points.
In certain embodiments, the buoyancy modules may include acoustic Doppler current profiler units mounted thereon. An acoustic Doppler current profiler (“ADCP”) is sonar equipment that produces a record of water current velocities for a range of depths. ADCP's may be made of ceramic materials, and may include transducers, an amplifier, a receiver, a mixer, an oscillator, a clock, a temperature sensor, a compass, a pitch and roll sensor, and computer components to save the information collected.
Still further, in certain embodiments, impressed current cathodic protection (“ICCP”) systems may be integrated with the buoyancy modules to control corrosion of any metal surfaces. One or more anodes, connected to a DC or AC power source through the umbilical, may be disposed on the buoyancy modules. In alternate embodiments, alternative power sources for the ICCP system may be employed, including, but not limited to, surface solar panels, wind power, or gas powered thermoelectric generators. Those skilled in the art will appreciate any number of cathodic protection systems that may be used with the buoyancy modules in accordance with one or more embodiments of the present disclosure.
Advantageously, embodiments of the present disclosure provide a single system including multiple downhole components and configured to provide a base line of buoyancy to an entire riser, thus lowering the vertical load on the floating platform. As such, lowering the vertical load on the floating platform may reduce costs and provide more available payload on the floating platform for other equipment. In addition, a fatigue life of the riser is increased and potential wall thickness of the riser pipe is reduced by being able to control the stresses and touchdown points on multiple risers simultaneously. The ability to move the touchdown point of the riser with buoyancy modules also simplifies the drilling and production operations by eliminating having to move the floating platform itself to multiple locations in order to move the touchdown points and reduce stresses. Further, the buoyancy system disclosed in embodiments herein provides the ability for an ROV to remove and install riser monitor sensors subsea, the riser monitor sensors used to detect stress points along a length of the riser. Finally, the buoyancy system provides a safe way to carry an umbilical needed to power and control all downhole devices at a fraction of the cost and space required normally.
While the present disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the disclosure as described herein. Accordingly, the scope of the disclosure should be limited only by the attached claims. | A marine riser includes one or more buoyancy modules running along a length of the marine riser, wherein the one or more buoyancy modules are molded such that an umbilical may be secured along a length of the one or more buoyancy modules. | 4 |
FIELD OF THE INVENTION
The invention relates to the field of printing, and in particular, to automatic cancellation of a print job.
BACKGROUND
Printers receive and print data files (print jobs) that are submitted by host computer systems. Whenever a print job includes an error, a printer typically receives and prints the data from the beginning of the print job up to the point of the error. This behavior is common for a number of reasons (e.g., it is easy to implement, it may not be possible or practical to withhold printing a job until the complete job is received and processed, and a typical print policy is to print as much of a job as possible, even if the job contains an error).
In the case of a high speed production printer it may be desirable to avoid printing any part of a job when the job is known to include errors. By not printing a job that includes an error, waste production is avoided, as well as time required to implement a recovery process of printing a portion of the job. One particular type of error that may occur is a short print job, otherwise referred to as a “short job”. A short job occurs when the amount of data that the printer receives for a print job is less than the complete job.
A short job may occur due to a network error, or premature termination of the transfer by the host system. The early termination of a file transfer due to a transmission problem is typically not detectable by the printer. However, in some systems the printer is capable of detecting the correct size of a complete print job in advance.
Accordingly, a mechanism to discontinue processing a short job at a printer is desired.
SUMMARY
In one embodiment, a method for providing computer services is disclosed. The method includes a printer receiving an expected size of print data from a computer system during a printing operation, the printer receiving the print data, determining if the size of the print data is less than the expected size of the print data and aborting the printing operation if the size of the print data is less than the expected size of the print data.
Another embodiment discloses a network. The network includes a computer system to initiate a print operation and a printer to receive an expected size of print data from the computer system during a printing operation prior to receiving the print data, to determine if the size of the print data is less than the expected size of the print data and to abort the printing operation if the size of the print data is less than the expected size of the print data.
A further embodiment discloses an article of manufacture comprising a machine-readable medium including data that, when accessed by a machine, cause the machine to perform operations comprising a printer receiving an expected size of print data from a computer system during a printing operation, the printer receiving the print data, determining if the size of the print data is less than the expected size of the print data and aborting the printing operation if the size of the print data is less than the expected size of the print data.
In still a further embodiment, a printer includes a control unit to receive an expected size of print data from a computer system during a printing operation prior to receiving the print data, to determine if the size of the print data is less than the expected size of the print data and to abort the printing operation if the size of the print data is less than the expected size of the print data.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention can be obtained from the following detailed description in conjunction with the following drawings, in which:
FIG. 1 illustrates one embodiment of a data processing system network; and
FIG. 2 is a flow diagram illustrating one embodiment for cancellation of a print job.
DETAILED DESCRIPTION
A mechanism for the automatic cancellation of short print jobs is described. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without some of these specific details. In other instances, well-known structures and devices are shown in block diagram form to avoid obscuring the underlying principles of the present invention.
Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
FIG. 1 illustrates one embodiment of a data processing system network 100 . Network 100 includes a data processing system 102 , which may be either a desktop or a mobile data processing system, coupled via communications link 104 to network 106 . In one embodiment, data processing system 102 is a conventional data processing system including a processor, local memory, nonvolatile storage, and input/output devices such as a keyboard, mouse, trackball, and the like, all in accordance with the known art. In one embodiment, data processing system 102 includes and employs the Windows operating system or a similar operating system and/or network drivers permitting data processing system 102 to communicate with network 106 for the purposes of employing resources within network 106 .
Network 106 may be a local area network (LAN) or any other network over which print requests may be submitted to a remote printer or print server. Communications link 104 may be in the form of a network adapter, docking station, or the like, and supports communications between data processing system 102 and network 106 employing a network communications protocol such as Ethernet, the AS/400 Network, or the like.
According to one embodiment, network 106 includes a print server/printer 108 serving print requests over network 106 received via communications link 110 between print server/printer 108 and network 106 . The operating system on data processing system 102 is capable of selecting print server/printer 108 and submitting requests for services to print server/printer 108 over network 106 . Print server/printer 108 includes a print queue for print jobs requested by remote data processing systems 102 . Further, print server/printer 108 includes a control unit 109 to perform operations associated with printing a request.
Although described as incorporated within the same entity, other embodiments may include the print server and the printer as being physically separate components. Therefore, the data processing system network 100 depicted in FIG. 1 is selected for the purposes of explaining and illustrating the present invention and is not intended to imply architectural limitations. Those skilled in the art will recognize that various additional components may be utilized in conjunction with the present invention.
According to one embodiment, data processing system 102 implements a job transmission protocol to transmit print jobs to print server/printer 108 . In such an embodiment, the job transmission protocol provides the ability for control unit 109 at print server/printer 108 to determine the size of a print job prior to receiving the data for the job. In one embodiment, the job transmission protocol is implemented with a Hot Folders protocol. However, other job transmission protocols (e.g., Line Printer Remote (LPR) and Push Print) may be implemented in other embodiments.
FIG. 2 is a flow diagram illustrating one embodiment of the operation of control unit 109 for cancelling a short print job at print server/printer 108 . At processing block 210 , a user at data processing system 102 initiates a print job by forwarding a job to print server/printer 108 . At processing block 220 , print server/printer 108 receives data prior to the transmission of the print job data from print server/printer 108 that enables print server/printer 108 to determine the size of the print job. At processing block 230 , print server/printer 108 receives the print job data.
In a Hot Folders embodiment, a CloseFile message is received at print server/printer 108 , subsequently a worker thread in the Hot Folders protocol makes a check to insure that the entire file was transferred. At decision block 240 , it is determined whether the size of the received print job data is less than the expected print job size.
If the print job data is greater than or equal to the amount of data expected, the print job data is accurate and thus printed, processing block 250 . If, however, the print job data is less than what was expected, a short job has been received. Consequently, the short job is aborted at print server/printer 108 , processing block 260 . At processing block 270 , text is displayed at print server/printer 108 indicated that a short job has occurred. In an additional embodiment, an indication of the error may be transmitted back to data processing system 102 to alert the user of the error.
The above-described print cancellation mechanism enables a short print job to be aborted, thus eliminating a print job resulting in a processing error or an otherwise undesirable output that would result in inefficient use of a high speed printer.
Embodiments of the invention may include various steps as set forth above. The steps may be embodied in machine-executable instructions. The instructions can be used to cause a general-purpose or special-purpose processor to perform certain steps. Alternatively, these steps may be performed by specific hardware components that contain hardwired logic for performing the steps, or by any combination of programmed computer components and custom hardware components.
Elements of the present invention may also be provided as a machine-readable medium for storing the machine-executable instructions. The machine-readable medium may include, but is not limited to, floppy diskettes, optical disks, CD-ROMs, and magneto-optical disks, ROMs, RAMs, EPROMs, EEPROMs, magnetic or optical cards, propagation media or other type of media/machine-readable medium suitable for storing electronic instructions. For example, the present invention may be downloaded as a computer program which may be transferred from a remote computer (e.g., a server) to a requesting computer (e.g., a client) by way of data signals embodied in a carrier wave or other propagation medium via a communication link (e.g., a modem or network connection).
Whereas many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description, it is to be understood that any particular embodiment shown and described by way of illustration is in no way intended to be considered limiting. Therefore, references to details of various embodiments are not intended to limit the scope of the claims, which in themselves recite only those features regarded as essential to the invention. | A method for providing computer services is disclosed. The method includes a printer receiving an expected size of print data from a computer system during a printing operation, the printer receiving the print data, determining if the size of the print data is less than the expected size of the print data and aborting the printing operation if the size of the print data is less than the expected size of the print data. | 6 |
BACKGROUND OF THE INVENTION
[0001] In the recent years, the frequently occurred flood related problems in the nationally metropolitan areas have indicated that the applied sluicing standards are unable to process the huge water volume caused by heavy rainfalls. Flood has even become inevitable in the low-lying regions, especially in the ground-lever stores, the residences and the basements. It usually causes severe life and property damage as well as makes people extremely panic. Without any efficient method, most people use the sand bags as the means to prevent the flood. However, the sand bags can only block the water up to about 30 to 60 centimeters but they functions poorly for flooded water exceeding one meter height because the higher the flood is, the greater the water pressure will be; failing to resist the water pressure, the embankment built by the sand bags might burst. In addition, to handle the used sand bags after the flood is another troublesome issue. Therefore, to use sang bags is not the preferred method for preventing the flood. The best way to solve the problem is to research and develop efficient equipment for replacement.
SUMMARY OF THE INVENTION
[0002] An assembled sluice gate for flood-prevention and water-blocking comprises two wall posts, a plurality of sluice gates and a connection plate disposed in an entrance area of a doorframe, wherein the two wall posts respectively and fitly mount with a left and a right grooved boards on a doorframe and with the connected sluice gates; the connection plate is fixed between two sluice gates to form a piece of vertical door wall which is covered by a top cover at the upper aspect thereon. A plurality of tight retaining belts fasten the top cover and a fixed groove at the lower portion of the doorframe thereby enabling the door wall to block the water and resist a huge water pressure so as to prevent the water from flowing into the houses or basements. Furthermore, when not in use, the sluice gates are superposed for storage at a proper and hidden position without occupying the space but allowing the automobiles and motorcycles to freely enter and exit unaffectedly.
[0003] To enable a further understanding of the structural features and the technical contents of the present invention, the brief description of the drawings below is followed by the detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIG. 1 is a pictorial and exploded drawing of a water-blocking sluice gate of the present invention.
[0005] [0005]FIG. 2 is a pictorial and assembled drawing of a front view of the water-blocking sluice gate of the present invention.
[0006] [0006]FIG. 2A is a drawing of a fastened state of an upper end of a tight retaining belt of the present invention.
[0007] [0007]FIG. 2B is a drawing of a fastened state of a lower end of a tight retaining belt of the present invention.
[0008] [0008]FIG. 3 is a pictorial and assembled drawing of a rear view of the water-blocking sluice gate of the present invention.
[0009] [0009]FIG. 3A is a drawing of the present invention fastened by a transverse latch.
[0010] [0010]FIG. 4 is a pictorial and exploded drawing of the sluice gate of the present invention.
[0011] [0011]FIG. 5 is a pictorial and assembled drawing of the sluice gate of the present invention.
[0012] [0012]FIG. 6 is a cross-sectional drawing of section 6 - 6 of the sluice gate in FIG. 5.
[0013] [0013]FIG. 7 is a cross-sectional drawing of a top cover of the present invention.
[0014] [0014]FIG. 8 is a cross-sectional drawing of a fixed groove of a doorframe of the present invention.
[0015] [0015]FIG. 9 is a cross-sectional drawing of the assembled fixed groove, sluice gate and top cover of the present invention.
[0016] [0016]FIG. 10 is a cross-sectional drawing of a grooved board of the doorframe of the present invention.
[0017] [0017]FIG. 11 is a cross-sectional drawing of a wall post of the present invention.
[0018] [0018]FIG. 12 is a cross-sectional drawing of section 12 - 12 of the sluice gate in FIG. 5.
[0019] [0019]FIG. 13 a cross-sectional drawing of the assembled grooved board, wall post and sluice gate of the present invention.
[0020] [0020]FIG. 14 is a cross-sectional drawing of a connection plate of the present invention.
[0021] [0021]FIG. 15 is a cross-sectional drawing of the sluice gate mounted with a connection plate of the present invention.
[0022] [0022]FIG. 16 is a cross-sectional drawing of the assembled sluice gate and connection plate of the present invention.
[0023] [0023]FIG. 17 is a pictorial drawing of the doorframe connected with the top cover of the present invention.
[0024] [0024]FIG. 18 is a cross-sectional drawing of section 18 - 18 in FIG. 17.
[0025] [0025]FIG. 19 is a drawing of an exemplary embodiment of the water-blocking sluice gate of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] [0026]FIGS. 1 and 2 show the pictorial, exploded and assembled drawings of a water-blocking sluice gate; as indicated, a doorframe ( 1 ) with a height up to 2.5 meters is assembled by a left and a right grooved boards ( 10 ) and a fixed groove ( 20 ) on the lower portion thereof; wherein the grooved boards ( 10 ) fitly mount with two wall posts ( 40 ) and the fixed groove ( 20 ) fitly mounts a door wall assembled by a plurality of sluice gates ( 50 ) and a connection plate ( 60 ); a top cover ( 30 ) covers the top of the door wall; a plurality of tight retaining belts ( 80 ) fasten the front and the back sides of the door wall; the tight retaining belt ( 80 ) is made of a resilient rubber belt or a metal strap ( 81 ) as shown in FIG. 2A; the top end of the tight retaining belt ( 80 ) connects with a lock handle ( 82 ) and the lower end has a through hole ( 83 ) as shown in FIG. 2B. The lateral wall of the top cover ( 30 ) is disposed with a plurality of u-shaped hooks ( 30 ) for hooking the lock handle ( 82 ); the lateral wall of the fixed groove ( 20 ) is disposed with a plurality of n-shaped hooks ( 21 ) for hooking the through holes ( 83 ).
[0027] [0027]FIG. 3 shows the pictorial and assembled drawing of a rear view of the water-blocking sluice gate ( 50 ); as indicated in FIG. 3A, a transverse latch ( 66 ) connects and fastens the connection plate ( 60 ) and the sluice gate ( 50 ); as indicated in FIG. 2, a transverse latch ( 65 ) also connects and fastens the connection plate ( 60 ) and the sluice gate ( 50 ). However, the two transverse latches ( 65 , 66 ) are not symmetrically disposed; they must be preferably disposed diagonally. To assemble the door wall by the wall posts ( 40 ), all of the sluice gates ( 50 ), the connection plate ( 60 ) and the doorframe ( 1 ) finishes the disposition of a flood-preventing and water-blocking sluice gate ( 50 ) structure.
[0028] [0028]FIG. 4 shows the pictorial and exploded drawing of the sluice gate ( 50 ) that is assembled by a plurality of crisscrossed frames ( 51 ) made of squeezed aluminum; in the exemplary embodiment, the sluice gate ( 50 ) is assembled by a bottom frame ( 511 ), a top frame ( 513 ), a left frame ( 515 ), a right frame ( 517 ) and a plurality of transverse frames ( 510 ); two metal facial boards ( 52 ) are respectively and fitly disposed on the front and rear sides of the aluminum frame ( 51 ); furthermore, a waterproof pad ( 53 ) is inserted between the aluminum frame ( 51 ) and the facial board ( 52 ) as well as fastened by a plurality of draw nails ( 54 ), as shown in FIG. 5, to prevent the water from permeating between the frames and the boards.
[0029] [0029]FIG. 6 shows the cross-sectional drawing of section 6 - 6 in FIG. 5; it is also a longitudinally sectional drawing of the sluice gage ( 50 ); as indicated, the bottom frame ( 511 ) of the aluminum frame ( 51 ) is a protruding frame having a waterproof pad ( 55 ) disposed on the bottom side thereof; neck portions ( 512 ) are disposed on two lateral walls of the protruding portion; the top frame ( 513 ) of the aluminum frame ( 51 ) is a concave frame and the top surface thereof is disposed with a waterproof pad ( 56 ) to from a horizontal side; the two outer lateral walls thereof have protruding tenons ( 514 ).
[0030] [0030]FIG. 7 shows the cross-sectional drawing of the top cover ( 30 ); as indicated, the top cover ( 30 ) is a concave frame made of squeezed aluminum; concave necks ( 321 ) are respectively disposed on the two inner lateral walls of a concave opening ( 32 ); a waterproof pad ( 33 ) is disposed inside the concave opening ( 32 ); two u-shaped hooks ( 31 ) are fixed on two outer lateral walls of the concave frame made of squeezed aluminum. Referring to FIG. 9, when the top cover ( 30 ) covers on the sluice gate ( 50 ), the tenons ( 514 ) insert into the concave neck ( 321 ) for fixedly retaining; the upper and lower waterproof pad ( 33 , 56 ) are tightly affixed to each other.
[0031] [0031]FIG. 8 shows the cross-sectional drawing of the fixed groove ( 20 ) of the doorframe ( 1 ); as indicated, the fixed groove ( 20 ) is unitarily molded by a concave frame and a bottom board made of squeezed aluminum disposed with a layer of waterproof pad ( 25 ) on the bottom side for preventing the water permeation. Two lateral sides of the bottom board are fastened on the ground through gecko nails ( 22 ); the two inner lateral walls of the concave opening ( 23 ) of the concave frame are disposed with protruding tenons ( 24 ); a waterproof pads ( 26 ) is disposed on the inner bottom side of the concave frame; two outer lateral walls of the concave frame made of squeezed aluminum are disposed with protruding tenons ( 27 ) and fixed with n-shaped hooks ( 21 ). Referring to FIG. 9, when the bottom frame ( 511 ) of the sluice gate ( 50 ) inserts into the fixed groove ( 20 ), the tenons ( 24 ) insert into the neck portions ( 512 ) for fastening thereby tightly affixing the upper and the lower waterproof pads ( 55 , 26 ) so as to prevent the water permeation.
[0032] [0032]FIG. 9 shows the cross-sectional drawing of the assembled fixed groove ( 20 ), sluice gate ( 50 ) and top cover ( 30 ); as indicated, the tight retaining belt ( 80 ) fastens the n-shaped hooks ( 21 ) on two lateral walls of the fixed groove ( 20 ) and the u-shaped hooks ( 31 ) on two lateral walls of the top cover ( 30 ), wherein, the lock handle ( 82 ) at the upper end of the tight retaining belt ( 80 ) hooks the hook ( 31 ) by a hook ring ( 821 ); the through hole ( 83 ) at the lower end of the tight retaining belt ( 80 ) is hooked by the hook ( 21 ). The tight retaining belt ( 80 ) firmly fastens the sluice gate ( 50 ) and the connection plate ( 60 ) inserted between the fixed groove ( 20 ) and the top cover ( 30 ) thereby increasing the strength of pressure resistance of the entire door wall so as to sufficiently resist the stronger water flow.
[0033] [0033]FIG. 10 shows the cross-sectional drawing of the left and the right grooved boards ( 10 ) of the doorframe ( 1 ); as indicated, the grooved board ( 10 ) is made of squeezed aluminum and the left and the right lateral sides thereof are fastened onto the wall side through a plurality of gecko nails ( 11 ) as shown in FIG. 13. The bottom side thereof is disposed with a waterproof pad ( 12 ) to prevent the water permeation; the inner wall is disposed with a dovetail groove ( 13 ) for guiding and fitly mounting the wall post ( 40 ).
[0034] [0034]FIG. 11 shows the cross-sectional drawing of the wall post ( 40 ); as indicate, the wall post ( 40 ) is also made of squeezed aluminum and divided into an upper groove ( 41 ) and a bottom board ( 42 ); wherein, the cross-section of the upper groove ( 41 ) is almost concave and the bottom board ( 42 ) is of a dovetail shape; a waterproof pad ( 43 ) is disposed on the bottom side of the bottom board ( 42 ) for preventing the water permeation. In addition, a waterproof pad ( 44 ) is disposed also in the upper groove ( 41 ); both of the two inner walls of the upper groove ( 41 ) are disposed respectively with protruding tenons ( 45 ).
[0035] [0035]FIG. 12, shows the transversely cross-sectional drawing of the sluice gate ( 50 ) and it is also the cross-sectional drawing of section 12 - 12 in FIG. 5; as indicated, the left frame ( 515 ) of the sluice gate ( 50 ) is a convex frame and the bottom side thereof is disposed with a waterproof pad ( 57 ); the two lateral walls of the bottom portion are disposed with concaved neck portions ( 516 ); the right frame ( 517 ) of the aluminum frame ( 51 ) is a concave frame and has a waterproof pad ( 58 ) disposed inside the concave opening of the concave frame; protruding tenons ( 518 ) are disposed on two inner walls of the concave opening.
[0036] [0036]FIG. 13 shows the cross-sectional drawing of the assembled grooved board ( 10 ), wall post ( 40 ) and sluice gate ( 50 ); as indicated, the bottom board ( 42 ) of the wall post ( 40 ) is guided into the dovetail groove ( 13 ) of the grooved board ( 10 ); the convex left frame ( 515 ) of the sluice gat ( 50 ) inserts into the upper groove ( 41 ) of the wall post ( 40 ) for fastening; the protruding tenons ( 45 ) insert into the neck portion ( 516 ); two waterproof pads ( 44 , 57 ) connect each other in a sealed contact; the convex left frame of one sluice gate ( 50 ) inserts into the concave right frame ( 517 ) of another sluice gate ( 50 ); the protruding tenons ( 518 ) insert into the neck portion ( 516 ); two waterproof pads ( 57 , 58 ) tightly contact each other. The water permeation is prevented through the disposition of the waterproof pad ( 12 ) inserted between the grooved board ( 10 ) and the wall sides, the waterproof pad ( 43 ) between the grooved board ( 10 ) and the wall post ( 40 ), the waterproof pads ( 44 , 57 ) between the wall post ( 40 ) and the sluice gate ( 50 ) as well as the waterproof pads ( 57 , 58 ) between the sluice gates ( 50 ).
[0037] In order to make the sluice gates ( 50 ) cooperate tightly to increase the function of pressure resistance, it is necessary to dispose a connection plate ( 60 ) between two sluice gates ( 50 ). Since the connection plate ( 60 ) is installed after all of the sluice gates ( 50 ) and the fixed groove ( 20 ) are fitly mounted, it is the last plate to fit with the fixed groove ( 20 ). For an easy installation, the connection plate ( 60 ) is not of a concave-convex structure; therefore, as indicated in FIG. 14, it is made of squeezed aluminum and the left frame ( 61 ) thereof is in an L-shape; a waterproof pad ( 62 ) is fixed at the protruding end thereof; the right frame ( 63 ) is a convex frame with a concave opening disposed with a waterproof pad ( 64 ). In addition, two manual-type transverse latches ( 65 , 66 ) are diagonally disposed on the front and the rear sides of the connection plate ( 60 ).
[0038] For cooperating with the left frame ( 61 ) of the connection plate ( 60 ), the structure of the right frame ( 517 ) of one sluice gate ( 50 ) is changed accordingly. In the structure of a sluice gate ( 50 ′) as indicated in FIG. 15, the structure of a right frame ( 519 ) is of the same L-shape as that of the left frame ( 61 ) of the connection plate ( 60 ); a waterproof pad ( 59 ) is also disposed at the protruding end; latch slots ( 67 ) are disposed diagonally on the front and the rear sides thereof.
[0039] After the connection plate ( 60 ) and the sluice gate ( 50 ′) connect, as indicated in FIG. 16, the left frame ( 61 ) of the connection plate ( 60 ) joins with the right frame ( 519 ) of the sluice gate ( 50 ′) to make two waterproof pads ( 62 , 59 ) tightly contact each other. The front and rear transverse latches ( 65 , 66 ) are manually latched into the latch slots ( 67 ) to firmly connect and fasten the connection plate ( 60 ) and the sluice gate ( 50 ′). The convex right frame ( 63 ) of the connection plate ( 60 ) fitly mounts with the concave left frame ( 515 ) of a reversely disposed sluice gate ( 50 ″), as shown in FIGS. 2 and 3. The convex right frame ( 517 ) of the reversely disposed sluice gate ( 50 ″) fitly mounts with the wall post ( 40 ).
[0040] [0040]FIG. 17 shows the pictorial drawing of the doorframe ( 1 ) structure in a regular state; as indicated, the wall post ( 40 ) of the doorframe ( 1 ), the sluice gate ( 50 ) and the connection plate ( 60 ) are dismounted and only the top cover ( 30 ) covers on the fixed groove ( 20 ) as indicated in FIG. 18 also; the reason is that the covered opening of the fixed groove ( 20 ) prevents the foreign objects from falling in. It is hard to store the top cover ( 30 ) if the length thereof is too long; therefore, the most preferable method for storage is to cover the top cover ( 30 ) on the fixed groove ( 20 ). As shown, the top side of the top cover ( 30 ) is not flush with the ground surface; however, in a real situation, the top cover ( 30 ) has to be flush with the ground level to facilitate the entering and exiting automobiles and motorcycles. Another exemplary embodiment is to pave a slope respectively on the front and the rear sides of the fixed groove ( 20 ) to facilitate the entering and exiting automobiles and motorcycles.
[0041] The implementation of the present invention achieves the following functions:
[0042] 1. Before the flood, the sluice gates are fast assembled to form a door wall to achieve the function of flood-prevention and water-blocking; when not in use, the sluice gate are divided into a plurality of pieces for convenient transportation; with smaller area size, the present invention is very easy for storage without occupying a considerable space.
[0043] 2. During the regular time, the top cover covers on the fixed groove of the doorframe allowing the automobiles and motorcycles to enter and exit safely; for implementing a water-blocking sluice gate, the top cover covers on the door wall and fits with the tight retaining belt to make the door wall a pressure resistant and water-blocking sluice gate.
[0044] 3. All of the seams between the doorframe, the wall post, the sluice gate and the connection plate are disposed with the waterproof rubber pad; therefore, they are connected tightly to prevent any water leakage.
[0045] 4. All of the structures are molded by drawing alloy aluminum; the surfaces thereof has been treated specially to make it weight lightly, easy for processing, have a lower price and a useful life up to thirty years.
[0046] It is of course to be understood that the embodiment described herein is merely illustrative of the principles of the invention and that a wide variety of modifications thereto may be effected by persons skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims. | An assembled sluice gate for flood-prevention and water-blocking includes two wall posts, a plurality of sluice gates and a connection plate, wherein the two wall posts respectively and fitly mount with a left and a right grooved boards on a doorframe and with the connected sluice gates; the connection plate is fixed between two sluice gates to form the entire body into a piece of vertical door wall which is covered by a top cover at the upper aspect thereof. A plurality of tight retaining belts fasten the top cover and a fixed groove at the lower portion of the doorframe thereby enabling the door wall to block the water and resist a huge water pressure so as to prevent the water from flowing into the houses or the basements. | 4 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of United Kingdom Application No. 0822223.4, filed Dec. 5, 2008, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a surface treating appliance, such as a vacuum cleaner. More particularly this invention relates to a surface treating appliance having a fluid flow path extending between at least one fluid inlet and at least one fluid outlet wherein at least a part of the fluid flow path is housed within a releasable portion of the surface treating appliance.
BACKGROUND OF THE INVENTION
[0003] Surface treating appliances such as vacuum cleaners are well known. The majority of vacuum cleaners are either of the ‘upright’ type or of the ‘cylinder’ type. A typical vacuum cleaner comprises a main body which houses the main components of the vacuum cleaner, such as a motor and fan for drawing dirty air into the machine and some form of separating apparatus for separating dirt, dust and other debris from a dirty airflow drawn in by the fan.
[0004] Vacuum cleaners having at least one and often a plurality of alternative airflow paths between an air inlet and an air outlet are known. Such vacuum cleaners often incorporate a valve for selecting one of the said airflow paths to carry an airflow from an air inlet to an air outlet.
[0005] The airflow path(s) of vacuum cleaners can become blocked during use. In prior art vacuum cleaners, it was found to be somewhat awkward to gain access to the portions of the airflow paths in which blockages can occur. The construction of these vacuum cleaners was therefore improved in order to facilitate maintenance and repair.
[0006] This was achieved by providing a releasable portion in the airflow path which allows the user of the vacuum cleaner to release the releasable portion should any blockages occur in the airflow path. Release of the releasable portion gives the user of the vacuum cleaner easy access to the airflow path allowing any blockages to be quickly and easily cleared.
[0007] In the known prior art the releasable portion was retained in an operational position with respect to the remainder of the vacuum cleaner by a release device, for example a resilient push-button, to enable an unskilled user of the vacuum cleaner to carry out basic maintenance and removal of blockages. This advantageously reduces the amount of professional time required to maintain the vacuum cleaner and keeps the vacuum cleaner operational for longer periods, thus increasing user satisfaction and decreasing the amount of time required for maintenance and repair.
[0008] A disadvantage has however been found to occur with some of the prior art arrangements and in particular with those where the release device is located on the lower half of a vacuum cleaner. The release device has generally been placed somewhere which is very visible and accessible. Such a location and visibility however make the release device prone to being knocked or kicked by accident which may cause the releasable portion to fall off.
[0009] The term “surface treating appliance” is intended to have a broad meaning, and includes a wide range of appliances for cleaning or treating a surface in some manner. It includes, inter alia, appliances which apply suction to the surface so as to draw material from it, such as vacuum cleaners (dry, wet and wet/dry), as well as appliances which apply a fluid to a surface, such as polishing/waxing machines, pressure washing machines, ground marking machines and shampooing machines.
SUMMARY OF THE INVENTION
[0010] Accordingly the present invention provides a surface treating appliance comprising a fluid flow path extending between a fluid inlet and a fluid outlet, a portion of the fluid flow path being housed within a releasable portion of the surface treating appliance, a release means or release device for releasing the releasable portion, and an accidental release prevention means or accidental release device for preventing accidental release of the release device.
[0000] This is advantageous because the accidental release prevention device may help to prevent a user from accidentally knocking or kicking the release device during normal use of the surface treating appliance.
[0011] In a preferred embodiment the surface treating appliance is a vacuum cleaner.
[0012] Preferably the fluid flow path is an airflow path.
[0013] In an embodiment the release device may comprise a catch, for example a quick-release catch or other suitable locking, attaching or snap fit device. The release device may comprise a user-operated interface, for example a button.
[0014] In a particular embodiment the release device may comprise a first part integral with, associated with or located on the releasable portion and a second cooperating part integral with, associated with or located on the remainder of the surface treating appliance.
[0015] In a preferred embodiment the two parts inter-engage to keep the releasable portion in position on the remainder of the surface treating appliance during normal use. The two parts may be disengaged to release the releasable portion from the remainder of the surface treating appliance. In a particular embodiment this may be achieved by a user activating, for example by pressing on, a user-operated interface.
[0016] In an embodiment the accidental release prevention device may comprise one or more projections located adjacent the release device or a part thereof. In a preferred embodiment the accidental release prevention device may be located adjacent the user-operated interface. The one or more projection(s) may comprise one or more raised rib(s), wall(s), point(s), hood(s) or any other suitable raised region(s).
[0017] Preferably the projection(s) is located from 0.25 cm, or 0.5 cm or, 1 cm or 1.5 cm, or 2 cm, or 2.5 cm, or 3 cm, or 3.5 cm to 4 cm, or 4.5 cm, or 5 cm, or 5.5 cm, or 6 cm, or 6.5 cm or 7 cm from the user-operated interface.
[0018] The projection(s) may encircle or form an enclosure around the user-operated interface, for example the projection(s) may be located on all sides of the user-operated interface forming a circle, square, rectangle or other shape around it. In a particular embodiment a single projection may surround the user-operated interface.
[0019] In an alternative embodiment several projections may be located adjacent the user-operated interface. For example, the user-operated interface may have from one, two, three, four or more projections located adjacent to it.
[0020] In a particular embodiment projections may be located on at least two sides of the user-operated interface such that it is flanked by the projections. The projections may comprise a pair of elongate ribs which are preferably arranged parallel to one another. They may be arranged either vertically or horizontally. The ribs may have a level outwardly facing surface or alternatively they may be tapered along at least a part of their length. In a preferred embodiment the outer surface of one or both ribs may have a level portion and one or two sloping portions which may slope towards the remainder of the surface treating appliance. In a particular embodiment one rib slopes towards both ends and has a level portion between the two sloped portions and the other rib has a level surface at one end and slopes towards the remainder of the surface treating appliance at the other end.
[0021] In a preferred embodiment the projections are spaced far enough apart to allow access to the user-operated interface by a user's fingers, but close enough together to ensure that a users foot cannot accidentally activate the user-operated interface. Preferably the projections are from 1 cm or, 1.5 cm, or 2 cm, or 2.5 cm, or 3 cm, or 3.5 cm to 4 cm, or 4.5 cm, or 5 cm, or 5.5 cm, or 6 cm, or 6.5 cm or 7 cm apart.
[0022] In a particular embodiment the at least one projection, or the outer surface of the projection may project the same distance or further from the remainder of the surface treating appliance than the user-operated interface. Alternatively the at least one projection may project the same distance or further from the remainder of the surface treating appliance than the distance from the remainder of the surface treating appliance that the user-activated interface projects in it's activated position, for example when it has been pressed by a user.
[0023] The releasable portion may be a simple straight fluid flow path or it may comprise a bend for changing the direction of fluid flow, the bend being housed within the releasable portion. Additionally or alternatively the releasable portion may comprise other components, for example if the surface treating appliance comprises a plurality of alternative fluid flow paths, the releasable portion may further comprise a valve.
[0024] In a preferred embodiment the releasable portion may be arranged to be releasable from the remainder of the surface treating appliance in a rearward direction away from the remainder of the surface treating appliance. However, the releasable portion may be arranged to be releasable from the remainder of the surface treating appliance in any suitable direction. The releasable portion may be attached to the remainder of the surface treating appliance in such a way that when the user-operated interface is activated the releasable portion is released but remains associated with the remainder of the surface treating appliance. For example the releasable portion may remain hingedly attached to the remainder of the surface treating appliance. In an alternative embodiment the releasable portion may completely disassociate from the remainder of the surface treating appliance when the user-operated interface is activated.
[0025] In a particular embodiment the first part of the catch may comprise the at least one projection. In an alternate embodiment the second part of the catch may comprise the at least one projection. Alternatively or additionally at least one projection may be provided on the releasable portion or on the remainder of the surface treating appliance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] A preferred embodiment of a surface treating appliance according to the invention will now be described in detail with reference to the accompanying drawings in which:
[0027] FIG. 1 a is a rear perspective view of a prior art vacuum cleaner which has a releasable portion;
[0028] FIG. 1 b is a close up of the releasable portion shown in FIG. 1 a;
[0029] FIG. 2 a is a rear perspective view of a prior art vacuum cleaner showing the releasable portion removed from the remainder of the vacuum cleaner;
[0030] FIG. 2 b is a close up of the releasable portion shown in FIG. 2 a;
[0031] FIG. 3 a is a rear perspective view of an embodiment of the present invention which has a releasable portion;
[0032] FIG. 3 b is a close up of the releasable portion shown in FIG. 3 a;
[0033] FIG. 4 a is a rear perspective view of an embodiment of the present invention showing the releasable portion removed from the remainder of the vacuum cleaner;
[0034] FIG. 4 b is a close up of the releasable portion shown in FIG. 4 a;
[0035] FIG. 5 a is a rear perspective view of an embodiment of the present invention showing a connector between the releasable portion and the releasing device; and
[0036] FIG. 5 b is a close up of the releasable portion shown in FIG. 5 a
[0037] FIG. 6 a is a rear perspective view of an alternative embodiment of the present invention which has a releasable portion;
[0038] FIG. 6 b is a close up of the releasable portion shown in FIG. 6 a;
DETAILED DESCRIPTION OF THE INVENTION
[0039] With reference to FIGS. 1 a to 2 b the structure of a prior art vacuum cleaner can be seen. The vacuum cleaner indicated generally by the reference numeral 1 comprises a main body 2 , a user-operable handle 3 and a cleaner head 4 . The cleaner head 4 is pivotably mounted to the lower end of the main body 2 , and serves, in use, to treat a floor surface. The lower, floor-facing side of the cleaner head 4 has an air inlet slot 11 .
[0040] The vacuum cleaner 1 houses a motor and fan for generating a suction airflow (not visible in these drawings). The main body 2 houses separating apparatus 6 for separating dirt, dust and other debris from a dirty airflow drawn into the cleaner 1 by the fan and motor.
[0041] In this prior art cleaner the separating apparatus 6 is cyclonic, in which the dirt and dust is spun from the airflow. The cyclonic separating apparatus 6 comprises two stages of cyclone separation arranged in series with one another. The first stage is a cylindrically-walled chamber 7 and the second stage comprises a set of tapering, substantially frusto-conically shaped chambers 8 arranged in parallel with one another. Airflow is directed tangentially into the upper part of the chamber 7 by a duct 9 . Larger debris and particles are removed and collected in this cyclonic chamber 7 . The airflow then passes through a shroud (not shown) to the set of cyclonic chambers 8 . Finer dust is separated by these chambers 8 and collected in a common collecting region. The second set of separators 8 can be upright, i.e. with their fluid inlets and outlets at the top and their dirt outlets at the bottom, or inverted, i.e. with their fluid inlets and outlets at the bottom and their dirt outlets at the top. The nature of the separating apparatus 6 is not material to the present invention.
[0042] The main body 2 also houses filters (not visible in these drawings) for trapping fine particles in the cleaned airflow. These filters remove any fine particles of dust which have not already been removed from the airflow by the separating apparatus 6 . A first filter, called a pre-motor filter, is provided before the motor and fan. A second filter, called a post-motor filter, is provided after the motor and fan. Where the motor for driving the suction fan has carbon brushes, the post-motor filter also serves to trap any carbon particles emitted by the brushes. Clean air is then expelled to the atmosphere.
[0043] The cleaner has two different airflow paths 12 , 13 which direct the air either from the air inlet slot 11 during floor cleaning use or from the end of the wand 14 during above floor cleaning. A change over valve 15 is provided to automatically change between the two airflow paths 12 , 13 in response to movement of the vacuum cleaner 1 between its upright position as shown in FIG. 1 a and an inclined position.
[0044] As can be seen in FIG. 1 the airflow paths 12 , 13 comprise bends. Whenever a vacuum cleaner incorporates a bend in the airflow path 12 , 13 , there is an increased risk of blockages occurring.
[0045] In order to help an end user to clear blockages in the airflow paths 12 , 13 prior art vacuum cleaners 1 have been provided with releasable portions 16 , 160 . Releasable portion 16 can be seen in its released configuration in FIGS. 2 a and 2 b. Removal of these releasable portions 16 , 160 gives the user of the vacuum cleaner 1 easy access to the airflow paths 12 , 13 which allows any blockages to be quickly and easily cleared.
[0046] It can be seen that the releasable portion 16 can be retained in an operational position with respect to the remainder of the vacuum cleaner 1 by a quick release mechanism 17 .
[0000] The quick release mechanism 17 comprises a user-operated interface, for example a button 18 . The quick release mechanism 17 also has a first part 19 located on the releasable portion 16 and a second cooperating part 20 located on the remainder of the vacuum cleaner 1 . The two parts 19 , 20 inter-engage to keep the releasable portion 16 in position on the vacuum cleaner 1 during normal use, but can be disengaged quickly by a user pressing on the button 18 and sliding the two parts 19 , 20 out of engagement with each other.
[0047] It can be seen in FIGS. 1 a to 2 b that the button 18 stands proud of the features adjacent to it and it is therefore prone to being knocked or kicked by accident. This is especially true during normal use of the cleaner 1 due to the location of the button 18 near the base of the cleaner 1 . When the button 18 is kicked the releasable potion 16 may be released from the remainder of the vacuum cleaner 1 by accident.
[0048] Accordingly the present invention aims to help with this problem. As can be seen in FIGS. 3 a to 5 b the vacuum cleaner 1 of the present invention shares many features with the vacuum cleaner described with reference to FIGS. 1 a to 2 b and the same numbers will be used to donate similar features.
[0049] In FIGS. 3 a to 5 b it can be seen that the vacuum cleaner 1 of the present invention further comprises an accidental release prevention device 24 in the form of a pair of projecting ribs positioned one on either side of the user-operable button 18 . These ribs 24 help to prevent accidental activation of the user-operable button 18 .
[0050] The ribs 24 are elongate and are preferably parallel to one another. They are vertically arranged in the Figures but may be arranged horizontally or at any suitable angle. The ribs 24 have a level surface 26 opposite their attachment surface. The outer surface of one or both ribs 24 may also comprise one or more sloping portions 30 which slope towards the remainder of the vacuum cleaner 1 . In the embodiment shown in FIGS. 3 a to 5 b, one of the ribs 24 slope towards both ends from a level surface 26 in the middle and the other rib 24 slopes towards one end from a level surface 26 .
[0051] In a preferred embodiment the ribs 24 are spaced far enough apart to allow access to the button 18 by a user's fingers, but close enough together to ensure that a users foot or other unintended part of the body cannot accidentally activate the button 18 . Preferably the ribs 24 are from 1 cm or, 1.5 cm, or 2 cm, or 2.5 cm, or 3 cm, or 3.5 cm to 4 cm, or 4.5 cm, or 5 cm, or 5.5 cm, or 6 cm, or 6.5 cm or 7 cm apart.
[0052] The outer surface of at a least a portion of the ribs 24 preferably projects the same distance or further from the remainder of the vacuum cleaner 1 than the button 18 . Alternatively at least a portion of the ribs 24 may project the same distance or further from the remainder of the vacuum cleaner 1 than the distance from the remainder of the vacuum cleaner 1 that the button 18 has to be pressed before the quick release mechanism 17 is activated and the releasable portion 16 can be released from the remainder of the vacuum cleaner 1 . If during use of the vacuum cleaner 1 a user accidentally kicks the area were the button 18 is located, the user's foot will hit the ribs 24 and not the button 18 .
[0053] In FIGS. 3 a to 5 b it can be seen that the releasable portion 16 can be retained in an operational position with respect to the remainder of the vacuum cleaner 1 by the quick release mechanism 17 . The quick release mechanism 17 comprises the button 18 , a first part 19 and a second cooperating part 20 . The two parts 19 , 20 inter-engage to keep the releasable portion 16 in position on the vacuum cleaner 1 during normal use, but can be disengaged quickly by a user pressing on the button 18 .
[0054] In FIGS. 5 a and 5 b it can be seen that the first part 19 is removably attachable to a connector 32 on the removable portion 16 for ease of manufacture. The first part 19 may be releasably attachable to the second cooperating part 20 by any suitable device. In a preferred embodiment in order to locate the releasable portion onto the remainder of the vacuum cleaner a user may slide the first part 19 onto runners 34 (one can be seen in FIG. 4 b ) of the second part 20 until it snaps into a locking engagement.
[0055] In order to release the releasable portion 16 a user can press the button 18 which is arranged to release the mechanism which secures the first part 19 into the second part 20 . The first part 19 can then be slid out of engagement with the second part 20 and the releasable portion is then free and can be inspected for blockages.
[0056] FIGS. 6 a and 6 b show an alternative embodiment where ribs 24 ′ are positioned one on either side of the user-operable button 18 ′ to protect the removable portion 160 from accidental release.
[0057] Appropriate modifications and alternative arrangements will be apparent to a reader skilled in the art. | The present invention relates to a surface treating appliance, such as a vacuum cleaner having a fluid flow path extending between at least one fluid inlet and at least one fluid outlet wherein at least a part of the fluid flow path is housed within a releasable portion of the surface treating appliance. | 0 |
TECHNICAL FIELD
[0001] The present invention pertains generally to a hydraulic mount for vibration damping and, more particularly, a hydraulic mount assembly including a decoupler that functions as an air spring to provide remotely selectable damping characteristics to match the characteristics of the input vibration.
BACKGROUND OF THE INVENTION
[0002] Hydraulic mounts are used in many situations where it is desired to isolate sources of vibration, or to protect sensitive equipment from shock and vibration. Examples include, but are not limited to: industrial equipment and machinery isolators; industrial robotics; building, bridge and ship isolators; military weapons systems; agricultural equipment; and construction equipment. Hydraulic mounts are also often used with vehicle powertrains to control movement of the powertrain in response to forces, such as reaction torque and vibration. The mounts serve a second function, that of isolating the engine from the body of the vehicle. A well-known type of hydraulic vibration damping mount generates damping in a predetermined frequency range of vibrations by pumping a hydraulic fluid through an orifice track of predetermined dimensions. The dimensions of the orifice track are typically such that the hydraulic fluid resonates at certain frequencies of input vibration, which maximizes the damping of the mount. At vibration frequencies above the track resonance the dynamic rate of the mount increases, reducing the isolative properties of the mount. Hydraulic mounts may also be provided with devices known as decouplers, which are disposed in a space formed within the mount orifice plate, for example, and allowed limited free travel within the space to “short circuit” the fluid from flowing through the orifice track, thus generating a low magnitude of dynamic stiffness necessary to provide isolation of certain vibrations. When the input vibration to the mount exceeds the allowable limit of the free motion of the decoupler, the hydraulic fluid flows through the orifice track, thereby generating the mount damping characteristics.
[0003] For optimum isolation, the dynamic rate of the mount at the input vibration or “disturbance” frequency should be as low as possible. Since the resonant frequency of the hydraulic damping mount is fixed by the dimensions of the orifice track, prior art mounts must be designed to cover as broad a range of vibration characteristics as possible, or to damp the most prevalent vibration frequencies, to provide effective damping. This necessarily results in a tradeoff or compromise in the performance of the mount. For example, a vehicle's powertrain exhibits varying vibration characteristics as the engine changes from an idle state, where the engine is operating at a low rate (typically measured in revolutions per minute or “RPM”), to an operating state, where the engine operates at a higher RPM. These changing input vibration frequencies are imposed upon the mount. However, due to the fixed physical properties of the mount, the mount's effectiveness at damping the vibration will be greater or lesser, depending upon the mismatch between the disturbance frequency and the resonant frequency of the mount. Accordingly, there is a need for a hydraulic damping mount that provides improved performance over a broader range of disturbance frequencies.
SUMMARY OF THE INVENTION
[0004] The present invention is a bi-state hydraulic mount that provides improved damping performance over a broader range of input vibration frequencies by means of a first hydraulic fluid track, a second hydraulic fluid track and a decoupler functioning as an air spring having two remotely selectable settings. The characteristics of the air spring can thus be tailored to provide mount damping compatible with a particular engine operating state. For example, a first setting of the air spring may reduce the dynamic rate of the mount during engine idle conditions for improved isolation. The second air spring setting may be tuned to provide mount damping tailored to the disturbances generated by the engine when it is operating at RPMs above idle.
[0005] The air spring is formed by an elastomeric decoupler that is held captive in an orifice plate assembly and encloses a selectable volume of air. The characteristics of the air spring are controlled by the volume of air. An integral solenoid is used to select either a first air cavity alone, or the first cavity in combination with a second air cavity. When the solenoid is not energized, a spring-actuated plunger seals an orifice between the first and second air cavities, limiting the volume of air enclosed by the decoupler to the first cavity and increasing the compliance of the decoupler. The relatively high stiffness of the decoupler does not allow hydraulic fluid to easily pass into the first fluid track, forcing the fluid to flow into the second fluid track to control vibration from the engine, such as when the engine is operating above idle. When the engine is at idle, the solenoid may be actuated, moving the plunger away from the orifice and allowing communication between the first and second air cavities. The resulting increased volume of air enclosed by the decoupler reduces the compliance of the decoupler, allowing resonance in the first fluid track such that the dynamic rate of the mount is reduced for improved isolation during engine idle conditions.
[0006] An integral controller is used to energize the solenoid. The controller allows low-level logic control of the solenoid, reducing the electrical load placed on powertrain control components. The controller also compensates for variations in temperature and operating voltage. In addition, the controller limits the actuation rate of the solenoid so as to reduce noise during actuation.
SUMMARY OF THE DRAWING
[0007] Further features of the present invention will become apparent to those skilled in the art to which the present embodiments relate from reading the following specification and claims, with reference to the accompanying drawing, in which FIG. 1 is a longitudinal central section view of a hydraulic mount in accordance with an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0008] In the description which follows, like parts are marked throughout the specification and drawing with the same reference numerals. The drawing figure is not necessarily to scale in the interest of clarity and conciseness.
[0009] FIG. 1 shows a hydraulic mount, generally designated 10 , embodying the invention. The mount 10 includes a generally cylindrical, cup-shaped base 12 suitably secured to a mounting member or bracket assembly 14 by any conventional means, such as by molding, adhesives, press fit, welding and fasteners. The base 12 may be made from any suitable material, such as formed metal, and includes a peripheral side wall 16 and a circumferential, radially outwardly projecting flange 18 . The base 12 may also include a key 41 to orient the mount 10 to an external bracket or brace (not shown) during installation and prevent the mount from rotating after being installed. The mount 10 is further characterized by a generally cylindrical molded elastomer body 20 , which is reinforced by a suitable core part 22 made from any suitable material, such as metal, plastic or composites. The body 20 is molded to a central metal hub member 24 , which supports a mounting member 26 for connecting the mount 10 to an engine assembly or the like.
[0010] The elastomer body 20 includes a central, generally cylindrical depending portion 28 that, in the position shown, is engageable with an orifice plate assembly 32 comprising an upper, generally cylindrical orifice plate 34 and a lower, generally cylindrical orifice plate 36 . The upper orifice plate 34 further comprises an annular opening 35 , which defines a first fluid track 33 . The lower orifice plate 36 further comprises an orifice 38 . Upper and lower orifice plates 34 , 36 are shown in assembly to define an annular passage or second fluid track 42 which opens through a first port 44 to a pumping chamber 46 . A circumferentially spaced second port 48 communicates hydraulic fluid between second fluid track 42 and a second fluid chamber or reservoir 50 defined by a generally cup-shaped flexible diaphragm 62 .
[0011] Lower orifice plate 36 also defines a generally cylindrical recess 51 that receives an elastomeric, cylindrical, disk-shaped decoupler member 40 . A first air cavity 52 is defined by a peripheral outer wall 54 and a reduced-diameter, generally planar bottom wall surface 56 , which is relieved to provide a space between bottom wall surface 56 and the decoupler 40 , as shown. The decoupler 40 is also characterized by a circumferential rim part 58 that is trapped in fluid-tight sealing engagement between the upper orifice plate 34 and the lower orifice plate 36 . However, a major part of the body 60 of the decoupler 40 radially inward of the rim 58 may be annularly recessed and allowed limited space within the recess 51 between the bottom surface 56 and the decoupler 40 . Upper orifice plate 34 is also provided with a relieved cylindrical wall surface 37 to provide space between decoupler 40 and orifice plate 34 except at the rim 58 .
[0012] A second air cavity 70 , defined by lower orifice plate 36 and bottom wall surface 56 , is in communication with first air cavity 52 via orifice 38 . In this regard, the first and second air cavities may be filled with air or a suitable inert gas. A solenoid 64 having a plunger 66 and a spring 68 is mounted to the lower orifice plate 36 such that an actuating tip or end 67 of the plunger is aligned with orifice 38 . The action of the solenoid 64 is such that the tip 67 of plunger 66 is held away from orifice 38 when the solenoid is energized, allowing communication between first air cavity 52 and second air cavity 70 . When the solenoid is unenergized, tip 67 is held against orifice 38 by spring 68 , effectively blocking communication between first air cavity 52 and second air cavity 70 . An integral controller 72 , mounted to lower orifice plate 36 within mount 10 , is electrically connected to solenoid 64 . The integral controller 72 provides switched electrical power to energize solenoid 64 upon command, and also provides compensation for variations in temperature and source voltage. Further, the controller 72 controls the energization rate of the solenoid 64 to reduce the generation of electrical noise by the solenoid. In addition, controller 72 accepts low-power logical control signals, reducing the electrical load placed on powertrain control components. An electrical connector 74 is mounted to the lower orifice plate 36 and sealed from internal exposure to the hydraulic fluid within the mount 10 . The electrical connector 74 provides an external interface for electrical power and logical control to the integral controller 72 .
[0013] In a first embodiment of the present invention, the second fluid track 42 is tuned to provide the desired dynamic rate to provide engine control during operation above idle. Movement of the elastomer body 20 causes fluid movement between the pumping chamber 46 and the reservoir 50 , which are in communication via first and second ports 44 , 48 and second fluid track 42 . Solenoid 64 is unenergized in this state, causing the first air cavity 52 and second air cavity 70 to be blocked from communication by virtue of tip 67 of plunger 66 closing off orifice 38 . The air volume of only the first air cavity 52 in communication with decoupler 40 increases the compliance of decoupler. The decoupler 40 functions as an air spring supported by the first air cavity 52 to damp relatively low amplitude vibrations. The relative stiffness of the decoupler 40 does not allow fluid to easily pass into the first fluid track 33 , forcing the fluid to flow into the second fluid track 42 to damp vibration. When the engine is at idle, the solenoid is actuated, causing tip 67 of plunger 66 to move away from orifice 38 and allowing first and second air cavities 52 , 70 to communicate. The increased air volume resulting from the communication of air cavities 52 , 70 with decoupler 40 lowers the compliance of the decoupler, allowing resonance in the first fluid track 33 and generating a reduction in the dynamic response of the mount to better match the disturbance frequencies of the engine at idle.
[0014] In an alternate embodiment of the present invention, the first fluid track 33 is configured to provide dynamic response reductions at two different frequency ranges. One example would be to provide a reduction in the dynamic rate of the mount 10 during warm idle and cold idle engine states for improved isolation. A second example is to provide reduction in the dynamic rate of the mount 10 at several structural resonant frequencies. The volume of first air cavity 52 is sized for a dynamic response reduction at a first desired frequency range. When solenoid 64 is unenergized, first air cavity 52 generates a decoupler compliance for resonance of first fluid track 33 at the first desired frequency range. When the solenoid 64 is energized and the first and second air cavities 52 , 70 are in communication with decoupler 40 , the compliance of the decoupler will be reduced due to the increased volume of air in communication with decoupler 40 , lowering the resonant point of the first fluid track 33 to a second, lower desired frequency range. The second frequency range is determined by the combined volume of the first and second cavities 52 , 70 . The second fluid track 42 is tuned to provide the desired dynamic rate to provide engine control during operation above idle.
[0015] The present invention provides a simple method for assembling a controllable hydraulic mount. A diaphragm 62 is placed onto the orifice plate assembly 32 . The diaphragm 62 and orifice plate assembly 32 are then placed inside the base 12 . The elastomer body 20 is placed over the base 12 , and the elastomer body is then crimped around the base. The mount is filled with hydraulic fluid by any conventional means, such as fill ports, plugs, caps, seals, and the like. The hydraulic fluid (referred to herein generally as “fluid”) may be any compatible fluid, such as a mixture of water and ethylene glycol.
[0016] The various embodiments have been described in detail with respect to specific embodiments thereof, but it will be apparent that numerous variations and modifications are possible without departing from the spirit and scope of the embodiments as defined by the following claims. | A hydraulic mount having first and second fluid tracks, and a decoupler finctioning as an air spring with two remotely selectable settings. The settings allow tailoring of the air spring characteristics to provide mount damping for differing engine operating states, such as engine idle. A solenoid is used to select a smaller or larger air volume to control the characteristics of the air spring and, in turn, the dynamic response of the hydraulic mount. An integral controller provides switched operation of the solenoid and compensates for variations in temperature and input voltage, as well as minimizing electrical noise generated by the solenoid when it is energized. | 5 |
This application claims priority to U.S. Provisional Application No. 61/711,188, filed Oct. 8, 2012, the entire contents of which are incorporated herein by reference.
BACKGROUND
The present invention relates to refrigerated merchandisers, and specifically to dual temperature refrigerated merchandisers that condition low and medium temperature product display areas.
Existing refrigerated merchandisers typically include a case that defines one or more display areas accessible by consumers from the front of the case. Some merchandisers include doors that enclose the product display area. The display area is cooled by a refrigeration system that includes an evaporator assembly and a condenser assembly arranged in a circuit, and a fan distributes cooled air toward the product display area. In some merchandisers, the condenser and evaporator assemblies are positioned separate and remote from each other within the refrigerated merchandiser. In some cases, the refrigeration system is modular and can be removed from the merchandiser as a unit. For example, U.S. Pat. No. 7,703,295, assigned to Hussmann Corporation, describes and illustrates a merchandising display cooler that includes an accessible compartment for receiving a removable refrigeration unit, the refrigeration unit including both an evaporator assembly and a condenser assembly.
Typically, the product display area of existing merchandisers is maintained within a predetermined temperature range that depends on the type of product to be cooled. For example, a low temperature merchandiser typically maintains the product display area at temperatures less than 32 degrees Fahrenheit, whereas a medium temperature merchandiser typically maintains the product display area at temperatures between 33-41 degrees Fahrenheit. Often, existing merchandisers include either a low temperature refrigeration system or a medium temperature refrigeration system.
In some existing low temperature merchandisers, the product display temperature provided by the low temperature refrigeration system is adjusted via electronic control to a temperature that is warmer than the low temperature range for which the refrigeration system is designed. However, product in the product display areas of these merchandisers frequently freezes due to very cold discharge air upon startup of the low temperature refrigeration system. That is, because these low temperature refrigeration systems frequently use a large compressor, which is designed to lower the suction temperature to accommodate the low temperature range, air discharged into the product display area is much colder than desired when trying to use the low temperature system in this manner.
While some of these systems incorporate a suction pressure regulating valve in addition to a solenoid valve to avoid frozen product, these systems are typically manually actuated. Also, regardless of how existing systems try to avoid frozen product, use of low temperature refrigeration systems to accommodate a product display temperature associated with a medium temperature merchandiser significantly lowers the efficiency of the merchandiser and necessitates additional components and complex controls.
SUMMARY
In one construction, the invention provides a refrigerated merchandiser system including a case defining a product display area to support food product. The case has a door adjacent a front of the case and a door heater that is coupled to the door, and the case defines a compartment. The system includes a low temperature modular refrigeration unit sized to fit within the compartment and operably couple to the case to maintain food product within a low temperature range, and a medium temperature modular refrigeration unit sized to fit within the compartment and operably couple to the case to maintain food product within a medium temperature range. The system includes a controller in communication with the door heater, and the controller is programmed to activate the door heater only in response to the low temperature modular refrigeration unit positioned within the compartment. One of the low temperature modular refrigeration unit and the medium temperature modular refrigeration unit is removably coupled to the case within the compartment. The modular refrigeration unit removably coupled to the case is replaceable by the other modular refrigeration unit to change the temperature range of the product display area.
In another construction, the invention provides a refrigerated merchandiser system including a case defining a product display area to support food product. The case has a door adjacent a front of the case and a door heater that is coupled to the door, and the case defines a compartment. The system includes a low temperature modular refrigeration unit sized to fit within the compartment and operably couple to the case to maintain food product within a low temperature range, the low temperature modular refrigeration unit including an electronic control. The system includes a medium temperature modular refrigeration unit sized to fit within the compartment and operably couple to the case to maintain food product within a medium temperature range, the medium temperature modular refrigeration unit including an electronic control. The system includes a controller in electrical communication with the electronic control on one of the low temperature modular refrigeration unit and the medium temperature refrigeration unit, and in electrical communication with the door heater. The controller is programmed to activate the door heater only in response to the low temperature modular refrigeration unit positioned.
In another construction, the invention provides a method of controlling condensation in a merchandiser having a case defining a product display area includes determining whether the merchandiser is using a low temperature modular refrigeration unit disposed in the merchandiser, and determining whether the merchandiser is using a medium temperature modular refrigeration unit disposed in the merchandiser. The method includes determining whether a product display temperature is above a predetermined threshold in response to determining that the merchandiser is using a low temperature modular refrigeration unit, and activating a door heater to remove condensation from a door on the merchandiser in response to determining that the product display temperature is above the predetermined threshold. The method includes turning off the door heater in response to determining that the product display temperature is below the predetermined threshold.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a refrigerated merchandiser embodying the present invention.
FIG. 2 is a cross-section of the refrigerated merchandiser of FIG. 1 , illustrating a removable modular refrigeration unit disposed in the merchandiser.
FIG. 3 is an exploded perspective view of a portion of the refrigerated merchandiser and the modular refrigeration unit of FIG. 2 .
FIG. 4 is a perspective view of the modular refrigeration unit.
FIG. 5 is a flow chart of a control process for the refrigerated merchandiser of FIG. 1 .
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
DETAILED DESCRIPTION
FIGS. 1 and 2 show a refrigerated merchandiser 10 that may be located in a supermarket or a convenience store (not shown) for presenting fresh food, beverages, and other food product to consumers. The refrigerated merchandiser 10 includes a case 12 that has a base 14 , a rear wall 16 , side walls 18 , 20 , and a canopy 22 . The area partially enclosed by the base 14 , the rear wall 16 , and the canopy 22 defines a product display area 24 for supporting the food product in the case 12 . For example, the food product can be displayed on racks or shelves 26 extending forwardly from the rear wall 16 , and is accessible by consumers through doors 28 adjacent the front of the case 12 .
The case 12 can include a frame 30 adjacent a front of the merchandiser 10 . FIG. 1 shows that the frame 30 includes vertical mullions 32 that define openings 34 , with the doors 28 positioned over the openings 34 . The openings 34 and the doors 28 allow access to food product stored in the product display area 24 . The mullions 32 are spaced horizontally along the case 12 to provide structural support for the case 112 . Each mullion 32 is defined by a structural member that can be formed from a nonmetallic or metallic material. A handle 36 is positioned along an edge of each door 28 to move the door 28 between an open position and a closed position. In the illustrated construction, the refrigerated merchandiser 10 includes three doors 28 . In other constructions, the refrigerated merchandiser 10 may include fewer or more than three doors 28 depending on the size of the case 12
Each door includes a door frame 35 and a glass member 37 that is secured to each door 28 by the respective door frame 35 to allow viewing of the food product from outside the case 12 . The glass member 37 can include one or more glass panes that have a low-emissivity coating. Condensation generally forms on a surface of the glass member when the temperature of the surface is lower than a dew point of air that is in contact with the surface. Condensation is a result of a combination of surface temperature and moisture in the surrounding air. Thus, condensation can form on an interior surface of the glass member after the door has been opened due to exposure of the generally cold interior surface to generally warm ambient conditions. Similarly, condensation can form on an exterior surface of the glass member when the temperature of the exterior surface is below the dew point of the ambient air.
In the illustrated construction, a door heater 39 in the form of an electrically conductive film or resistive coating is adhered to the interior surface of each glass member 37 . The conductive film is generally transparent to minimize interference with viewing the food product stored in the product display area 24 . In some constructions, the conductive film may be adhered to the exterior surface of the glass member 37 , or alternatively, to the interior surface and the exterior surface.
Referring to FIGS. 1-3 , the base 14 defines refrigeration unit compartments 38 that support refrigeration units 40 . As shown in FIGS. 1-3 , the compartments 38 are covered by a removable grill 42 , and include front side openings 43 for inserting and removing the refrigeration units 40 relative to the case 12 . The refrigerated merchandiser 10 is equipped with a harness and quick connect features for quickly coupling the refrigeration units 40 electrically to the case 12 . Although two compartments 38 are illustrated, fewer or more than two compartments 38 (and refrigeration units 40 ) can be provided in the merchandiser 10 depending in part on the length of the merchandiser 10 and the amount of cooling needed to condition the product display area 24 .
With reference to FIGS. 3 and 4 , each refrigeration unit 40 defines a modular unit that can be inserted into and removed from one compartment 38 . As illustrated in FIGS. 2-4 , the refrigeration unit 40 defines a closed refrigerant circuit and includes an evaporator 44 , a compressor 56 (e.g., one compressor or several compressors in an assembly), and a condenser 46 . The refrigeration unit 40 can also include other components.
The evaporator 44 (e.g., microchannel or round tube plate-fin) is fluidly coupled with the compressor to deliver evaporated refrigerant from the evaporator to the compressor, and is fluidly coupled with the condenser to receive cooled, condensed refrigerant from the condenser 95 . An expansion valve (not shown) is disposed between the evaporator 44 and the condenser to create a pressure differential and to control the pressure of the refrigerant fluid delivered to the evaporator 44 . As illustrated, the refrigeration unit 40 is positioned in the compartment 38 so that the evaporator 44 is disposed adjacent the rear wall 16 . The evaporator 44 is in communication with an air passageway 70 disposed within the case 12 and in communication with the product display area 24 . As illustrated, fans 54 are coupled to the evaporator to direct an airflow through the evaporator 44 and the air passageway to the product display area 24 . With reference to FIG. 4 , an evaporator pan 76 is positioned under the evaporator 44 to collect any condensed moisture dripping from the evaporator 44 .
The evaporator 44 is mounted to a dividing wall 48 , and the compressor and the condenser 46 are separated from the evaporator 44 by the dividing wall 48 . As illustrated, the compressor 56 and the condenser 46 are mounted on supports 50 that are coupled to the dividing wall 48 and are disposed adjacent and accessible from a front of the case 12 when the refrigeration unit 40 is installed in the merchandiser 10 . Referring to FIGS. 3 and 4 , support 50 includes forward gripping portions 96 that provide an operator with a convenient gripping surface for moving a refrigerator system 40 into or out of the accessible compartment 38 .
As is known in the art, the evaporator 44 receives a saturated refrigerant that has passed through an expansion valve (not shown). The saturated refrigerant is evaporated as it passes through the evaporator 44 as a result of absorbing heat from the airflow passing over the evaporator assembly 44 . The absorption of heat by the refrigerant allows the temperature of the airflow to decrease as it passes over the evaporator assembly 44 . The heated or gaseous refrigerant then exits the evaporator 44 and is pumped back to the compressor 56 for re-processing into the refrigeration unit 40 . The cooled airflow exiting the evaporator assembly 44 via heat exchange with the liquid refrigerant is directed through the remainder of the air passageway and is introduced into the product display area 24 where the airflow will remove heat from and maintain the food product at desired conditions.
The refrigerated airflow provided by the evaporator 44 conditions the product display area 24 within a predetermined temperature range based on the type of product supported in the product display area 24 . When the merchandiser 10 is a low temperature merchandiser, a low temperature refrigeration unit 40 is positioned in the compartment 38 to condition the airflow so that the product display area 24 is maintained, for example, at or below 32 degrees Fahrenheit. When the merchandiser 10 is a medium temperature merchandiser, a medium temperature refrigeration unit 40 is positioned in the compartment 38 to condition the airflow so that the product display area 24 is maintained within a temperature range of for example, 33-41 degrees Fahrenheit.
The refrigeration units 40 can be either low temperature refrigeration units or medium temperature refrigeration units. Both low and medium temperature refrigeration units include an electronic control 66 (e.g., for controlling the components of the systems 40 based on the desired product display temperature and other factors). The illustrated electronic controls 66 are mounted to the supports 50 , and the electronic controls 66 can be factory preset or adjusted prior to or during installation of the refrigeration unit 40 .
The refrigeration units 40 are exchangeable. Thus, a low temperature refrigeration unit 40 is replaceable with a medium temperature refrigeration unit 40 , and vice versa, to selectively alter the temperature range of the product display area 24 . Alternatively, a damaged or older refrigeration unit 40 is replaceable by a new refrigeration unit 40 .
In some constructions, the merchandiser 10 can include a partition (not shown) that divides the product display area 24 into a low temperature and medium temperature product display areas 24 a , 24 b . The partition can be permanent or removable, and defines a vertical wall that extends from the canopy to the base. The partition can be coupled to the case 12 via a quick lock system or another quick attach and release system. Depending on how the partition is installed in the case 12 , one or more of the shelves 26 may be removed prior to insertion of the partition. Depending on the length of the merchandiser 10 , one or more partitions can be provided to define a plurality of product display areas 24 .
When a partition is provided in the merchandiser 10 , a low temperature refrigeration unit 40 can be installed into one compartment 38 so that the corresponding product display area 24 a conditions product within the low temperature range, and so that at least one of the doors 28 corresponds with the low temperature product display area 24 a and low temperature refrigeration unit 40 . A medium temperature refrigeration unit 40 can be installed into another compartment 38 so that the corresponding product display area 24 b conditions product within the medium temperature range, and so that at least another of the doors 28 corresponds with the medium temperature product display area 24 b and medium temperature refrigeration unit 40 . In these constructions, each section of the merchandiser 10 can include at least one independently operable sensor 80 to control the door heaters 39 , as described in detail below, based on the product display temperature (or other factors) and whether the refrigeration unit 40 for that section is a low temperature refrigeration unit 40 .
FIG. 1 shows that the merchandiser 10 further includes a control system that has one or more sensors disposed inside the case 12 , and a controller 90 in electrical communication with the merchandiser 10 , the sensors, and the door heaters 39 . As illustrated, the sensors are located adjacent the doors and are in communication with the product display area 24 to detect the product display temperature. In other constructions, the sensors can be located elsewhere in the merchandiser 10 (e.g., located along an interior portion of side walls 18 , 20 , behind the mullions 32 , etc.), and can sense other characteristics of the case 12 that relate to fogging and condensation of the doors. The sensors are also in electrical communication with the controller 90 to deliver signals indicative of the product display temperature. The illustrated sensors are defined by bi-metal switches wired in series with the door heaters 39 to control the door heaters 39 based on the sensed temperature. The sensors can take any suitable form for detecting the temperature of the product display area 24 or other characteristics of the case 12 , and for controlling the door heaters 39 .
The controller 90 is in remote electrical communication with the door heaters to regulate current through the conductive film based on the signals received from the sensors. The current is passed through the conductive film, which heats the glass member to remove condensation. Alternatively the controller 90 can be attached to the merchandiser 10 in any suitable location (e.g., the base 14 , on the case canopy 22 , etc.).
Generally, condensation only forms on the doors 28 when the merchandiser 10 is a low temperature merchandiser. FIG. 5 illustrates an exemplary control process for the merchandiser 10 to determine, among other things, when to apply heat to the doors 28 . At step 100 , the controller determines the status of the merchandiser 10 (e.g., whether the merchandiser 10 is operational, the conditions of the components supported by the merchandiser 10 , etc.). At step 104 , the controller determines whether the merchandiser 10 is being operated as a low temperature merchandiser 10 (i.e. has a low temperature modular refrigeration unit 40 disposed in a compartment 38 ), or a medium temperature merchandiser 10 (i.e. has a medium temperature modular refrigeration unit 40 disposed in a compartment 38 ). For example, the controller 90 can make this determination based on the product display temperature detected by the sensors, based on manual input from an operator, based on communication with the electronic controls 66 , or based on other information indicative of the type of refrigeration unit 40 being used. If the merchandiser 10 has a medium temperature refrigeration unit 40 (i.e., the answer at step 104 is “No”), the door heaters 39 are turned off at step 108 . The process then returns to step 100 and repeats. In some constructions, the control process can include a time delay after step 108 so that the determination at step 104 repeats at predetermined time intervals. In other constructions, the control process only makes the determination at step 104 once each time the merchandiser is varied from an “off” state to an “on” state.
If the merchandiser 10 has a low temperature refrigeration unit 40 (i.e., the answer at step 104 is “Yes”), the control process determines whether the product display temperature is above the predetermined temperature threshold at step 112 . If the product display temperature is below this threshold (i.e., the answer at step 104 is “No”), the controller 90 keeps the door heaters 39 in an “off” state (i.e., no current is passed through the conductive film) at step 116 . The control process then returns to step 100 and repeats.
If the product display temperature is above the predetermined temperature threshold (i.e., the answer at step 112 is “Yes”), the door heaters 39 are turned on at step 120 to inhibit or remove condensation from the doors 28 . The control process then proceeds to step 124 to determine, at a later time, whether the product display area temperature is at or below the predetermined temperature threshold. If the product display temperature remains above the predetermined temperature threshold (i.e., the answer at step 124 is “No”), the door heaters 39 remain on and the control process returns to step 112 . If the product display temperature is at or below the predetermined temperature threshold (i.e., the answer at step 112 is “Yes”), the door heaters 39 are turned off at step 116 . The control process then returns to step 100 and repeats.
The control system regulates the merchandiser 10 so that when the merchandiser 10 is a low temperature merchandiser and the product display temperature rises above a predetermined temperature threshold, the controller 90 activates one or more of the door heaters 39 to warm the corresponding doors 28 to minimize or remove condensation on the doors 28 . The control system also regulates the merchandiser 10 so that when the merchandiser 10 is a medium temperature merchandiser, the door heaters 39 are kept off regardless of the temperature in the product display area 24 .
The modular refrigeration units 40 can be removed and installed relative to the case 12 so that the merchandiser 10 can operate as a low temperature merchandiser or a medium temperature merchandiser, or both. As illustrated, the controller 90 controls the door heaters 39 so that the doors 28 are only heated when the refrigeration unit 40 is a low temperature system and the product display area temperature is above the threshold. The sensors 80 keep the door heaters 39 off when the merchandiser 10 is a medium temperature merchandiser to limit the amount of power needed by the merchandiser 10 to operate. In constructions of the merchandiser 10 including a partition installed in the product display area 24 , the sensors 80 can regulate each product display section so that the door heaters 39 are activated only when the section is a low temperature section and the corresponding product display temperature is above the predetermined threshold.
A single merchandiser 10 can be modified so that the merchandiser 10 encompasses a low temperature merchandiser, a medium temperature merchandiser, or a low and medium temperature merchandiser depending on desired characteristics for the merchandiser 10 . The product display area or areas within the merchandiser 10 can be can be controlled and adjusted as desired by removing and replacing the low or medium temperature refrigeration units 40 with other low or medium temperature refrigeration units, and by removing or adding partitions within the merchandiser 10 . For example, a low temperature refrigeration unit 40 in the merchandiser 10 can be replaced by removing the grill and the low temperature refrigeration unit 40 , and installing another low temperature refrigeration unit 40 or a medium temperature refrigeration unit 40 in the compartment 38 . Likewise, a medium temperature refrigeration unit 40 can be replaced by a low temperature refrigeration unit 40 or another medium temperature refrigeration unit 40 .
Various features and advantages of the invention are set forth in the following claims. | A merchandiser system includes a case that has a door and a door heater. The system includes a low temperature refrigeration unit sized to fit within a case compartment and to operably couple to the case to maintain food product within a low temperature range. The system also includes a medium temperature refrigeration unit sized to fit within the compartment and operably couple to the case to maintain food product within a medium temperature range. The system includes a controller in communication with the door heater and is programmed to activate the door heater only in response to the low temperature modular refrigeration unit positioned within the compartment. One of the low temperature refrigeration unit and the medium temperature refrigeration unit is removably coupled to the case within the compartment, and is replaceable by the other refrigeration unit to change the temperature range of the product display area. | 5 |
RELATED U.S. APPLICATION
[0001] This application is Continuation in Part of non-provisional application Ser. No. 12/853,511 titled “method and Apparatus for Remote Monitoring of Dailey Dispensing of Medication” filled on Sep. 13, 2011.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of wireless health Monitoring system, specifically to the monitoring of daily dispensing of medications.
DESCRIPTION OF THE RELATED ART
[0003] As the national health care systems cope with the increasing the cost of care for the growing number of patients with chronic diseases, or an elderly requiring a daily dose of medication to sustain their quality of life, there is a need for a low cost, low maintenance monitoring system that insures that the patient actually remembers to take his/her daily dose of medication at the correct time.
[0004] In recent years, the use of mobile devices and, in particular, cellular telephones has proliferated. As a result, cellular telephones or other wireless devices, installed in primary residences, are considered as candidates to provide various health care-monitoring and even health care-delivering functions.
[0005] Considering that strict adherence to the timely dispensing of medication is critical to the quality of provided health care, combining of simple dispensing mechanism with the ubiquitous cellular phone can provide the benefits of virtual medical supervision of the medication dispensing regime at very low cost.
[0006] Many medication dispensing methods were proposed in the past—from very simple containers with daily compartments and a textual information cards, through programmable dispensing systems, to complex systems intended for centralized dispensing in hospitals. However, none of these systems provides a quality of medical supervision at costs applicable for personal use.
[0007] Most dispensing systems intended for a personal use consist of a daily, weekly, etc. containers and textual information card describing dosage to be dispensed at each dispensing period. Sometimes the supplied information card allows the patient to enter “reminder” information. While previous devices provide some form of organized dispensing for personal use, they lack the ability to verify usage and/or to allow intervention should usage not occur or be inaccurate. Example of previously described systems may be found in: U.S. Pat. No. 6,550,618 and U.S. Pat. No. 7,584,849 and U.S. Pat. No. 7,543,718 and U.S. Pat. No. 7,621,231
[0008] Another type of a medicine dispensing system intended for a personal use consists of a programmable device capable of time-tracking and reminding the patient when to take their next medication. Such devices provide some enforcement of medication regime, but their capability is limited to a simple audio or visual reminder and unable to verify medication compliance or receive instructions from a remote medical supervisor. Example of such systems may be found in: U.S. Pat. No. 7,6539,120, U.S. Pat. No. 7,359,765.
[0009] Another type of medicine dispensing system embeds some supervisory function either in the medication packaging, such as in U.S. Pat. No. 7,612,662 or US Patent Application 20090301925, or rely on complicated electromechanical system where each type of the medication (pill) resides in a separate container with the dispensing from those multiple containers controlled by the micro-processor, such as in U.S. Pat. No. 7,711,449, or an electromechanical pill dispenser such as describe in U.S. Pat. No. 7,713,238. A common problem of these systems is their reliance on new packaging technology (e.g. inclusion of RFID into every package, while providing no solution for multi-pill containers), or proposing complicated electromechanical dispensers unable to hold different size(s) of the medication. Moreover, none of these devices provide feedback or other important information to the medical supervisor regarding patient compliance of medication consumption.
SUMMARY OF THE INVENTION
[0010] This invention allows for the remote monitoring of the daily dispensing of prescription drugs by at-home care, an elderly patient or a clinical trial patient. The system consists of a dispensing unit equipped with sensor(s), a monitoring application and a wireless terminal, such as a cell-phone providing access to the Internet. The monitoring application and wireless Wide Area Network (WAN) modem can reside within the dispensing unit or alternatively, the dispensing unit can communicate with the application residing in the user/patient cell phone over suitable RF interface, such as Bluetooth, etc.
[0011] The proposed invention integrates a simple medication dispensing container similar to one well known from prior art with a sensitive weighting mechanism in the form of a scale or balance, or Microelectromechanical System (MEMS) sensor(s) interfacing over a short range wireless link similar to Bluetooth with the medicine dispensing application residing in the patient's cell phone.
[0012] Such a system can provide real-time monitoring of medication compliance by alerting the user when the next set of medication should be taken. In addition the dispenser can sense the removal of the medication via weight change and thereby help to confirm compliance of the dispersion of the medication. Furthermore, if the medication is not dispensed at the prescribed time, such a system may provide a local alert to the patient and if no dispensing is again verified, a remote alerts a list of patient medical supervisors (family, friends, physicians, etc) that medication compliance has not been confirmed.
[0013] Furthermore, if such system is equipped with additional monitoring sensors such as: heart rate, blood pressure, glucose level, etc, it can provide close-loop monitoring of the patient's response to the drug delivery, thereby allowing a physician to change the medication when a negative response (or no response) to the prescribed drug has been detected. Beside compliance verification, the cell-phone based application guarantees a continuous and secure connection with clinical and family supervisors, thereby providing low cost and reliable patient care. Such a monitoring system can operate using any of wireless WAN technology such as: cdma2000 (1xRTT and EV-DO), UMTS, LTE, WiMax, etc.
[0014] Various embodiments for a method for monitoring the daily dispensing of medication are presented.
[0015] In one embodiment, the method may include a daily medication container integrated with a scale or balance which is capable of measuring the weight of dispensed medication and an integrated wireless Persona Area Network (PAN) such as Bluetooth which interfaces with the monitoring application residing in the patient's cellular phone.
[0016] In some embodiments, the daily medication container is a separate container of any sort which can be placed on a scale or balance which is capable of measuring weight of dispensed medication integrated with PAN wireless network such as Bluetooth which interfaces with the monitoring application residing in the patient's cellular phone. In such embodiment the cell phone based application must be able to calibrate weight (and subsequent changes over time) of the medication container.
[0017] In another embodiment, the daily medication container is equipped with MEMS sensors capable of detecting the dispensing of the medication either by measuring the change of the weight, before and after dispensing, and communicate over the integrated PAN wireless network such as Bluetooth with the monitoring application residing in the patient's cellular phone.
[0018] In all of these embodiments, the monitoring application performs all the functions related to patient and medical supervisor authentication, calibration of medication containers and medication, supervision of dispensing time and medication quantity including alerts and notification to the user/patient, “book-keeping” of the dispense medication, scheduling of the next dispensing time, and in case of detected non-conformance to the prescribed dispensing regime executes local and remote alarms to other interested third parties.
[0019] Furthermore, when the application is augmented with additional sensors capable of monitoring specific bio-functions such as: pulse, heart rate, arrhythmia, blood pressure, etc. monitors, the proposed method may provide near-real-time feedback about the effects of the medication to the supervising medical professional.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
[0021] FIG. 1 is an exemplary medicine dispensing compliance system according to one embodiment;
[0022] FIG. 2 is an exemplary block diagram of the medicine dispensing unit;
[0023] FIG. 3 is a flowchart of an exemplary method for processing of the cell-phone based medicine dispensing application;
[0024] FIG. 4 is an exemplary flow of entering patient medication schedule.
[0025] FIG. 5 is a flowchart of an exemplary method of the supervisory process of the exemplary medicine dispensing application.
[0026] FIG. 6 is a block diagram of the medicine dispensing and analysis system;
[0027] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The following is a glossary of terms used in the present application:
[0029] Memory Medium—Any of various types of memory devices or storage devices. The term “memory medium” is intended to include an installation medium, e.g., a CD-ROM, floppy disks 104 , or tape device; a computer system memory or random access memory such as DRAM, DDR RAM, SRAM, EDO RAM, etc.; or a non-volatile memory such as a magnetic media, e.g., a hard drive, or optical storage. The memory medium may comprise other types of memory as well, or combinations thereof. In addition, the memory medium may be located in a first processor in which the programs are executed, or may be located in a second different processor which connects to the first processor over a network, such as wireless PAN or WAN network or the Internet. In the latter instance, the second processor may provide program instructions to the first processor for execution. The term “memory medium” may include two or more memory mediums which may reside in different locations, e.g., in different processors that are connected over a network.
[0030] Application—the term “application” is intended to have the full breadth of its ordinary meaning. The term “application” includes: 1) a software program which may be stored in a memory and is executable by a processor; or 2) a hardware configuration program useable for configuring a programmable hardware element.
[0031] Software Program—the term “software program” is intended to have the full breadth of its ordinary meaning, and includes any type of program instructions, code, script and/or data, or combinations thereof, that may be stored in a memory medium and executed by a processor. Exemplary software programs include programs written in text-based programming languages, such as C, C++, Visual C, Java, assembly language, etc.; graphical programs (programs written in graphical programming languages); assembly language programs; programs that have been compiled to machine language; scripts; and other types of executable software. A software program may comprise two or more software programs that interoperate in some manner.
[0032] Computer System—any of various types of computing or processing systems, including cell phone, personal computer system (PC), mainframe computer system, workstation, network appliance, Internet appliance, personal digital assistant (PDA), television system, grid computing system, or other device or combinations of devices. In general, the term “computer system” can be broadly defined to encompass any device (or combination of devices) having at least one processor that executes instructions from a memory medium.
[0033] Medical Supervisor—in the context of this invention, any person or institution (pharmacy, medical personnel, family member, etc.) authorized to enter or modify dispensing operational parameters, receive remote alerts, notifications or transmission of monitored data.
[0034] Patient—in the context of this invention, person supervised by the medicine dispensing application.
[0035] Medication Schedule—in the context of this invention, information pertaining to timing and dosage of medications, medication related instruction and other information provided to the patient by the pharmacy, or physician.
DESCRIPTION OF PREFERRED EMBODIMENT
[0036] The proposed method leverages on the properties of wireless Personal Area Network (PAN) such as Bluetooth and wireless Wide Area Network (WAN), such as a cell-phone, and combines the inherent benefits provided by those networks with the medicine dispensing device which may take the form of a simple multi-compartment container, where the compartment are labeled with the day-of-the-week and a weighting station, capable of detecting when the medications are removed and able to communicate with the cell-phone based monitoring application over short range wireless link similar to Bluetooth
[0037] Assuming that both the precise weight of the dispensing container and the single dosage of medication is known and calibrated, and the total number of individual doses in the container is known, one can determine if a single dosage of medication was dispensed by measuring the total weight of the dispenser containing medication before and after dispensing.
[0038] Such dispenser and associated weighting device is equipped with a PAN wireless communication link, such as Bluetooth. The device is controlled over this said PAN communication link by the Dispensing Application control software residing in the cell-phone which in turn is connected to the wireless WAN and consequently to the Internet. In this fashion one may provide a reliable remote medication dispense monitoring system.
[0039] In such a system the intelligence and supervision is embedded in the medication dispensing application software residing in the user/patient cell-phone. This application is able to determine the time and dosage which needs to be dispense, alert the user/patient of the need to dispense medication, verify the correct amount of medication was dispensed, and if not dispensed then alert the user. In the case that this alert provides no verifiable results, additional alerts will then be extended to “medical supervisors” or other interested third parties thereby alerting important others that medical compliance has not been achieved.
[0040] This invention integrates wireless access technology with a simple dispensing unit to provide reliable remote medication compliance system without constant supervision by a health professional or family member. An example of such system is presented in FIG. 1 and FIG. 2 .
[0041] The medicine dispensing unit 100 consisting of a weekly medication container 110 , where each compartment is dedicated for a single day (dosage) of the medications, a weighting unit 120 capable of measuring the weight of the dispensed medication, a dispense unit control program 130 in form of stand-alone software of integrated into radio interface Media Access layer (MAC) functionality, and a PAN wireless interface 140 in form of Bluetooth, etc. communicating over the 141 RF link with the application.
[0042] The medicine dispensing application 300 resides inside the wireless phone 200 program memory and is under general control of phone Operating System (OS) 201 and communicates with the dispensing unit 100 over the phone Bluetooth modem 210 and with the wireless WAN network over the cellular modem 200 and RF 221 . Furthermore, the medicine dispensing application interface with the phone user through the phone User Interface (UI) 202 , speaker 203 and microphone 204 .
[0043] The wireless phone (also referred to as access terminals) 200 may include any type of device which may be used in a cellular network, e.g., RF communication. Mobile devices 200 may include cellular (or cell) phones (including smart phones), personal digital assistants (PDAs) with mobile communication capabilities, laptops or computer systems with mobile communication components, and/or any device which is operable to communicate with a cellular network. The mobile devices may use various different protocols, e.g., cdma2000 (1xRTT and EV-DO), UMTS, LTE, WiMax, or others).
[0044] The functional relationship of various operational parameters necessary to control dispensing application is presented in FIG. 3 . Operational parameters, current dispense status (medication status after last dispense period), and the and the current measurement obtained from the dispense unit are presented to the Dispense Supervision Task 301 .
[0045] Operational parameters, such as: User Parameters 303 , medication and medication Calibration Parameters 302 , medication instructions and messages (local alerts 305 , external alerts 306 ), pharmacy message, etc. may be entered/modified after authentication 302 by the pharmacy, physician or by the user, locally, or remotely. The local entry using UI 202 may consist of manual entry or scanning of the bar-code such as QR code containing user information or remotely 2014 using the WAN/PAN radio interface.
[0046] When operational parameters are entered through a scan of the bar-code, such as QR (Quick Response) code, then the method to enter such parameters consist of three phases: 1) data entry; 2) data extraction, formatting and code generation; 3) data upload. An exemplary procedure for the first two steps of this process is presented in FIG. 4 .
[0047] In phase 1, the pharmacy staff fills the user and pharmacy info, medication type and schedule as well as medication specific instructions, and general messages into medication schedule template.
[0048] In phase 2, data from the medication template is extracted and processed by a Script/Program, such as Pearl, etc. to remove all redundancies (spaces, new lines, etc.) and formatted to allow easy extraction of parameters into the application, then the QR code is generated.
[0049] In phase 3, the QR code is scanned by the application, information is extracted and application DB is populated with operational parameters.
[0050] The first information, 3031 , may include identity information of the user, pharmacy, medical personnel and plurality of parameters indicating phone numbers or IP addresses of family members, medical personnel, etc.
[0051] The second information 3032 may include the exact weight of each individual medication, or the total weight of medication for dispense in a specific period as well as a specific actions if one of the prescribed medication was not dispensed. Medication weight may be calibrated at the pharmacy and included into the bar-code, or may be calibrated by the user during self-calibration process 304 .
[0052] The third information 3033 may include the dispensing schedule and more specifically plurality of parameters such as: medication name using NDC code (National Drug Code); number of times and amount of medication to be dispensed at each period; length of the dispensing cycle; medication request refill; special instructions, such as: advise to take medication with/without food/liquid, before/after meal; requests to monitor specific bio-functions, such as: heart rate, blood pressure, etc. at the specified interval before and/or after medication dispense; pharmacy specific messages, such as: special offers, etc. Additionally, it may contain the amount of time application will wait for the responses, i.e. wake-up time of the dispensing unit, conformation by the user or response to various alert messages.
[0053] The fourth information 3034 may contain a list of valid responses pre-approved by the medical supervisor used to cancel alerts. Those valid responses may be selected from the list included into the pharmacy instruction messages embedded into the medication schedule.
[0054] The fifth information 3035 may contain the type of local alert messages and the actions the monitoring application must take in such cases. More specifically, it may contain the selection of one or more of the predefined audio and/or textual messages intended to alert the user/patient about the next medication dispensing or in case such dispensing didn't occurred or if the dispensing amount was different from the scheduled one or in the case the total medication weight before dispensing was not equal to the weight stored after the previous dispensing.
[0055] The six information 3036 may contain the type of remote alerts messages and the actions the monitoring application must take in such cases. More specifically, it may contain the selection of one or more of the predefined audio and/or textual messages intended to alert the patient medical supervisor about the discrepancy in medication dispensing or in case medication dispensing didn't occur, or if the dispensing amount was different from the scheduled one or in the case the total medication weight before dispensing was not equal to the weight stored after the previous dispensing and the local alert was not canceled by the user/patient corrective action.
[0056] The information contained within the operational parameters are used by the Dispensing Supervision task 301 from FIG. 3 . The operation of the Dispense Supervision task is presented in FIG. 5 and described below.
[0057] In Step 1 of FIG. 5 after the RESET, the Scheduler programs all appropriate timers with the values defined by the third information 3033 , then start the application. When the next dispense interval arrives, application enters Step 3 to wake-up the dispensing unit by sending appropriate commands over the PAN wireless interface, then enters Step 4 waiting for medication dispensing and Step 7 to alert patient about the incoming medication period.
[0058] In Step 4, when the weighting unit of the dispenser is READY, the application retrieves user parameters stored in second information 3032 , the weight values stored in Dispensing Buffer 3030 after the previous dispense, and compare those values with the current wait measurement W k received from the weighting unit.
[0059] If the calibrated weight obtained in Step 3 is within the limit of the current dispensing cycle, the dispensing application enters Step 4 and waits for a length of time specified in the third information 3033 then records the dispensing.
[0060] However, if the calibrated weight is different than the one retrieved form the Dispensing Buffer 3030 after the previous dispensing period, the application enters into Step 7 and issues local alerts. Application will stay in Step 7 until the local alert is canceled or until the time stored in third information 3033 elapses. Local alarms may be in the form of predefined audio or textual messages.
[0061] In response to local alarm, a patient may select on of the entries from the list of valid reasons pre-approved by the medical supervisor and stored in Approved Reasons Buffer 3034 . One entry in such list may be patient's need to take some of the medication ahead of time due to his/her condition, another may be the patient's schedule conflict, yet another may be a recent directive by the medical personnel. If a valid reason for such discrepancy was received, the new weight value is calculated in Step 6, the Dispensing Buffer 3030 is updated and the dispensing process may continue to Step 4.
[0062] Local alerts and the pre-approved reason for temporary deviations in the amount (weight) of medication to be dispensed in the current dispensing period allows for emergency dispensing as well as recovery from minor patient or system errors, such as: out of RF coverage area; battery power down, etc. while still providing high reliability and minimizing unnecessary external alarms.
[0063] If the local alert is not cancelled within the period of time defined in third information 3033 , the application enters Step 8 and sends an external alarm to the predefined recipients over the cellular network. Such external alarm may have a form of predefined SMS, or voice messages or patient related data.
[0064] After external alarm is sent, application waits for the intervention from the medical supervisor, which will cancel such alarm. To cancel the alarm, the medical supervisor must log into the application using either phone UI 202 or remotely using API interface 2011 (remote access if such functionality is provided or command embedded in the SMS message), after appropriate authentication. If such intervention is not received within the time period specified in third information 3033 , the application goes to the STOP state, from which it can only recover after RESET provided of by the medical supervisor.
[0065] When application is in Step 4 and the change in the dispensing container weight was detected, and the dispensing weight change is equal to the predefined dosage, the dispensing application subtracts the weight of the current dispense from the previous container weight and through Step 6 updates the Dispensing Buffer which then is used as the calibration value for the next dispensing period. Additionally, through the Step 5 it updates the Scheduler and instructs the dispensing unit to enter low-power or SLEEP mode.
[0066] When application is in Step 4 and the change in the dispensing container weight was detected, and the weight change is not equal to the predefined dosage weight, the dispensing application enters Step 7 to alert the patient. In response to the local alarm, the patient may select one of the entries from the list of valid reasons pre-approved by the medical supervisor and stored in Approved Reasons Buffer 3034 .
[0067] If this local alert is not cancelled within the period of time specified in third information 3033 , application enter Step 8 sending an external alarm to the predefined recipients over the cellular network. Such external alarm may have a form of predefined SMS, or voice messages, or patient related data. After external alarm is sent, application waits for the intervention from the medical supervisor, which will cancel such alarm. To cancel such alarm the medical supervisor must log into the application using either phone UI 202 or remotely using API interface 2011 (remote access if such functionality is provided or command embedded in the SMS message), after appropriate authentication. If such intervention is not received within the time period specified in third information 3033 , the application goes to the STOP state, from which it can only recover after RESET provided of by the medical supervisor.
[0068] Depending on the type of the dispensing container design, the dispensing application may instruct the container to open the “current” compartment, or wait for an ACCEPT command from a dedicated unit interface (i.e. push-button), or simply monitor the change in the weight of the dispensing container.
[0069] When the application 300 of FIG. 6 includes additional monitoring functionality to support monitoring of various bio-function, such as: blood pressure 400 ; glucose level sensor 500 , heart rate/arrhythmia sensor, etc. it can provide real-time feedback to the medical personnel regarding patient's reaction to medication.
[0070] In such case, at the predefined time for medication dispensing, and after alerting the patient in step 2 and calibration procedures in step 3 application 300 performs all normal procedures specified for the current dispense period. Then it enters in the Medication Response Monitoring mod, in which depending on the parameters stored in the second information 3032 and the third information 3033 it will perform monitoring of specified bio-functions. The results of such measurements may be store in the local RAM or sent to the medical supervisor.
[0071] In case patients related data are to be sent to the external destination, the application task 307 formats the data records then using encryption service 2013 sends data to the cellular modem for transmission over the WAN wireless network. | A remote monitoring of the daily dispensing of prescription drugs by at-home care, an elderly or clinical trial patient is proposed. The system consists of a dispensing unit equipped with weight sensing mechanism such as scale or balance which communicates with the monitoring application residing in the wireless terminal, such as cellular phone over the Personal Area Network (PAN) wireless interfaces such as Bluetooth. The monitoring application provides supervision over the medication dispensing process as well as communication with unauthorized medical supervisor using wireless Wide Area Network (WAN) connection to the Internet. | 0 |
BACKGROUND
Personal communication, productivity, and entertainment devices such as cellular phones, PDAs, portable email devices, tablet computers, e-books, hand-held games, portable media players, etc. (all referred to hereafter as “smart devices”) are known to include features such as graphical user interfaces on color touch screens, Bluetooth and/or WiFi capability, etc. Increasingly, such smart devices also incorporate support for ancillary applications (hereafter referred to as “apps”) for example calendars, email, maps and navigation, etc. Such ancillary applications may be pre-installed in a smart device or may be made available for download by a user. Certain apps may comprise an ability to issue commands to entertainment and other appliances, for example in conjunction with a GUI offering the features and functionality of a universal remote control, as a user convenience in conjunction with a TV guide display to enable channel selection, etc.
In order to effect such control functionality, it is known in the art to provision a smart device with hardware and/or firmware suitable for the generation of appliance command signals. Provision of such hardware and/or firmware may be internal, i.e. built into a smart device; may be external, i.e., in the form of add-on attachments to a smart device; or may be discrete, i.e., in the form of a separate self-contained unit which receives wireless signals from a smart device and converts them to appropriate appliance command transmissions.
SUMMARY OF THE INVENTION
This invention relates generally to systems and methods for equipping a smart device with appliance command functionality, and in particular to the provision of a discrete device for receiving and converting appliance command requests from a smart device, which discrete device may also include the ability to directly issue appliance commands in response to user input.
It is known in the art to provide a self-contained bridge device, comprising for example a receiver, a processing/translation means, and a transmitter, which bridge device is capable of receiving generic appliance command requests from a smart device via, for example, an RF link such as Bluetooth or WiFi and translating these command requests into appliance-recognizable transmissions, these transmissions usually (but not necessarily) taking the form of infrared (“IR”) encoded signals which may emulate a target appliance's original equipment remote control. The availability of such bridge devices greatly facilitates the deployment of remote control apps for smart devices, since apps intended for use in conjunction with bridge devices may then comprise a simple software GUI with no requirement for additional hardware or firmware installed onto or built into the target smart device.
However, the use of smart device apps for appliance control, with or without prior art bridge units as described above, may remain less than optimal in many environments. Since a smart device, particularly a smart phone, is essentially a personal device, it may not be readily available for communal use when several persons are present in the environment to be controlled, for example a family watching TV in the home. Furthermore, minor equipment adjustments which necessitate repeated activation of a smart device remote control app, for example such as may occur each time a TV commercial airs and audio volume needs to be adjusted, may constitute a considerable inconvenience to the owner of the smart device.
The improvement presented herein addresses these and other shortcomings. An inventive bridge unit provides the RF reception and command translation functionality of prior art units while additionally accepting direct control inputs for a limited number of commonly used appliance command functions. These direct control inputs may take the form of pushbuttons, knobs, touchpads, etc., located on the physical bridge unit itself, which unit may be designed to be placed in the environment at an easily accessible location such as, for example, on a coffee table. In this manner, commonly used adjustments such as volume or muting, playback pause/resume, etc. may be made readily available without necessitating the use of a smart device, whilst the more sophisticated GUI provided by a smart device remote control app may be advantageously utilized when more complex or less frequently used command functions are to be performed, and/or where appliance or media control is a feature of the app, for example when implementing functionality such as described in co-pending U.S. patent application Ser. No. 12/327,875 “System and Method for Interacting with a Program Guide Displayed on a Portable Electronic Device” or Ser. No. 12/761,161 “System and Methods for Enhanced Metadata Entry” both of common ownership and both incorporated herein by reference in their entirety.
A better understanding of the objects, advantages, features, properties and relationships of the invention will be obtained from the following detailed description and accompanying drawings which set forth illustrative embodiments and which are indicative of the various ways in which the principles of the invention may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the various aspects of the invention, reference may be had to preferred embodiments shown in the attached drawings in which:
FIG. 1 illustrates an exemplary system in which an exemplary bridge device in accordance with the instant invention may be used alone and/or in conjunction with a smart device as a controlling device;
FIG. 2 illustrates in block diagram form the major components of the exemplary bridge device of FIGS. 1 and 3 ;
FIG. 3 further illustrates the exemplary bridge device of FIG. 1 ;
FIG. 4 illustrates an exemplary operational flow as may be implemented in one embodiment of the bridge device of FIGS. 1, 2 and 3 ;
FIG. 5 illustrates a system incorporating an exemplary alternate embodiment of a bridge device in accordance with the instant invention; and
FIG. 6 illustrates a system incorporating a yet further exemplary alternate embodiment of a bridge device in accordance with the instant invention.
DETAILED DESCRIPTION
Turning now to FIG. 1 , there is illustrated an exemplary system in which a smart device, such as a smart phone 102 , may be adapted to control various controllable appliances, such as a television 108 , a cable set top box combined with a digital video recorder (“DVR”) 114 , an AV receiver 112 , and a DVD payer 110 . Transmission of commands to the appliances may be facilitated by a combination command input and bridge device 100 , which when functioning as a bridge device may receive wireless signals 104 from an app resident in smart phone 102 and convert these to appropriate infrared (“IR”) signals 106 recognizable by the target appliances, and when functioning as a command input device may accept user mechanical input via one or more knobs or switches and likewise convert these inputs to appropriate IR signals 106 ; all to cause the appliances to perform one or more operational functions. While illustrated in the context of a television 108 , DVR 114 , AV receiver 112 , and DVD player 110 it is to be understood that controllable appliances may include, but need not be limited to, televisions, VCRs, DVRs, DVD players, cable or satellite converter set-top boxes (“STBs”), amplifiers, CD players, game consoles, home lighting, drapery, fans, HVAC systems, thermostats, personal computers, etc. Also, while illustrated in the context of IR command transmissions, it will be appreciated that in general, command transmissions by bridge device 100 may take the form of any convenient IR, RF, hardwired, point-to-point, or networked protocol, as necessary to cause the respective target appliances to perform the desired operational functions. Further, while communications 104 , 106 , etc., between exemplary devices are illustrated herein as direct links, it should be appreciated that in many instances such communication may take place via a local area network or personal area network, and as such may involve various intermediary devices such as routers, access points, etc. Since these items are not necessary for an understanding of the instant invention, they are omitted from the Figures for the sake of clarity.
With reference to FIG. 2 , for use in commanding the functional operations of one or more appliances, an exemplary bridge device 100 may include, as needed for a particular application, a processor 200 coupled to a ROM memory 208 ; a RAM memory 210 ; a non-volatile read/write memory 206 ; user input means 220 such as hard keys, soft keys on a touch sensitive surface, knobs, sliders, etc.; transmission circuit(s) and/or transceiver circuit(s) 202 (e.g., IR and/or RF) for issuance of commands to controlled appliances; receiver and/or transceiver circuit(s) 204 for receipt of command requests, e.g., from a smart phone 102 ; means 218 to provide feedback to the user (e.g., one or more LEDs, illuminable keys, display, speaker, and/or the like); an input/output port 216 such as a serial interface, USB port, modem, Zigbee, WiFi, or Bluetooth transceiver, etc.; a power source 220 such as a battery or a mains power adapter; and clock and timer logic 212 with associated crystal or resonator 214 .
As will be understood by those skilled in the art, some or all of the non-transient, physically embodied memories 206 , 208 , 210 may include executable instructions (collectively, the bridge device program memory) that are intended to be executed by the processor 200 to control the operation of the bridge device 100 , as well as data which serves to define the necessary control protocols and command values for use in transmitting command signals to controllable appliances (collectively, the command data). In this manner, the processor 200 may be programmed to control the various electronic components within the controlling device 100 , e.g., to monitor the input means 220 and request receiver 204 , to cause the transmission of appliance command signals, etc. The non-volatile read/write memory 206 , for example an EEPROM, battery-backed up RAM, FLASH, Smart Card, memory stick, or the like, may additionally be provided to store setup data and parameters as necessary. While the memory 208 is illustrated and described as a ROM memory, memory 208 can also be comprised of any type of readable media, such as ROM, FLASH, EEPROM, or the like. Preferably, the memories 206 and 208 are non-volatile or battery-backed such that data is not required to be reloaded after battery changes. In addition, the memories 206 , 208 and 210 may take the form of a chip, a hard disk, a magnetic disk, an optical disk, and/or the like. Still further, it will be appreciated that some or all of the illustrated memory devices may be physically combined (for example, a single FLASH memory may be logically partitioned into different portions to support the functionality of memories 206 and 208 respectively), and/or may be physically incorporated within the same IC chip as the microprocessor 200 (a so called “microcontroller”) and, as such, they are shown separately in FIG. 2 only for the sake of clarity.
To cause the bridge device 100 to perform an action, the bridge device 100 may be adapted to be responsive to events, such as a sensed user interaction with input means 220 , receipt of a request from a smart phone 102 , etc. In response to an event, appropriate instructions within the program memory (hereafter the “bridge device operating program”) may be executed. For example, when a command request is received from a smart phone 102 , the bridge device 100 may retrieve from the command data stored in memory 206 , 208 , 210 a command value and control protocol corresponding to the requested function and device and transmit that command to an intended target appliance, e.g., TV 108 , in a format recognizable by that appliance to thereby control one or more functional operations of that appliance.
Bridge device 100 may comprise a universal controller, that is a device provisioned with a command data library which encompasses a multiplicity of command codes and protocols suitable for controlling appliances of various different model and manufacture. The library of command data may represent a plurality of controllable appliances of different types and manufacture, a plurality of controllable appliances of the same type but different manufacture, a plurality of appliances of the same manufacture but different type or model, etc., or any combination thereof as appropriate for a given embodiment. In all such cases, for selecting sets of command data to be associated with the specific appliances to be controlled (hereafter referred to as a setup procedure), data may be provided to the bridge device 100 that serves to identify each intended target appliance by its make, and/or model, and/or type. Such setup data allows the bridge device 100 to identify the appropriate command data set within the library of command data that is to be used to transmit recognizable commands in formats appropriate for such identified appliances.
The setup procedure for an illustrative bridge device 100 may comprise any method appropriate for a particular embodiment. For example, a setup procedure may entail one or more of: manipulating user input means 220 such as activating pre-defined combinations of buttons or other controls; performing configuration selection using an external system such as a PC or DVR 114 and downloading the resultant setup data to bridge device 100 via, for example, a USB port 216 or wirelessly via a WiFi or Bluetooth transceiver 204 ; executing a setup app on smart phone 102 and wirelessly transferring setup data as above; etc. Additionally, in some embodiments all or part of the required command data library may be downloaded into bridge device 100 as part of the set up process, originating for example from a local database resident in DVR 114 or smart phone 102 (i.e., stored in conjunction with a smart phone app), or from a remote Internet server based database accessed either directly by bridge device 100 or by using DVR 114 or smart phone 102 as an intermediary. Further, PC, DVR or smart phone based set up application processes may be local, Web server based, or a combination thereof as appropriate for a particular embodiment. Since systems and methods for setting up a universal controlling device to command the operation of specific home appliances are well-known, these will not be described in greater detail herein. Nevertheless, for additional information pertaining to setup procedures, the reader may turn, for example, to U.S. Pat. Nos. 4,959,810, 5,872,562, 7,653,212, or 7,612,685, all of which are incorporated herein by reference in their entirety.
As is known in the art, the bridge device operating program may be adapted to monitor wireless receiver circuit 204 for command request messages originating from a smart phone 102 . Upon receipt of such a request, the bridge device operating program may retrieve from the command data stored in memory a command value and control protocol corresponding to the requested function and the identified device and may cause transmitter circuit 202 to output that command in a format recognizable by the target appliance. In accordance with the instant invention, an exemplary bridge device may additionally include means for direct user input on the device itself and further operating programming to monitor such input(s) 220 and output appliance commands in response thereto. With reference now FIG. 3 , an illustrative bridge device 100 in accordance with the instant invention may include on its external surface various means for user input comprising buttons 304 , 308 , a twistable ring 302 , and a rotatable wheel 306 which wheel may also function as a button or switch when depressed. In this manner seven distinct user inputs may be supported: three buttons presses, clockwise and anticlockwise ring twists, and clockwise and anticlockwise wheel rotations. As will be appreciated, many other configurations of input mechanisms are possible and accordingly the example presented in FIG. 3 is intended to be illustrative and not limiting. As shown, the exemplary bridge device 100 of FIG. 3 may include multiple IR transmitters arranged around the periphery of bridge device 100 so as to radiate IR signals 106 in multiple different directions, e.g., positioned at 180 degree or 90 degree or 45 degree intervals about the device, thus ensuring that command transmissions are visible to the target appliance(s) regardless of the orientation of bridge device 100 . In the illustrative embodiment, for aesthetic reasons and/or for mechanical protection such transmitters may be positioned behind an IR-transparent lens 310 of tinted polycarbonate or acrylic plastic.
In the illustrative embodiment, the operating program of bridge device 100 may comprise two modes for acceptance of direct user interaction: In a default mode of operation, clockwise and anti-clockwise twists 320 , 322 of outer ring 302 may result in transmission of volume up/down commands to TV 108 , while clockwise and anti-clockwise rotations 324 , 326 of wheel 306 may result in transmission of forward/rewind commands to DVR 114 and depression 328 a of wheel 306 may result in transmission of a play/pause command to DVR 114 . In this embodiment, activation of button 304 may result in both the transmission of a command to DVR 114 to cause a display of program guide information by DVR 114 and setting bridge device operating program to a navigation mode, wherein user interactions 320 through 328 with ring 302 or wheel 306 may result in transmission of DVR 114 program guide navigation commands up/down, left/right, and select. Activation of either the “select” function 328 of wheel 306 or the “Exit” button 308 may cause transmission of an appropriate command to DVR 114 together with restoration of the bridge device operating program to the default mode. In this manner, the direct commands currently available to a user of the bridge device 100 may be automatically adapted as appropriate to the operational status of a controlled device such as DVR 114 . In some embodiments the current operational mode of bridge device 100 may be indicated the user via, for example, a user feedback device 218 comprising an illuminable translucent ring surrounding wheel 306 . It will be appreciated that in various embodiments such bridge device mode switching functionality may be supported or supplemented via other means: for example one or more of the controlled devices may communicate current system status directly to bridge device 100 , e.g., DVR 114 may indicate a current operational status; TV 108 may indicate a currently selected input to bridge device 100 to allow automatic selection of DVR 114 or DVD 110 at the target appliance for play/pause commands; an app loaded in smart phone 102 may signal a preferred operational mode to a bridge device; etc.
By way of further example, a series of steps which may be performed by an exemplary bridge device operating program is illustrated in FIG. 4 . Upon initial power-up, at step 402 the bridge device operating program may place bridge device 100 into a known initial state, which may include in the example presented setting the initial operational mode to a default value. Thereafter, at steps 404 , 406 the exemplary bridge device operating program may commence scanning receiver 204 and user input devices 206 (i.e., 302 through 308 ) for activity. As will be appreciated, in certain embodiments, particularly those in which a bridge device power source 222 is battery-based, such input scanning may not entail active execution of program instructions but may rather comprise placing microprocessor 200 into a low power state pending a wake up interrupt from one or more of these input sources. If user interaction with any of input devices 302 through 308 is detected, at step 414 the exemplary bridge device operating program may first determine the current operating mode of the bridge device, i.e., navigation mode or default mode as described above in connection with FIG. 3 . According to this determination, at steps 420 or 422 the appropriate target appliances may be set. For example, as described earlier in conjunction with FIG. 3 if bridge device 100 is operating in default mode the target appliance for ring rotations 320 , 322 may be TV 108 , while if bridge device 100 is operating in navigation mode the target appliance for the same user actions may be DVR 114 . As will be appreciated, the exact assignment of appliances to particular modes and to specific user interactions may be configurable and/or dynamic (assigned for example by interaction with appliances themselves to determine which are currently active) and as such, the assignments mentioned herein are by way of example only and not limiting.
Once a target appliance has been determined, at steps 424 , 428 and 432 the exemplary bridge device operating program may next determine the desired command (i.e., the action to be performed by the target appliance), retrieve from command data storage the appropriate command value and control protocol for the selected target appliance, and transmit the command in a format recognizable by the appliance to be controlled. Upon completion of these steps, at step 426 the exemplary bridge device operating program may next determine if the command transmitted comprised a “Guide” command (i.e. corresponding to button 304 ). If so at step 434 the bridge device operational mode is set to “Navigation”, thus ensuring that subsequent user interactions with inputs 302 through 308 will be directed to the appliance(s) configured for this mode of operation. If not, at step 440 it is next determined if the command just transmitted was either of “Select” or “Exit” in which case, in keeping with the methodology described above in conjunction with FIG. 3 , at step 438 the bridge device operational mode is returned to “Default”. Thereafter, processing of the event is complete and receiver and input scanning is resumed.
If receipt of a transmission by receiver 204 is detected, at step 412 the exemplary bridge device operating program may determine if the received transmission comprises an appliance control request, for example from smart phone 102 . If so, at step 418 the target appliance type is set as indicated in the received request, and thereafter processing continues at step 424 as described previously. If the received transmission is not a control request, at step 410 it is next determined if this comprises a request to alter the bridge device mode of operation (i.e. the response to user interactions with inputs 302 through 308 ). This may occur, for example, in embodiments where an appliance such as DVR 114 may explicitly signal operational state to the bridge device. If it is determined that a request to place the bridge device into a specific mode has been received, then appropriate action may be taken by the exemplary bridge device operating program at steps 426 and 430 .
Finally, at step 408 it is determined if the received transmission comprises updated bridge device configuration data, such as may for example have been created via a set up app on smart phone 102 , a PC or STB based configurator, etc. If so, at step 416 the updated configuration data is stored, for example in non-volatile memory 206 , whereafter input event scanning resumes at steps 404 and 406 .
With reference to FIG. 5 , in certain cases a bridge device 100 may not have a wireless communication protocol in common with smart phone 102 , for example and without limitation bridge device 100 may support only RF4CE and/or Bluetooth communication while smart phone 102 supports only WiFi local communication. In such instances, an intermediary device 500 may serve to receive wireless signals 104 a comprising command requests from smart phone 102 and retransmit these command requests in a format which is compatible with a communication protocol supported by bridge device 100 . As will be appreciated, though illustrated in the form of wireless transmission 502 , in general such retransmission may take any form appropriate for a particular embodiment of bridge device 100 : RF, IR, ultrasonic, hardwired, etc. Also, the functionality of intermediary device 500 may reside in a standalone unit provisioned expressly for this purpose, or may be incorporated in some other item of equipment, for example DVR 114 .
As illustrated in FIG. 6 , in a yet further embodiment a remote control 600 which is capable of two-way communication 602 with a STB or DVR 114 via any convenient protocol such as for example RF4CE or XMP may also serve as a bridge device when equipped with appropriate programming. In such an application, STB or DVR 114 may act as an intermediary device in a similar manner to that described above, receiving command requests from smart phone 102 and relaying these to remote control 600 via two-way communication link 602 . Programming in remote control 600 may perform as previously described to translate the received requests into command transmissions 106 in a format recognizable by an appliance to be controlled, for example TV 108 . In some embodiments, the remote control 600 may be adapted to be placed into a recharging station. Such a remote control 600 may then be limited to serving as a bridge only when the remote control 600 is sensed to be placed into the docking station. Further, the docking station could be provided with the circuitry need to receive signals from an intermediary device with the docking station then functioning to relay any signals so received to a docked remote control 600 , for example, transmitted via the charging contacts.
While various concepts have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those concepts could be developed in light of the overall teachings of the disclosure. For example, in an alternate embodiment, a bridge device may be incorporated into some other item of equipment, for example a smart phone charging base, a portable keyboard or game controller device, a table lamp, etc.
Further, while described in the context of functional modules and illustrated using block diagram format, it is to be understood that, unless otherwise stated to the contrary, one or more of the described functions and/or features may be integrated in a single physical device and/or a software module, or one or more functions and/or features may be implemented in separate physical devices or software modules. It will also be appreciated that a detailed discussion of the actual implementation of each module is not necessary for an enabling understanding of the invention. Rather, the actual implementation of such modules would be well within the routine skill of an engineer, given the disclosure herein of the attributes, functionality, and inter-relationship of the various functional modules in the system. Therefore, a person skilled in the art, applying ordinary skill, will be able to practice the invention set forth in the claims without undue experimentation. It will be additionally appreciated that the particular concepts disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any equivalents thereof.
All patents cited within this document are hereby incorporated by reference in their entirety. | A bridge device, in communication with a smart device, functions to command one or more controllable appliances in response to communications received from the smart device. The bridge device also includes input elements by which the bridge device can be used to directly command common functional operations of the one or more controllable appliances. In this manner, common functional operations, such as volume control, playback pause/resume control, etc., may be made readily available without necessitating the use of the smart device, while the more sophisticated GUI provided by the smart device remote control app may be advantageously utilized when more complex or less frequently used command functions are to be performed. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application 60/486,037, filed Jul. 10, 2003, which is incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates to yarn filament configuration, yarn fiber combination, yarn spinning techniques, and ecologically friendly and functionally sustainable textile design solutions.
BACKGROUND OF THE INVENTION
[0003] The present invention may be understood in light of the following state of the art.
[0004] Ever since processes of converting crushed plastic bottles made of polyethylene terephthalate (PET) into fiber for textiles was proposed as a substitute for virgin polyester, attempts have been made to commercialize the processes. However, development of filaments, staple fiber, yarn, and fabric for the purposes of expanding the potential end uses of these fibers has been relatively limited. This has been attributed primarily to the inherently high cost of acquiring a clean raw material source. When one uses polymer made from the inherently impure post consumer recycled (PCR) polyethylene terephthalate (PCR-PET), one is limited to staple spun yarn rather than a continuous filament yarn because of the unpredictable weak points in monofilaments caused by the impurities. Practical uses for the staple spun yarn have been limited.
[0005] When particular domestic-based end use product manufacturers brought products containing fabric made from recycled plastic bottles to market and charged a premium for a product that had inherent quality deficiencies, they were unable to sustain significant enough market demand for these products to merit the expansion of plastic bottle fiber production. Instead, the fiber mills, which had originally predicted growth In market consumption of the fiber, were forced to close fiber plants that were originally supplying these domestic-based end use product manufacturers with their fiber.
[0006] Therefore, a longstanding need has existed for an economical method of utilizing PCR-PET to manufacture useable yarn of high quality.
[0007] Several highly cost-intensive PCR-PET purification methods now exist which are able to almost eradicate contamination from the recycled materials stream. They produce food-grade materials, and such materials might be suitable for producing continuous filament yarn. Because of their cost, however, they are not presently useful for producing commercially viable fiber.
[0008] The manufacture of yarn, whether in the form of thread or higher denier yarns, is one of the oldest technologies known. Numerous manufacturing methods are known for making continuous filament yarns, for combining continuous filaments into yarns, and for making yarns from shorter, staple fibers. Spinning staples into yarns has been known since prehistory.
[0009] Today, the three most popular spinning frames for staple spun yarn are ringspun, open end, and air jet. Prior to air jet, ringspun was considered the best in terms of quality and strength. Open end spinning has always been considered to be cheap and fast. Air jet is now hailed by most industry experts to be the optimal type of spinning frame for almost any application. Air jet spinning produces a fasciated yarn including a sheath of generally axially aligned staples bound together with discontinuous generally helical bundles of staples. Air jet machines are expensive; however their output speeds even at fine counts make them the best solution from an economic standpoint. From the standpoint of performance, the air jet produces the lowest pill yarn ever spun. The only complaint thus far is that the strength of an air jet yarn is slightly less than the strength of a ringspun yarn; however, this issue is easily overcome by placing a filament core inside the air jet yarn. The general rule for staple fiber going into air jet spinning frames is that it should be between about 1.2 and 2.0 inches (3 to 5 cm) in length, preferably between about 1.2 and 1.7 inches (3 to 4.3 cm) in length, and most preferably about 1.5 inches (3.8 cm) in length. Diameter of the staples can range from about 0.5 to about 2.0 denier per filament (dpf). A variant of an air jet spinning frame is known as a vortex spinning frame. A vortex spinning frame is capable of spinning a wider range of natural staple fibers, including cotton fibers, than is easily obtained with the earlier forms of air jet spinning frames. The vortex spinning frame produces a three-dimensional cotton sheath having better hand than does the basic air jet frame. It is also faster.
[0010] Air jet spinning frames are well known in the art. Air jet spinning is presently dominated by Murata Kikal KK of Kyoto, Japan. Its MJS air jet spinning machine, MTS twin spinning machine, and MVS vortex spinning machines are widely used and their details are known to those skilled in the art. Such machines are described for example in Oxenham, “Fasciated Yarns—A Revolutionary Development?” Journal of Textile and Apparel, Technology and Management, Vol. 1, issue 2, Winter 2001, pp. 1-7; Oxenham, “Developments In Spinning,” TextileWorld.com, May 2003; and in numerous patents, such as Shaikh et al., U.S. Pat. No. 6,405,519; Scheerer et al, U.S. Pat. No. 6,250,060; Scheerer et al., U.S. Pat. No. 5,960,621; Ota, U.S. Pat. No. 5,481,863; Griesshammer et al., U.S. Pat. No. 6,679,043; Shigeyarni et al., U.S. Pat. No. 6,655,122; and Mori, U.S. Pat. No. 6,370,858.
[0011] Other yarns include those in which a core is covered with a continuous filament helix using a covering machine (sometimes called coverwrapping machine or wrapping machine). These machines are traditionally used to cover spandex or other continuous filament stretch yarns. A single or double helix is applied by a standard covering machine. Covering machines are occasionally used to cover non-stretch continuous filament cores to produce “fancy” yarns for small niche markets or industrial yarns. Such machines are sold by a number of manufacturers, for example by Rieter/ICBT, now known as the Filament Yarn Technologies Group, of Rieter Machine Works, Ltd., Winterthur, Switzerland. They are also widely described in the patent literature, for example in Siracusano, U.S. Pat. No. 4,350,731; Tillman, U.S. Pat. No. 4,137,698; and Payen, U.S. Pat. No. 4,525,992.
[0012] Continuous filament yarns are sometimes texturized (also called textured) by a texturizing machine to give them particular surface or geometrical properties. For example, a filament may be given a “false twist” by twisting it, heating it, cooling it, and then untwisting it, or it may be given a more random shape by the several high-speed air methods described in Bertsch et al., U.S. Pat. No. 6,088,892. Surface features are given by other methods, known to those skilled in the art. Generally, texturizing yarn filaments is done for the purpose of giving a synthetic (plastic) yarn some of the characteristics of a natural fiber.
[0013] Synthetic yarns are generally superior to yarns made of natural fibers in tenacity (tensile strength), abrasion resistance, quick-drying properties, and dimensional stability, but they generally lack the hand, drape, and moisture absorbance of their natural fiber counterparts. It is frequently desirable to produce yarns having special characteristics such as fire retardancy, high moisture permeability, bacterial resistance, ultraviolet ray resistance, low surface friction, or special aesthetic texturing. Generally, providing one of these characteristics requires compromising other characteristics of a synthetic or natural yarn. For example, high tenacity synthetics such as polyarnides including aromatic polyarnides (aramids) and high-tenacity aliphatic polyarnides (nylon), carbon, or glass provide much higher tenacities than many other synthetics or most natural fibers, but they lack many desirable characteristics as a yarn for numerous fabrics. Aramids provide greater tenacity than high-tenacity nylons, but they are susceptible to ultraviolet radiation. Providing other characteristics in a high-tenacity synthetic yarn generally reduces the tenacity of the yarn.
SUMMARY OF THE INVENTION
[0014] The present invention produces enhanced performance yarns which comprise, and are functional and economic alternatives to, 100 % petroleum oil based virgin continuous filament yarns, such as polyesters (like virgin polyethylene terephthalate), polyarnides (like nylon and aramids), polyolefins (like polypropylene and polyisobutylene), fluorocarbons (like polytetrafluoroethylene), high tenacity nylon, high tenacity polyester, and yarns formed of regenerated natural materials (like rayon and acetate). A list of man-made fibers, all of which are to some extent useable with embodiments of the present invention is contained in ISO Standard 2076: 1999(E) and in United States 16 Code of Federal Regulations part 303, particularly §303.7 (Dec. 1, 2000), both incorporated by reference. The invention also produces enhanced performance yarns which comprise, and are functional and economic alternatives to, natural spun vegetable yarns (like cotton, linen, hemp, jute, and bamboo), silk yarns, and wool and other animal fiber yarns. These yarns are achieved by way of new yarn filament configurations and yarn manufacturing methods which, among other things, provide a sustainable avenue to incorporate highly significant amounts of recycled plastics, particularly post consumer recycled (PCR) thermoplastic material such as polyethylene terephthalate (PET), which contains medium to high levels of contamination, into a yarn without sacrificing many if any of the performance characteristics or properties that are inherent to the related competing alternate yarn type. The alternate yarn type may be, for example, 100% petroleum oil based virgin continuous filament yarn or may be natural or synthetic staple spun yarn.
[0015] Corespun yarns with a continuous filament core, a spun sheath of recycled thermoplastic such as PCR-PET, and a spun cover formed either with an air jet (Including vortex Jet) machine or a cover wrapping machine are particularly advantageous. Other yarns and methods of making them also fall within the purview of the present invention, as will be understood by those skilled in the art in light of the following description, drawings, and claims.
[0016] Only post consumer recycled polyethylene terephthalate (PCR-PET) which in its pre-extruded liquid form contains substantial enough levels of contamination to prevent it from remaining in a continuous filament at post extrusion due to the unpredictable points of weakness caused by the inherent impurities contained within the polymer, is economically logical for use in a staple form.
[0017] in present economic conditions, the cleanest PCR-PET pre-extruded liquid polymer that this invention is appropriate for accommodating can not run through a filament extrusion hole smaller than seventeen to twenty microns. Another way of stating this is that a suitable pre-extruded liquid PCR-PET, in a standard pressure drop test, requires a pressure of greater than about 100 pounds per square inch (psi) for a twenty micron opening in order to be economically viable. Typically, the pressure drop of suitable pre-extruded PCR-PET will be about 500 psi or less for use in an extruder having a 20 micron opening and producing a 1.2 dpf staple. If the liquid polymer is pure enough to economically run through an extrusion hole smaller than seventeen microns in a manufacturing operation, then it is likely to have a more appropriate use elsewhere than in producing staple fiber, even staple fiber for use in the present invention. Larger diameter staple, extruded through a larger hole, may be used with other spinning methods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic view of a standard commercially available air jet spinning machine for use in performing steps of preferred embodiments of the present method.
[0019] FIG. 2 is a view in side elevation, partially cut away, of the yarn produced by the machine of FIG. 1 .
[0020] FIG. 3 is a schematic view of standard commercially available machine for winding a covering thread around a core.
[0021] FIG. 4 is a view in side elevation, partially cut away, of a yarn of this invention produced from the yarn of FIG. 2 by the machine of FIG. 3 .
[0022] FIG. 5 is a schematic view of a standard commercially available air jet spinning machine modified for use in performing steps of preferred embodiments of the present method.
[0023] FIG. 6 is a somewhat schematic detailed view of part of the machine of FIG. 5 , showing two types of sliver emerging from an outlet of a T-trumpet portion of the machine and being formed into a yarn of this invention.
[0024] FIG. 7 is a view in side elevation, partially cut away, of a yarn of this invention produced by the machine of FIGS. 5 and 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The embodiments of the present invention described below are not meant to be limiting of the invention but to illustrate presently preferred embodiments.
EXAMPLE 1
Preparation of an Intermediate Yarn
[0026] Referring now to the drawings, and in particular to FIGS. 1 and 2 , a preferred form of an intermediate yarn 1 for use in some illustrative preferred embodiments of the present invention is produced on a standard Murata MJS or MVS spinning frame 3 . The spinning frame 3 , as is well known in the art, includes a sliver supply 5 which feeds sliver through a trumpet 7 , into a drafting zone. Sliver is staple which is processed by a carding machine into a solid controllable and soft form. The drafting zone comprises a pair of back rolls 9 , a pair of middle rolls 11 , a pair of apron rolls 13 , and a pair of front rolls 15 . If desired, a guide or condenser may be included between the back rolls 9 and middle rolls 11 .
[0027] As shown in FIG. 1 , the spinning frame 3 is set up with a standard core attachment for inclusion of a core. A continuous filament core yarn 17 is fed through a pigtail guide 19 into the spinning frame at the forward end of the drafting zone, at front rolls 15 .
[0028] The front rolls 15 feed the core yarn 17 and drafted sliver into a spinning zone comprising spinning nozzles 21 and delivery rolls 23 which form the sliver into a spun sheath surrounding and hiding the core yarn 17 in accordance with well-known principles.
[0029] The completed corespun yarn 1 is passed through a yarn clearer 25 and rolled onto a core package 27 .
[0030] The corespun yarn 1 which forms an intermediate yarn for use in the present invention is shown in FIG. 2 . In this illustrative embodiment, the sliver 5 , hence the spun sheath 5 of the yarn 1 is formed of PCR-PET having a staple length of about 1.5 inches (3.8 cm) and a diameter of about 0.7 to 2 denier. The PCR-PET is cleaned sufficiently to be suitable for the formation of staple fibers but not continuous filament. The continuous filament core is illustratively formed of a high tenacity multifilament bundle, illustratively high tenacity nylon having a tenacity rating of about fifteen. The functions of the core and sheath will be discussed hereinafter in connection with particular constructions of the invention utilizing this intermediate yarn 1 .
EXAMPLE 2
Production of a Wrapped PCR-PET Yarn
[0031] As shown in FIG. 3 , a standard coverwrapping machine 31 , modified for use with the intermediate corespun yarn 1 , is used for this step. The coverwrapping machine is illustratively a Model G-307-UE covering machine sold by Rieter/ICBT (Filament Yarn Technologies Group, Rieter Machine Works, Ltd.). The machine is adjusted to accept the intermediate corespun yarn 1 , which differs in construction and physical properties from the usual elastomer (spandex) core fed into the machine. The intermediate yarn 1 is placed on the supply rolls 33 of the covering machine 31 , from which it is fed to a first covering station 35 which applies an inner helix of an inner cover yarn, then to a second covering station 37 which applies an outer helix of an outer cover yarn, wrapped in a direction opposite the first helix. The completed yarn of this embodiment is then rolled on takeup rolls 39 . The outer helix forms the outer cover, which is the surface of the completed yarn.
[0032] As shown in FIG. 4 , the completed yarn 41 includes a double helix composed of two continuous filament yarns, an inner helix yarn 43 and an outer helix yarn 45 , which together form a cover that wraps around the outside of the sheath of the corespun yarn 1 .
[0033] The continuous filament core 17 acts as a central load bearing point for the entire yarn. In other embodiments of this construction, the filament type of the core 17 can be stretch, high tenacity or standard polymer. The presently preferred core material is high tenacity nylon or polyester, a combination of the two, or a combination of one of the two fiber types with another high tenacity or standard continuous filament yarn possessing a grams per denier tenacity rating between 8 and 35. To date, the optimal core judged from the standpoint of achieving a high strength without generating a high cost, is a high tenacity polyester or high tenacity nylon continuous filament. The core can compose anywhere from 10% to 50% of the total weight of the finished yarn. However, the optimal percentage of the core when using high tenacity nylon or high tenacity polyester, is presently believed to be between 10% and 20%.
[0034] The sheath 5 has two main functions, the first being its inherent ability to be a highly compressible component in the yarn, and the second being a sustainable avenue for incorporating a recycled material component in the yarn without affecting the yarn's performance properties.
[0035] The sheath is illustratively composed of post consumer recycled polyethylene terephthalate (PCR-PET) staple length fiber. The optimal cut staple length is 1.5-3.0 inches, and the optimal staple dpf (denier per filament) ranges between 0.8 and 3.0 depending on the amount of fibers per cross-section required by the yarn's thickness.
[0036] The double helix has two main functions. The first is to provide a surface layer for the yarn having desired aesthetic characteristics and functional characteristics. The second is to interact mechanically with the core and sheath to provide surprising physical characteristics to the completed composite yarn.
[0037] In the illustrative embodiment of yarn, the main functions of the double helix is to give the yarn extremely high resistance to abrasion, protecting the inherently less abrasion resistant sheath 5 . Either high tenacity or standard tenacity nylon is recommended because of its traditionally high abrasion resistance properties. It will be seen that the yarn type of the wrap yarns 43 and 45 can be customized to accommodate the special needs of a particular end use application. When the yarn 41 , or a fabric formed from it, needs to have special properties such as fire retardancy, high moisture permeability, bacterial resistance, ultraviolet ray resistance, low surface friction, or special aesthetic texturing, a continuous filament yarn containing any of these mentioned special properties can be selected as the “wrap yarn” to best suit the needs of the yarn end use application. Depending on several variables, different or the same type of continuous filament or spun yarn can be used as the inner and or outer layer helix. Also, the amount of Individual filaments of which the wrap yarn is composed can play a large role in the cover's aesthetic, handling, and physical characteristics. Therefore, for end use applications in which abrasion resistance is paramount, it is best to use a wrap yarn with as few individual filaments as possible. It is even recommended to use a monofilament, so that the entire wrap yarn is composed of one filament. However, when the amount of total individual filaments in the yarn is limited, the yarn and fabric become progressively more rigid as fewer filaments are used in the wrap yarns.
[0038] The second function of the double helical cover is to participate in a physical relationship with the core and sheath to provide unexpected physical characteristics, particularly unexpectedly high tenacity.
[0039] Although not wishing to be bound by theory, I believe that the double helix wrapped corespun yarn combines the known physics concepts of compression and expansion to form an otherwise unexplainably strong strand of yarn. The standard logic in yarn manufacturing suggests that a high tenacity continuous filament yarn equaling the same diameter as the yarn of this example would be stronger because the yarn of this example is illustratively composed of 17% high tenacity continuous filament core, 43% inherently weaker standard-tenacity polyester staple sheath (PCR-PET), and 40% standard or high tenacity continuous filament yarn which forms the double helix. However, testing of a fabric of this example compared to a 100% high tenacity nylon continuous filament fabric of the equivalent denier proved the new yarn to have higher tenacity than the control fabric.
[0040] My interpretation of the interaction of the core, the sheath, and the cover is as follows.
[0041] A) The sheath made from staple length fibers is inherently lofty because the structure of a sheath consists of many small fibers spun together which creates tiny air pockets in-between the staples. One way to potentially increase the amount of sheath loft is to use a hollow staple fiber in the sheath; however this could potentially add cost and depending on the degree in which the hollow staple increases the overall strength of the yarn, it may or may not be of great value. Nevertheless, the use of a hollow staple fiber may achieve an even higher tenacity strength rated yarn.
[0042] B) The double helix is applied through a mechanical wrapping machine which wraps the two continuous filament wrap yarns tightly around the sheath simultaneously in opposite directions. When the helix yarns wrap, they compress the sheath, and in doing so push out all the air trapped between individual staple fibers. The act of compression alters the original shape and orientation of the sheath's internal structure, in turn forcing the sheath to inherently and continuously attempt to expand. In the sheath's effort to expand, it is consistently applying equivalent amounts of pressure to both the core and the helix. This distribution of pressure compounds the originally separate elements of core, sheath and double helix into one unified strand which has exceptional strength. A fabric composed of yarn made in accordance with this embodiment of the invention has now been tested to have 30% higher grams per denier tenacity levels than a similar fabric made of 100% high tenacity nylon continuous filament of the equivalent denier.
[0043] The turns per inch (TPI) is a measure of the density of the cover or double helix within one inch of the yarn. The TPI can greatly affect the degree of abrasion resistance generated by the double helix, and can also greatly affect the degree of grams per denier tenacity rating of the yarn. TPI can be converted into what is known as coverage percentage, meaning the percentage of the surface being wrapped that is covered by the wrap yarns. Higher wrap coverage percentages equal higher yarn abrasion resistance and higher yarn tenacity ratings. They also equal longer processing time and higher cost. Optimal double helix wrap coverage is between 70% and 100%.
EXAMPLE 3
First Alternative Yarn Construction
[0044] This construction and the construction of the following Example comprise a high tenacity, standard tenacity, or stretch continuous filament yarn core and a uniquely formed sheath. The sheath comprises two layers of distinctly different staple fiber types. The layers are constructed such that there is an inner layer which touches the core, and an outer layer which is essentially the yarn's exterior surface area. The inner sheath comprises PCR-PET staple length fiber. The outer sheath layer comprises an interchangeable and customizable staple fiber which has specific performance or aesthetic properties or attributes required by the end use application of the yarn.
[0045] The choice between the method of this Example and that of the following Example depends on what the needs of the end use application are, as discussed below.
[0046] The manufacturing method of this Example utilizes a Murata MJS or MVS spinning machine similar to that utilized in Example 1. Like the method of Example 1, it inserts a standard or high tenacity continuous filament ucoren by the use of a core attachment. It differs in that it produces a two-layer sheath which is created by the use of a T-trumpet 71 . The functional distinguishing feature of this method is its ability to control the placement of sliver. The T-trumpet 71 , unlike the standard trumpet 7 normally used to feed carded staple into the spinning frame, allows the feeding of two different types of carded sliver 51 and 53 into the spinning frame in such a way that one fiber type is placed on the inside of the yarn's sheath and another fiber type on the outside of the yarn's sheath. The T-trumpet 71 is shown in more detail in FIG. 6 , where the inner sheath sliver 51 , illustratively PCR-PET, is emerging from the vertical arm 73 of the T-trumpet, and the outer sheath sliver 53 , Illustratively standard or high tenacity nylon, is emerging from the horizontal arm 75 of the T-trumpet. As shown in FIG. 6 , a condenser 10 is included between the back rolls 9 and middle rolls 11 . When spun by the nozzles 21 , the outer edges of the silver 53 become the outer portion of the outer sheath of the finished yarn 81 , and the sliver 51 becomes the inner sheath surrounding the core 17 , as shown in FIG. 7 .
[0047] This method will not produce a 100% differentiation of inner and outer sheath fiber types; however, it will be very close. A small amount of the sliver 51 will migrate into the outer sheath, and a small amount of the sliver 53 will migrate into the outer sheath. Any yarn chosen to be manufactured with this method will have the ability to tolerate a less than perfect fiber differentiation. In fact the only time where this differentiation becomes important is when the yarn or fabric is color dyed and the two sheath materials require different dyes. For example, with a cotton exterior sheath and the standard polyester interior sheath, the cotton will be dyed with a cotton dye; however, the polyester will remain white and unaffected by the cotton dye. Therefore, a polyester dye must be used either simultaneously or separately along with the cotton dye in order to achieve color uniformity.
[0048] This manufacturing technique is suitable for all end use products except those which are being indigo dyed. Exterior sheath staple fibers which are compatible with this spinning technique include, for example, high tenacity fibers (such as high-tenacity nylon, glass, carbon, and aramid), low friction fibers, antimicrobial fibers, moisture management fibers (such high moisture permeability fibers and moisture repelling fibers), and natural fibers (such as cotton, wool, silk, rayon, and linen), or any blend of these fibers. Many of these fibers are characterized by having inherently long lengths or by being unpredictable in length due to the fact that they are natural fibers. Because of these characteristics, prior to spinning, fibers substantially shorter than 1.5 inches (3.8 cm) must be removed, and fibers substantially longer than 1.5 inches (3.8 cm) must be cut to 1.5″ (3.8 cm) length. The central reason for this is that the optimal spinning frame for these yarns is a Murata MJS or MVS (Murata Machinery, Ltd.), and these machines require a 1.5″ (3.8 cm) staple length. However, it has been found that shorter fibers tend to migrate to the outside of the yarn and longer fibers tend to migrate Inward. Therefore, the amount of intermingling of fibers in the sheath may be minimized by including at least some slightly shorter staples in the sliver for the outside sheath (perhaps somewhat longer than 1.2 inches) to fill the outside sheath, while eliminating such shorter staples in the sliver for the inner sheath. It may also be possible, although it is not presently preferred, to use modify the sliver for the inner sheath by adding slightly longer sliver (perhaps somewhat shorter than 1.8 inches) or by intermixing a little of the shorter staples of the fibers of the outer sheath.
[0049] The key reason why the use of Murata's air jet technology is preferred over ringspun technology, is that the Murata air jet yarn manufacturing process involves among other elements, a portion of the fiber which is channeled to the side; while the remainder of the fibers are twisted together in one direction; the channeled fiber acts independently by rapidly wrapping itself around the fiber in twist formation. The critical thing to recognize here, is that the wrapping fibers are not only the fastener of the “false twist”, but in this case, because of the fiber control provided by the T-trumpet, these fibers are an entirely different fiber type than the fibers which are being falsely twisted and being wrapped.
EXAMPLE 4
Second Alternative Yarn Construction
[0050] This technique is characterized by its ability to be used in indigo dye applications such as denim. The unique circumstance with denim is that the yarn used in denim is dyed with indigo dye while still in yarn form. The yarn is dipped in indigo dye and then aired. The reason for this is that by performing this dip and air procedure you allow only the surface cotton fibers of the yarn to absorb the indigo dye. This becomes important when the woven fabric is stonewashed. During subsequent stone washing some of the indigo dye contained in the surface cotton fibers is beaten out of the fabric, allowing the undyed white interior of the yarn/fabric to come into sight. This in turn gives the fabric a faded appearance.
[0051] In order to adapt my yarn design to be applicable to indigo dyed yarn and fabric manufacturing, a technique of yarn spinning is required which enables the yarn to have an outer sheath which consists 100% purely of one fiber type, which in the case of denim is essential to performing the stonewashing of the indigo dyed cotton without having a visible color variation.
[0052] The manufacturing method of this Example comprises using the Intermediate corespun yarn 1 of Example 1, containing a high tenacity, standard tenacity, or stretch continuous filament yarn core and a PCR-PET staple fiber sheath, as the core of a second corespun yarn. The intermediate yarn 1 is fed into the machine of FIG. 1 , and the sliver is whatever staple fiber is desired as the pure 100% surface of the yarn 81 and of a fabric woven or knit from it.
EXAMPLE 5
High Strength Multifilament Yarn Construction
[0053] A continuous and multi-filament yarn having a total denier of 12 to 800 and consisting of 10 to 90% by weight of continuous high tenacity and high modulus monofilaments such as aramid, glass, carbon, or any other fiber filament which has a tenacity higher than 15 and a modulus higher than 500 is provided for use as a core in the foregoing Examples, as a ripstop grid, and for other purposes. The high tenacity, high modulus fiber will be intermingled with monofilaments having a lower tenacity, lower modulus, such as high tenacity nylon, regular nylon, high tenacity polyester, regular polyester, or any other continuous filament fiber having a tenacity rating between 5 and 15. The ratio of the higher than 15 tenacity fiber to the lower than 15 high tenacity fiber is determined by the strength requirements of its end use application and the actual tenacity ratings of the fibers which are being intermingled.
[0054] The yarn forms a particularly good core for the PCR-PET sheath yarns of other embodiments of the invention, as well as being an outstanding ripstop yarn used in forming a ripstop grid in a high-strength fabric.
[0055] All the patents and articles mentioned herein are described as an integral part of this disclosure with regard to the technical disclosure and are incorporated herein by reference.
[0056] Numerous variations in the methods and products of this Invention, within the scope of the appended claims, will occur to those skilled in the art in light of the foregoing disclosure. Merely by way of example, the core materials, sheath materials, and (in the construction of Example 2) cover materials may all be varied to meet particular requirements. The core of the yarn of Example 2 may be omitted, although it is believed that its omission will weaken the yarn. The intermediate yarn 1 may be formed by other spinning methods, as may the sheaths of Examples 3 and 4, although the methods disclosed are believed to provide superior yarns. Staple fibers having a larger range of lengths and diameters may be utilized if other spinning frames are used. These variations are merely illustrative. | Enhanced performance yarns ( 41, 81 ) which comprise, and are functional and economic alternatives to, 100 % petroleum oil based virgin continuous filament yarns, and yarns of natural fibers and methods of making them. The yarns may comprise an inner portion of spun staple fibers of recycled plastic and an outer portion comprising a different material and incorporate highly significant amounts of recycled plastics, particularly post consumer recycled (PCR), thermoplastic material such as polyethylene terephthalate (PET) which contains medium to high levels of contamination. One embodiment of yarn comprises a core ( 17 ), an inner portion ( 5 ) of spun staple fibers surrounding the core, and an outer portion ( 41 ) comprising an inner helix ( 43 ) and an outer helix ( 45 ) formed of a material different from the inner helix. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/541,390, filed Jul. 3, 2012, the contents of which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] This invention relates to stereoscopic viewers for viewing three-dimensional images. In particular, this invention relates to a collapsible stereoscope for viewing two adjacent two-dimensional images as a single three-dimensional image.
BACKGROUND OF THE INVENTION
[0003] The present invention is directed to overcoming problems associated with collapsible three-dimensional viewers called stereoscopes. Three-dimensional viewing of photographs generally is achieved by having an observer view one image with the left eye, and another similar image with the right eye. These two images are different views of the same object(s) and are placed adjacent to each other forming what is called a stereogram. Often times, the two images on the stereogram are photographs of an object taken by a camera from two slightly different angles. When the left eye sees the left image and the right eyes sees the right image on the stereogram, the observer's brain interprets the two different images as a single composite image that appears three-dimensional. Collapsible stereoscopes come in various sizes and shapes and are useful in that they are light weight, portable, and can be mailed in thin envelopes.
[0004] Many collapsible stereoscopes are box shaped, and constructed from a single cardboard blank having flaps, wings, or protruding edges that can be configured together to form an assembled stereoscope. It is important that when the stereoscope is assembled, it remains in a fairly rigid formation because the distance from the stereogram to the observer's eyes is critical for the brain to interpret two two-dimensional images as a single three-dimensional image. Creating a stereoscope that is both easily collapsible but also rigid enough to keep images in a stable location when assembled has been difficult. It has also been a challenge to make collapsible stereoscopes that have enough light to illuminate the stereogram, but also reduce or prevent shadowing on the stereogram caused by light that enters from the side of the stereoscope. Furthermore, it has been difficult to create a stereoscope having an easy assembly but also has the capability of easily interchanging stereograms inside of the stereoscope.
[0005] There are several types of collapsible stereoscopes with different features. Some stereoscopes lack the structural support of having side walls, including: U.S. Pat. No. 712,410 to Reichenbach, U.S. Pat. No. 962,643 to Knopping, U.S. Pat. No. 2,018,739 to Pauchek, U.S. Pat. No. 1,097,601 to Maerz, U.S. Pat. No. 2,283,777 to Wendling, U.S. Pat. No. 2,757,573 to Turner, U.S. Pat. No. 2,984,153 to Brennan, and U.S. Pat. No. 5,002,363 to Tanaka. Other stereoscopes are formed from several separate pieces of unconnected material that must be joined together, or have no mechanism that keeps the stereogram in place, including: U.S. Pat. No. 2,368,480 to McClure, U.S. Pat. No. 5,309,281 to Rover, and U.S. Pat. No. 6,151,165 to Tomita. Other stereoscopes have side wall supports but would likely cause shadowing on the stereogram, or exclude outside light altogether, such as U.S. Pat. No. 2,616,333 to Tinker, U.S. Pat. No. 2,662,442 to Gowland, U.S. Pat. No. 2,789,460 to Kaufman, U.S. Pat. No. 2,821,884 to Austin, and U.S. Pat. No. 6,069,735 to Murphy. Others, because of a closed-box assembled configuration, would make it difficult for the user to interchange stereograms in the stereoscope, such as the one described in U.S. Pat. No. 3,734,596 to Nerlich.
[0006] Therefore, there is a need for improved collapsible stereoscopes that are sturdy, easy to assemble, brace the stereogram, and reduce or prevent shadowing on the stereogram.
SUMMARY OF THE INVENTION
[0007] In view of the foregoing, the present invention is directed to a collapsible but sturdy stereoscope made from a single piece of stiff but bendable material that allows for outside light to enter the stereoscope, but reduces shadowing on the stereogram. The collapsible stereoscope can be folded and inserted into an envelope and used as a greeting card for occasions such as a birthday, Christmas, Mother's Day, Father's Day, New Years, or a wedding anniversary. The stereoscope can be decorated on the outside or inside to match these and other occasions. The stereoscope can also have an integrated musical feature where the stereoscope can play music when the stereoscope is opened or assembled.
[0008] In the broadest sense, the stereoscope may be made of any material, such as paper, plastic, paperboard, cardboard, metal, and the like, or any suitable combination of the these materials. The stereoscope comprises a front viewing panel having apertures for receiving lenses, two lenses, a rear picture holding panel, two bracing side walls with a preformed crease for easy folding, and a bottom panel that is integrally hinged to the front viewing panel, rear picture holding panel and bracing side walls. Light enters the stereoscope from the top open section onto the stereogram.
[0009] In one embodiment, two complimentary images approximately 4 inches (101.6 mm) in height by 3 inches (76.2 mm) in width are adjacent to each other on a stereogram with dimensions of 4 inches in height by 6 inches (152.4 mm) in width (these dimensions are preferred because standard sized photographs are commonly printed on 4 by 6 inch photographic paper, and each one of the complimentary images would take up approximately half of the photographic paper). The stereogram is inserted into the stereoscope and placed against the rear picture holding panel, or in other embodiments, the rear picture holding panel may be an LCD display. Preferably, the rear picture holding panel of the stereoscope has a width of approximately 6 inches and a height of approximately 4 inches to accommodate the placement of the stereogram(s). In other embodiments, the stereoscope may be constructed to hold different sized stereograms, such as, but not limited to, 3-inch by 5-inch stereograms, 5-inch by 7-inch stereograms, 6-inch by 8-inch stereograms or 8-inch by 10-inch stereograms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above and various other objects and advantages of the invention will be described and understood from the following description of the preferred embodiments of the invention, the same being illustrated in the accompanying drawings.
[0011] FIG. 1 is a plan view of an unfolded stereoscope.
[0012] FIG. 2 is front perspective view of an assembled stereoscope.
[0013] FIG. 3 is a rear perspective view of an assembled stereoscope.
[0014] FIG. 4 is top view of an assembled stereoscope.
[0015] FIG. 5 is front view of an assembled stereoscope.
[0016] FIG. 6 is a side plan view of an assembled stereoscope.
[0017] FIG. 7 is a perspective view of a partially collapsed stereoscope.
[0018] FIG. 8 is a top view of a collapsed stereoscope.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims. Preferable embodiments of the present invention are described with reference to the FIGS. 1-8 .
[0020] The bottom panel has a rear long edge integrally hinged to the base of the rear picture holding panel. Where a standard 4 by 6 inch stereogram is placed against the rear picture holding panel, this rear long edge of the bottom panel is also preferably approximately 6 inches. A front short edge of the bottom panel, shorter than the rear long edge of the bottom panel, is integrally hinged to a front viewing pane. In an embodiment where a standard 4 by 6 inch stereogram is placed against the rear picture holding panel, the front short edge of the bottom panel is preferably approximately 5.5 inches (139.7 mm), and parallel to the rear long edge of the bottom panel. Preferably, the sides of the bottom panel extend from the long rear edge to the short front edge, creating a trapezoidal shape of the bottom panel having a trapezoidal height of preferably approximately 5.5 inches. The trapezoidal shape of the bottom panel is defined by having two parallel bases (the rear long edge and front short edge) of different widths. In a stereoscope having these dimensions the distance from the stereogram on the rear picture holding panel to the front viewing panel (where the observer places his eyes to see the stereogram) is approximately 5.5 inches. The trapezoidal aspect of the embodiment increases the structural stability of the stereoscope when assembled because the trapezoidal shape creates increased tension in the bracing side walls when the bracing side walls are secured to the front viewing panel. This tension drives each bracing side walls to bend in toward each other at a preformed diagonal crease without deforming other aspects of the stereoscope.
[0021] The bracing side walls of the stereoscope can have a range of heights, but the range of allowable dimensions are important in that the range of dimensions reduce or prevent shadows from forming on the stereogram and also give structural stability to the stereoscope. Preferably for viewing 4 by 6 inch stereograms, at a distance of between 28% to 34% of the height of the rear picture holding panel (approximately 1.12 inches (28.4 mm) to 1.36 inches (34.5 mm)), the height of each bracing side wall is between 28% to 34% of the height of the rear picture holding panel where the stereogram is placed. For a stereoscope for viewing 4 by 6 inch stereograms, if the height of each bracing side wall is less than 28% of the height of the picture holding panel, the bracing side wall tends to fall in and collapse, while if the height of each bracing side wall is greater than 34% of the height of the picture holding panel, then light entering from the sides of the stereoscope cast shadows on the stereogram.
[0022] At a distance of between 30% to 31% of the height of the rear picture holding panel (approximately 1.2 inches (30.5 mm) to 1.24 inches (31.5 mm) from the picture holding panel in an embodiment of a stereoscope for viewing a 4 by 6 inch stereograms), the height of each bracing side wall is between 30% and 31% of the height of the stereogram (1.2 to 1.24 inches).
[0023] In a preferred embodiment that provides structural support and prevents shadows on the stereogram, each bracing side wall has a height of approximately 1.25 inches (31.75 mm) at position that is 1.25 inches away from the picture holding panel when the stereoscope is in its assembled position.
[0024] In order to facilitate foldability of the stereoscope, each bracing side wall has a preformed (preferably scored) diagonal folding crease. Each diagonal folding crease has a first termination point starting from the corner intersecting the picture holding panel and bottom panel and a second termination point at the top edge of each bracing side wall at a predetermined distance away from the rear picture holding panel. As a consequence of the height of each bracing side wall being between 28% and 34% of the height of the rear picture holding panel, each diagonal folding crease is approximately between 1.58 (40.1 mm) to 1.92 inches (48.8 mm). Preferably, the length of each diagonal folding crease is approximately 1.75 inches (44.5 mm) (as a consequence of hypothetical right triangle with base and height of approximately 1.25 inches, where the top edge of each diagonal folding crease is 1.25 inches from the plane formed by the rear picture holding panel of the assembled stereoscope.
[0025] Each bracing side wall has a recess in close proximity to the front viewing panel when the stereoscope is in its assembled conformation. The front viewing panel has a left recess and a right recess. The recess on each bracing side wall is capable of engaging with one of the recesses on the front viewing panel to secure each bracing side wall to the front viewing panel. Bracing side walls may be secured to the front viewing panel by slats or inserts. The bracing side walls are secured to the rear picture holding panel through tape or other attachment device. When each bracing side wall is secured to the rear picture holding panel and to the front viewing panel, the stereoscope has the conformation of an open box-like structure.
[0026] The recesses on the bracing side walls are positioned such that the distance from the plane formed by the rear picture holding panel to the vertical plane formed by the recesses on each bracing side wall, is greater than the distance from the rear long edge of the bottom panel to the front short edge of the bottom panel. Preferably, if the length of the trapezoidal base is 5.5 inches, the diagonal length each bracing side wall is between 5.7 inches (144.8 mm) and 5.9 inches (149.9 mm) from the corner of the bracing side wall and picture holding panel to the recess on each bracing side wall. Since each bracing side wall at the position of the recesses is longer than the length of the trapezoidal bottom panel that integrally hinges the rear picture holding panel and the front viewing panel, each bracing side wall bends in order to accommodate the length difference (i.e. since each bracing side wall is longer than the bottom panel it is integrally hinged to, each bracing side wall must bend when the front viewing panel is engaged with each side bracing wall). This bend occurs at the preformed diagonal folding crease on each bracing side wall and drives each bracing side wall to bend in toward each other near the rear picture holding panel at the crease. This bend in the side bracing walls achieves the dual purpose of bracing the stereogram against the rear picture holding panel and stabilizing the stereoscope in its assembled conformation. Each bracing side wall can extend beyond the plane formed by the assembled front viewing panel, approximately 3.57 degrees from the perpendicular formed by the vertical plane of the front short edge of the bottom panel when the stereoscope is assembled. This assists with creating a bracing surface for the front viewing panel to engage when the front viewing panel is perpendicular to the bottom panel.
[0027] Each bracing side wall may have a middle section height that at least partly covers an ocular lens when the stereoscope is in its collapsed formation. Preferably, the height of this middle section is at least approximately 1.75 inches (44.5 mm). This height protects any pictures on the rear picture holding panel from coming into direct contact with the lenses on the front viewing panel when in its collapsed position, thereby protecting the pictures and the lenses from damage.
[0028] The front viewing panel has two apertures for the insertion of ocular lenses. The center of the lenses are preferably approximately 2.5 inches from the bottom panel of the assembled stereoscope. In the embodiment of a stereoscope for viewing 4 by 6 inch stereograms, each lens has a preferred focal distance of approximately 5.0 inches and the distance from rear picture holding panel to the front viewing panel is 5.5 inches. The shorter focal distance of the lens (5.0 inches) compared to the distance from the rear picture holding panel to the front viewing panel (5.5 inches) is to accommodate how the human eye focuses. In other embodiments of stereoscopes of different sizes, the focal lengths of the lenses are adjusted accordingly to have the observer view the stereogram in focus thereby providing comfortable full field of view of the respective image.
[0029] The stereoscope has a nasal space and septum panel formed from cut sections of the bottom panel and front viewing panel. The septum panel prevents cross-talk between left and right images of the stereogram by creating a barrier that prevents the left eye from seeing the right image of the stereogram and the right eye from seeing the left image of the stereogram. The nasal space preferably has a depth of approximately 1.5 inches from the front short edge of the bottom panel, and a width of approximately 1.625 inches in width centered on the bottom panel and front viewing panel to fit the nose of the observer. These dimensions allow an observer's eyes to be placed close to the lenses on the front viewing panel without the observer's nose pressing against the front viewing panel. By creating a nasal space with these dimensions, a septum panel forms a vertical barrier inside the structure when the stereoscope is assembled.
[0030] The septum panel has a preferable width of approximately 1.625 inches, and located approximately 1.5 inches from the plane formed by the assembled viewing panel. These dimensions prevent the left eye from viewing the right image of the stereogram, and the right eye from viewing the left image of the stereogram. The septum panel has a vertical height long enough to prevent both the left eye and the right eye from seeing over the septum panel and seeing the right image and left image respectively and in a preferred embodiment is approximately 3.25 inches in height.
[0031] In a preferred embodiment, the septum panel is integrally hinged to the bottom panel, and when the stereoscope is assembled, the septum panel is folded at the top portion along a preformed crease to form a nasal bridge integrally hinged to the viewing panel. When assembled, the front viewing panel and the septum panel are substantially parallel to each other, and the nasal bridge and bottom panel are substantially parallel to each other, and substantially perpendicular to the front viewing panel and septum panel.
[0032] FIGS. 1-8 are different views of a stereoscope in an unfolded, assembled, and collapsed configuration. In particular reference to the embodiment, FIG. 1 depicts an embodiment of an unfolded stereoscope 10 made of cardboard or other stiff but bendable material. The stereoscope 10 has front viewing panel 70 with apertures 64 for lenses 82 . The front viewing panel 70 is integrally hinged to a bottom panel 72 and can be folded such that the front viewing panel 70 is substantially perpendicular to the bottom panel 72 . Integrally hinged on the opposite side from the front viewing panel is a rear picture holding panel 12 . The rear picture holding panel 12 preferably has a width of 6 inches at its base 22 and a height of 4 inches for its two legs 14 , 16 so that the stereoscopic viewer 10 can hold a 4 by 6 inch stereogram. The rear picture holding panel 12 may be an LCD display.
[0033] Along the legs 74 , 76 of the bottom panel 72 are two integrally hinged bracing side walls 42 , 44 that can be folded such that they are substantially perpendicular to the bottom panel 72 when assembled. Each bracing side wall 42 , 44 , when assembled, is secured to the rear picture holding panel 12 by tape, glue, or other means of attaching the bracing side walls 42 , 44 to the rear picture holding panel 12 . Each bracing side wall 42 , 44 has a diagonal folding crease 24 , 26 that can be formed by scoring the bracing side walls 42 , 44 . Each diagonal folding crease 24 , 26 may be 1.75 inches from each corner 20 , 18 that connects the rear picture holding panel 12 to each bracing side wall 42 , 44 . The height of each diagonal folding crease 24 , 26 from the base 74 , 76 of each bracing wall 42 , 44 is approximately 1.25 inches to the top edge 32 , 34 of each bracing side wall 42 , 44 and also approximately 1.25 inches from the base 22 of the rear picture holding panel 12 , which is approximately 30%-31% percent of the height of the rear picture holding panel 12 . The dimensions and position of each diagonal folding crease 24 , 26 is optimal for reducing of shadows that may form on the stereogram due to light coming in from the sides of the bracing walls 42 , 44 . Each bracing wall 42 , 44 may have a middle region 36 , 38 of approximately at least 1.75 inches such that when the stereoscope 10 is in its collapsed configuration, the side walls 42 , 44 at least partially cover the lenses 82 to protect the stereogram and the lenses 82 .
[0034] Each bracing side wall 42 , 44 has a recess 46 , 48 that can engage with recesses 60 , 62 on the viewing panel 70 , when the stereoscope 10 is in the assembled position. The bracing side wall recesses 46 , 48 are positioned in front of the plane formed from the viewing panel 70 in its assembled position. The front legs 50 , 52 of the bracing side walls 42 , 44 extend beyond the plane formed from the viewing panel 70 when the bracing side walls 42 , 44 engage with the viewing panel 70 . This causes a bend in the bracing side walls 42 , 44 to occur at the preformed diagonal folding creases 24 , 26 on each bracing side wall 42 , 44 . The diagonal folding creases 24 , 26 causes the rear portion of the each bracing side wall 42 , 44 bend slightly in toward each other and helps hold a stereogram against the rear picture holding panel 12 . The bend also helps to brace the bracing side walls 42 , 44 against the rear picture holding panel 12 , and prevents the bracing side walls 42 , 44 from falling in towards each other, which would block the observer from seeing the entirety of the stereogram.
[0035] The front viewing panel 70 can have a nasal space, so that the observer's eyes can be close to the lenses 82 without the observers nose interfering with placement of the eyes. The nasal space can be created by cutting the bottom panel 72 and front viewing panel 70 along side edges that then form a septum panel 68 that spans both the viewing panel 70 and bottom panel 72 . The septum panel 68 is foldably hinged via a septum panel crease 40 to the bottom panel 72 . The septum panel 68 is foldably hinged to a nasal bridge 66 via a septum-bridge crease 80 , and the nasal bridge 66 is foldably hinged to the viewing panel 70 via a bridge-viewing panel crease 78 .
[0036] The septum panel 68 and nasal space have a preferable width of 1.625 inches. The distance from the plane formed by the viewing panel 70 when assembled, is preferably 1.5 inches. These dimensions are optimal for preventing crosstalk of the left and right images placed on the rear panel 12 . Using these dimensions, the left eye is substantially prevented from seeing the image on the right side of the rear picture holding panel 12 and the right eye is substantially prevented from seeing the image on the left side of the picture holding panel 12 .
[0037] In a preferred embodiment, the angle formed by each leg 16 , 14 of the rear picture holding panel 12 and the long leg 28 , 30 of each bracing wall 42 , 44 is an obtuse angle of about 91.79 degrees. The angle formed by the long leg 28 , 30 of each bracing wall 42 , 44 and each diagonal folding crease 24 , 26 may be 46 degrees, and the angle formed by the base 74 , 76 of each bracing wall 42 , 44 to the diagonal folding crease 24 , 26 is approximately 44 degrees. The angle formed from plane of the base 58 of the viewing panel 70 and each recess 46 , 48 on each of the bracing walls 42 , 44 is 3.57 degrees. In a preferred embodiment, the diagonal length of each bracing side wall 42 , 44 from the corner formed from the rear legs 28 , 30 and picture holding panel 12 to each recess 46 , 48 is approximately 5.7 to 5.9 inches. In a preferred embodiment, the shape of the bottom panel 72 is an isosceles trapezoid, with a portion of the small base cut or sliced to form a septum panel 68 .
[0038] With particular reference to FIG. 2 and FIG. 3 , these figures depict different views of an embodiment of the stereoscope 10 in its assembled configuration. FIG. 2 depicts an assembled embodiment from a front top perspective while FIG. 3 depicts an assembled embodiment from a rear top perspective. The bracing side walls 42 , 44 are foldably hinged substantially perpendicular to the bottom panel 72 , and fold up such that the legs 14 , 16 of the rear picture holding panel 12 are adjacent to the legs 28 , 30 of the bracing side walls 42 , 44 , which secured together by tape or other attachment mechanism. The front viewing panel 70 is substantially perpendicular to the bottom panel 72 , and bracing side walls 42 , 44 . The viewing panel 70 is substantially parallel to the rear picture holding panel 12 and septum panel 68 . The front viewing panel 70 , is engaged with each bracing side wall 42 , 44 via recesses 46 , 48 on the front viewing panel 70 with recesses 60 , 62 on the bracing side walls 42 , 44 . The diagonal folding creases 24 , 26 on the bracing side walls 42 , 44 allow the bracing side walls 42 , 44 to bend in toward each other and support the stereogram against the rear picture holding panel 12 , and supplies tension against the front viewing panel 70 to keep the final assembly together when the recesses 42 , 44 , 60 , 62 are engaged.
[0039] The distance from each rear vertical bracing side wall leg 28 , 30 to the recesses 46 , 48 on each bracing side wall 42 , 44 is greater than the length of the bottom panel side legs 74 , 76 , causing the bracing side walls 42 , 44 to angle and bend in toward each other at the diagonal folding creases 24 , 26 . When the height from the base of each of the bracing side walls 74 , 76 to the termination point on the bracing side walls 32 , 34 of the diagonal folding crease 24 , 26 is 28% to 34% of the height of the rear picture holding panel 12 (approximately 1.12 to 1.36 inches when the rear picture holding panel 12 has a height of 4 inches), the stereoscope 10 is structurally stable by the bracing side walls 42 , 44 , which do not fall in toward each other at this height, but also reduce or prevent shadowing on the stereogram, which is placed on the rear picture holding panel 12 .
[0040] With particular reference to FIG. 4 , this figure depicts an embodiment of the stereoscope 10 from a top view in its assembled configuration. Notably, the bottom panel 72 is trapezoidal in shape and depicts each bracing side wall 42 , 44 , angling in toward each at the preformed diagonal folding creases 24 , 26 .
[0041] With particular reference to FIG. 5 , this figure depicts an embodiment of the stereoscope 10 from the front view. An observer views the stereogram through lenses 82 within the front viewing panel 70 . The observer's nose is placed in cut out area in the front viewing panel 70 which forms the septum panel 68 when the stereoscope 10 is in its assembled configuration.
[0042] With particular reference to FIG. 6 , this figure depicts an embodiment of a stereoscope 10 from a side view in its assembled conformation. Notably, the distance from the base 74 of the bracing side wall 42 to the top edge 32 of the bracing side where the folding crease 24 terminates is approximately 1.25 inches. Preferably, the distance from the plane of the assembled rear picture holding panel 12 to the vertical plane of the recess 46 on the bracing side wall 42 is greater than the length of the base 74 of bracing side wall 42 . When the front viewing panel 70 is engaged with the recess 46 on the bracing side wall 42 , it will cause the bracing side wall 42 to bend in at the preformed folding crease 24 to accommodate the difference in lengths. The bend both acts as a brace for a picture against the rear picture holding panel 12 , as well increases structural stability of the assembled stereoscope 10 .
[0043] With particular reference to FIG. 7 and FIG. 8 , these figures depict perspective views of a partially folded stereoscope 10 , and top view of a completed folded stereoscope 10 , respectively. The front viewing panel 70 is disengaged from the bracing side walls 42 , 44 at the recesses 46 , 48 . The front viewing panel 70 is folded down such that it lays flat against the bottom panel 72 . The septum panel 68 and nasal bridge 66 are also folded down onto the bottom panel 72 . Each bracing side wall 42 , 44 is folded in toward each other, through the diagonal folding creases 24 , 26 causing the section of bracing side walls 42 , 44 nearer the front viewing panel 70 to lay flat on top of the front viewing panel 70 . A middle section 36 , 38 of each bracing side wall 42 , 44 covers at least a portion of the apertures 64 for lenses 82 . The rear picture holding panel 12 folds down on top of the bracing side walls 42 , 44 , forming a flattened stereoscope 10 , which may be useful for sending through the mail.
[0044] FIG. 8 depicts an embodiment of the stereoscope 10 in its collapsed configuration. To achieve this folded down configuration, the front viewing panel 70 is folded down on top of the bottom panel 72 . The bracing walls 42 , 44 are folded in and down onto the front viewing panel 70 . The picture holding panel 12 is then folded on top of the folded bracing side walls 42 , 44 to form a flat collapsed stereoscope 10 . | A collapsible stereoscope made of a stiff but bendable material. The stereoscope includes a front viewing panel with apertures for lenses, a rear picture holding panel, and bracing side walls, all integrally hinged to a bottom panel. Each bracing side wall varies in height so that it is tall enough in some regions to provide structural support, but short enough in other regions to reduce or prevent the casting of shadows on the stereogram. The length of each bracing side wall is longer than length of the bottom panel, so that when each bracing side wall is secured to the front panel, the bracing side walls bend in toward each other at a preformed folding crease which improves structural stability of the stereoscope, holds stereograms against the picture holding panel, and reduces shadowing on the stereogram. The collapsible stereoscope can be used as a greeting card. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for remedying polluted soil. In more detail, this invention relates to a method for remedying polluted soil in which the pollutant in the polluted region is decomposed by microbial activities.
2. Related Background Art
Recent rapid developments in science and technology have produced a vast amount of chemicals and chemical products. These substances are polluting nature slowly accumulating in the environment. Environmental pollution is a serious problem spreading all over the world since water and the air are circulating in the environment. Examples of hitherto known pollutants are chlorinated organic compounds (such as dichloroethylene (DCE), trichloroethylene (TCE), tetrachloroethylene (PCE) and dioxin), aromatic compounds (such as toluene, xylene and benzene) and fuels such as gasoline. Chlorinated aliphatic hydrocarbon compounds (such as dichloroethylene, trichloroethylene and tetrachloroethylene) are especially used in a large amount as a solvent for cleaning precision machine members and for dry cleaning, and pollution of soil and ground water by these solvents have been revealed. In addition, these organic compounds are so volatile that they may cause air pollution. It is also pointed out that these organic compounds are teratogenic and carcinogenic, so that it becomes evident that they seriously affect living creatures. Accordingly, an urgent theme is not only to cut off the pollution sources but also to clean the soil and ground water already polluted with these organic compounds.
One of the conventional methods for remedying the soil polluted with chlorinated organic compounds is, for example, to scoop out the polluted soil and subject it to a heat treatment. Although this method enables complete elimination of pollutants from the dug up soil, it requires much expenses and a long working period for turning up the soil. It is practically impossible to take out the polluted soil situated deep under the ground, limiting the application range of this method. In addition, the chlorinated organic compounds released from the dug up polluted soil should be recovered by adsorption onto an adsorbent such as activated charcoal to prevent secondary air pollution, and the used activated charcoal requires further processing. For example, when the used activated charcoal which adsorbed chlorinated compounds such as DCE, TCE and PCE is incinerated, more poisonous by- products such as phosgene may be generated. Accordingly, the final processing cost is predicted to be enormous because of the necessary additional steps to make the recovered pollutants harmless.
Vacuum-extraction of the pollutants from the polluted soil or use of a microorganism having pollutant-degrading ability can solve one of the problem of the above-mentioned method, i.e., limitations of the treating region. These methods do not require to dig up the soil and can purify the soil at the location where it is (called “in situ” hereinafter). Actually, these method are cheap and simple compared with the foregoing dig-up method; only small-scale work is required such as boring a well for introducing a vacuum extraction pipe or pollutant-degrading microorganisms into the polluted soil. The vacuum extraction method has problems that it cannot remove chlorinated organic compounds in a low concentration of several ppm or less efficiently, and that further treatment of the recovered chlorinated organic compounds is required as in the above-mentioned method.
On the other hand, the pollutant in soil can be degraded into harmless substance(s) by the microbial remediation method using microorganisms native or foreign to the soil. Thus, the microbial method dispenses the detoxification treatment of the recovered pollutant that is indispensable in the foregoing two methods. In addition, this method is highly efficient in degrading pollutant of a relatively low concentration.
Accordingly, now the microbial remediation method is attracting attentions.
When the native microorganisms (inherently living in the region to be remedied) are used in the remediation method, it is necessary to supply the soil region to be treated with activating agents such as inducers to induce degradation activity of the native microorganisms, nutrients to enhance the microbial degradation activity, oxygen and growth stimulating agents. When a foreign microorganism having the pollutant-degrading ability is used, it is necessary to introduce into the soil the microorganism and if necessary activating agents for that microorganism.
In both cases, it is preferable to introduce the microorganism or the activating agent in the soil as even as possible. Usually, soil structure is not so uniform as to allow uniform diffusion of a liquid containing the microorganism and activating agent into the soil. For the purpose of solving these technical problems, the inventors of the present invention have disclosed an art for uniform distribution in the soil of the injected liquid containing a microorganism and a microbial activating agent. Japanese Laid-Open Patent Application No. 8-224566.
SUMMARY OF THE INVENTION
The inventors of the present invention has found that when a liquid containing a microorganism and an activation agent is injected into the soil, a portion of the pollutant present in the voids (pores) of the soil may be pushed out according to the injection, and move along the diffusion of the liquid, so that the polluted region may be expanded by the liquid injection. This tendency is more evident with volatile pollutants such as DCE, TCE and PCE. Therefore, enlargement of the polluted region due to the liquid injection should be prevented as much as possible irrespective of the pollutant concentrations, especially in In situ remediation of the soil. As a conclusion, a technical development has been required to solve this problem.
Further studying how to solve the technical problems hitherto described, the inventors of the present invention found a method for remedying the soil which completes remediation of the soil in the closed space by isolating the polluted region in situ from the surrounding soil, or substantially enclosing the soil within a closed space.
The object of the present invention, based on the findings of the inventors of the present invention, is to provide a method for carrying out high remediation of the soil while preventing enlargement of the polluted region.
In accordance with one embodiment of the present invention, there is provided a method for remedying soil containing a region polluted with a pollutant which comprises a step of injecting into the soil a liquid containing a microorganism having an activity to decompose the pollutant or a liquid containing a microorganism having ability to decompose the pollutant and an activation agent for the microorganism, wherein the step comprises:
isolating the region from surrounding soil with a barrier made of a material that does not allow the pollutant, the microorganism, the activation agent or water to pass through; and
replacing void water in the isolated region with said liquid.
In accordance with another embodiment to achieve the foregoing object, the present invention provides a method for remedying soil containing a region polluted with a pollutant comprising a step of injecting into the soil a liquid containing a microorganism having an activity to decompose the pollutant or a liquid containing a microorganism having ability to decompose the pollutant and an activation agent for the microorganism, wherein the step comprises:
separating the region from the surrounding soil with a barrier made of a material that does not allow the pollutant, the microorganism, the activation agent or water to pass through; and
injecting into the region the liquid in an amount 1.1 times or more a volume of the void of the isolated region.
In accordance with the other embodiment, the present invention provides a method for remedying a soil polluted with a pollutant comprising a step of taking the soil in a treatment vessel to decompose the pollutant by introducing a liquid containing a microorganism capable of decomposing the pollutant or a liquid containing the microorganism and an activation agent for the microorganism, wherein the treatment vessel is composed of a material that does not allow the pollutant, microorganism, the activation agent or water to pass through, and the liquid is injected to replace void water in the soil in the vessel with the liquid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of a treatment system.
FIG. 2 is an illustrative drawing of the method for hardening the soil.
FIG. 3 is an illustrative drawing of the test apparatus used in Example 1.
FIG. 4 is a schematic drawing showing an example of a system for carrying out the present invention.
FIG. 5 is a graph showing TCE decomposition in Example 1, and Comparative Examples 1 and 2.
FIG. 6 is a graph showing TCE decomposition in Example 1, and Comparative Examples 1 and 2.
FIG. 7 is a graph showing TCE decomposition in Example 1, and Comparative Examples 1 and 2.
FIG. 8 is a graph showing TCE concentrations in the sample collected from the sampling hole 34 in Example 2.
FIG. 9 is a graph showing TCE concentrations in the sample collected from the sampling port 35 in Example 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the schematic drawing of FIG. 1, a remediation system for the polluted soil is explained. The treatment vessel 8 for pollutant decomposition installed at a site of the soil pollution is composed of a side wall 1 , a bottom 7 and a lid 2 . The treatment vessel 8 contains the polluted soil to isolate the soil from the surrounding soil. The lid 2 is provided with two opening 3 and 4 , and a liquid injection pipe 5 is inserted into the vessel 8 though the opening 3 to inject a liquid containing a microorganism or a liquid containing a microorganism and an activation agent into the soil for soil remediation. One end of the liquid injection pipe 5 is inserted into the soil 9 in the treatment vessel 8 to inject the liquid into it. The other end of the pipe 5 is connected to a tank 11 containing the liquid. The liquid is injected into the soil 9 with a pump 10 disposed on way of the pipe 5 .
A discharge pipe 6 is inserted into the treatment vessel 8 through an opening 4 to lead the pollutant or the overflowing liquid into a pollutant decomposition apparatus 12 , where the pollutant retained in the soil void is pushed out by an applied pressure due to the liquid injection from the injection pipe 5 . A trap 13 is provided to prevent the discharge of the pollutant from the pollutant decomposition apparatus 12 into the air.
It is preferable to construct the pollutant decomposition treatment vessel 8 so as to enclose the pollution source or the highly polluted soil in situ (where the soil to be treated exists). This enables not only efficient remediation of the soil but also prevention of the diffusion of the pollution. When there is a flow of ground water, it is effective in preventing spread of pollution to install the treatment vessel as upstream as possible. The shape and construction method of the side wall 1 is not limited as long as the wall is made of a material not permeable by water, microorganisms and pollutants. For example, an iron pipe may be driven into the polluted soil to form a iron pipe side wall 1 , or the side wall 1 may be formed by driving four iron plates into the soil as side walls.
The bottom 7 can be formed, for example, by injecting a soil hardening agent to harden the soil at the bottom. To form the bottom, after the steel pipe is driven into the treatment site or after four steel plates were driven into the site, a soil hardening agent is injected into the bottom of the region in the pipe or surrounded by the steel plates. Examples of the soil hardening agent are water glass, rapidly hardening cement, normal cement and special purpose cement, which may be properly selected according to the conditions of the site or the purpose. Admixtures such as montmorillonite, calcium, an anionic polymer surface active agent and/or a fluidity accelerating agent may be added to the soil hardening agent. When the pollutant is a volatile compound such as a chlorinated aliphatic hydrocarbon compound (for example, dichloroethylene, trichloroethylene or tetrachloroethylene), it is preferable to use an water glass type soil hardening agent not permeable by these compounds.
Examples of the injection method of the hardening agent into the ground are the CCP method, jet-grout method and roden jet pile method. Although these methods can be appropriately selected depending on the region of the polluted soil and conditions of the ground, CCP method is preferable since this method enables injection of the soil hardening agent without outflow of the polluted soil, thus dispensing the treatment of the outflow.
The CCP method in forming the bottom of the polluted soil to be treated by injecting the hardening agent at a high pressure is described referring to FIG. 2. A rod 57 to which a special jet equipment is mounted is attached to a boring machine 56 , and the other end of the special jet equipment is connected to a circulation water tank 60 via a super-high pressure pulse pump 58 and a valve 59 . The ground is bored to a depth of injection position with a rotation speed and a stroke number suitable for the soil conditions, while continuously sending the circulation water by keeping the pump discharge pressure at, for example, 30 Kgf/cm 2 or less. When reached to a desired depth, the rod is disconnected from the circulation water tank and connected to the soil hardening agent tank 61 by valve operation to inject the soil hardening agent, for example, at a rotation speed of 10 to 20 rpm and a discharge pressure of 200 to 400 Kgf/cm 2 . The pollutant decomposing microorganism may be injected, for example, from the rod connected to the microorganism storage tank 62 and pump 58 , or it may be injected by driving a separate injection pipe into the treatment region.
When the construction site has a water impermeable layer such as a rock-bed, the layer itself may be used as the bottom 7 .
It is preferable that the top of the treatment vessel is a sealed structure by providing a lid made of the same material not permeable by the pollutant as the side wall, not to release into the air the pollutant rising to the earth surface forced by the rising front of the injected liquid. Diffusion of the pollutant into the environment from the treatment vessel 8 due to injection of the liquid can be almost perfectly prevented by constructing such a treatment vessel at the site of the pollution. It can also prevent the pollutant-decomposing microorganism and the activation agent such as a nutrient or an inducer for the microorganism from diffusing into the environment.
Examples of the decomposition apparatus 12 to decompose the pollutant extruded from the soil 9 are a bioreactor filled with a pollutant-decomposing microorganism immobilized on a carrier, a bioreactor containing a liquid containing a pollutant-decomposing microorganism to which polluted gas or polluted soil water is introduced, or a chemical decomposition apparatus using ultraviolet light or iron.
Application of the method according to one embodiment of the present invention to a remediation method in which microorganism is introduced into the soil containing the pollutant will be explained hereinafter.
The pollutant-degradable microorganism grown in the fermentation tank 11 , together with a liquid medium, is introduced into the pollutant decomposition treatment vessel 8 through the injection pipe 5 . The injection position and injection method may be properly selected depending on the soil texture and consolidation. For example, the liquid medium can be sent up from the bottom of the treatment vessel using a pump, or it can flow down from the top of the treatment vessel by hydrostatic pressure. The liquid medium to be injected into the soil may contain an activation agent for the microorganism. As the activation agent, there is a growth medium containing nutrients for the microorganism or an inducer for the microbial expression of the pollutant-degrading activity.
When the pollutant is a volatile compound such as DCE, TCE or PCE, it is preferable to fill the treatment vessel with the liquid medium containing microorganism by injecting it from the bottom of the treatment vessel, so as to achieve soil remediation more efficiently. The volatile pollutant retained in the soil void is pushed up by the liquid front, and part of the pollutant moves toward the earth surface to finally seep from the surface as a gas or mixed with the liquid. According to the embodiment of the present invention, however, the extruded pollutant from the soil by the injected liquid will be guided to the pollutant decomposition apparatus 12 through the pipe 6 to be decomposed there. The pollutant remaining in the soil void not excluded by the injected liquid is decomposed by the microorganism injected into the soil. Thus, a much higher remediation of the soil is attained according to the embodiment of the present invention. The number of the injection port is not limited to one so long as the microorganism can be distributed in the vessel as uniform as possible. When a plurality of the injection ports are used, however, it is preferable that the ports are disposed, for example, upward to the earth surface so that the pollutant driven by the injection front can be trapped securely. It is also desirable that the position and shape of the drainage port for the overflow is properly devised depending on the injection method.
The microorganism to be injected into the treatment vessel has an activity to degrade the pollutant. For example, when the pollutant is an aromatic compound such as phenol or a halogenated aliphatic hydrocarbon compound such as DCE, TCE or PCE, a bacterial strain such as Pseudomonas cepacia strain KK01 (FERM BP-4235), strain J1 (FERM BP-5102), strain JM1 (FERM BP-5352), strain JMC1 (FERM BP-5960), strain JM2N (FERM BP-5961), strain JM6U (FERM BP-5962) and strain JM7 (FERM BP-5963) can be used. When the pollutant is a petroleum fuel, the present invention can be practiced using, for example, an Alcaligenes species, strain SM8-4L (FERM, P-13801).
It is preferable that the microorganism for the injection is in a state having high pollutant-degrading activity by cultivation. Since the microorganism usually shows the highest degradation activity to the pollutant in its logarithmic growth phase, it is preferable to introduce the microorganism in the logarithmic growth phase into the soil containing the pollutant.
Meanwhile, degrading chlorinated aliphatic hydrocarbon compounds, the microorganism is often damaged by the intermediate products. In such a case, the higher the concentration of the pollutant is, the more seriously the microorganism is damaged accompanied by the decrease in decomposition activity. One can solve such a problem according to the method of the present invention, that is, when the soil to be treated contains a high concentration of a pollutant in a treating vessel, an excess amount of a liquid medium containing the pollutant-degrading microorganism is injected into the vessel through the injection pipe 5 to fill all the void in the soil with the medium, thereby extruding the inherent soil water from the soil in the vessel. Since a liquid medium injected into the soil migrates through the soil while partly diluted with the inherent soil water, when the liquid medium is injected into the treatment vessel in a volume larger than the total soil void volume in the treatment vessel, it pushes out the inherent void water from the soil void and further pushes out the void water diluted with the liquid medium. Thus, extruding water containing the pollutant in a high concentration from the soil to be treated, which decreases the concentration of the pollutant in the soil thus lessens the damage to the microorganism. This also enables uniform distribution of the liquid medium into the soil in the treatment vessel.
The optimum injection amount of the liquid medium containing the microorganism depends on the soil properties, e.g., moisture content of the soil, it is preferable that the injection volume is 1.1 times or more, more preferably 1.2 times or more, the total volume of the soil void. When the injection volume is determined as described above, a part of the pollutant present in a high concentration in the soil is washed out along with the overflow of the injected medium, thereby decreasing the pollutant concentration in the soil. This procedure lessens the damage of the microorganism due to the pollutant itself or its intermediate products in degradation, enabling treatment of the region containing the pollutant in a high concentration.
The volume of the void (Vv) of the soil in a given region can be determined by the following equation (1):
Vv=V− 100· W /((100+ω)·γ s ) (1)
In the equation (1), V is the total volume of the soil, W is the total weight of the soil, ω is the moisture content of the soil and γs is the specific gravity of the soil particles ( of the solid matter). The total weight of the soil can be determined by multiplying the weight of a unit volume by the volume of the soil of the region, the former being determined by a conventional method (for example, a direct measurement method or a replacement measurement method).
The moisture content of the soil is determined, for example, as follows. A prescribed amount of soil is taken from the soil and placed in a watch glass to weigh the total weight (Wt) (the sum of the weights of the watch glass (Wp), the soil particles (dry weight) (Ws) and moisture contained in the soil sample (Ww)). After drying the soil sample at about 110° C. for 24 hours, it is weighed again, the weight Wa=Wp+Ws. Therefore, the moisture content of the soil sample (ω) is calculated as follows:
ω=100 Ww/Ws= 100( Wt−Wa )/( Wa−Wp )
The specific gravity of the soil particles is determined, for example, as follows. A pycnometer of an inner volume of Vp and of a weight of Wp is filled with distilled water and its weight (Wc) is measured, where Wc=Wp+γ w YP (γ w represents the weight of a unit volume of water). Then, this pycnometer is filled with the soil sample and water. After thoroughly deaerated, the total weight (Wt) is expressed by the following equation (2):
Wt=Wp+ ( Vp−Vs )γ w +Ws (2)
where Vs is the volume of the soil particles (solid) in the soil sample and Ws is the dry matter weight of the soil sample. The specific gravity (Gs) determined by dividing the weight of the unit volume of the sample soil γs (=Ws/Vs) by the weight of the unit volume of water is generally used as the specific gravity of the soil. Accordingly, the above equation (2) can be converted to: Wt = Wp + ( Vp - ( Ws / Gs γ w ) ) γ w + Ws = Wc + ( 1 - 1 / Gs ) Ws ( 3 )
Thus, after the soil sample is taken out from the pycnometer and dried to determine the dry matter weight Ws, the specific gravity of the sample soil can be determined using the following equation (4).
Gs=Ws /( Ws+Wc−Wt ) (4)
It is desirable to collect the soil samples from a plurality of places for determining the void volume of the isolated soil region, since construction of the soil isolated by the barrier is not always uniform. The average of the soil void volumes of the samples taken from a plurality of places may be used as the void volume of the isolated soil. When the value of the soil void volume varies greatly among samples, it is preferable to increase the sampling number. When the presence of soil layers containing soil particles of different nature is predicted or known in the isolated soil region, one can investigate the soil layer constitution previously to determine respective soil void volume, and use the sum of the void volumes of soil layers as the total soil void volume.
When a microorganism showing the highest activity and in its logarithmic growth phase is used, the cells consume a large amount of oxygen in the soil of the treatment vessel. Accordingly, the oxygen concentration in the soil may rapidly decrease immediately after the microorganism is introduced. Such decrease in oxygen concentration may cause decrease in pollutant-decomposing activity of the microorganism. Therefore, for effective remediation of the soil, it is preferable to aerate the liquid medium to be injected with the microorganism into the treatment vessel, with a sufficient amount of oxygen or air. Otherwise, when the liquid medium to be injected into the soil contains some nutrients as an activation agent for the growth of the microorganism, it is effective in soil remediation to lower the nutrient concentration in order to suppress the microbial growth in the soil, or to eliminate the carbon source for the microorganism to substantially halt the growth of the microorganism in the soil.
As hitherto described, according to one embodiment of the present invention, an environment polluted with a high concentration of a pollutant can be effectively remedied by using a microorganism. It can also suppress the efflux of the pollutant, the microorganism and the activation agent for the microorganism outside the environment to be remedied. According to the other embodiment of the present invention, more improved remediation of the polluted environment is possible in addition to the foregoing advantages.
Although the present invention will be described in detail referring to the examples, it is by no means limited thereto.
EXAMPLE 1
An experimental apparatus as shown in FIG. 3 was assembled for this example. A 2 liter stainless steel vessel 14 with a lid was prepared. The contact faces of the vessel 14 and lid 15 were mirror-polished and a Teflon O-ring 20 was used for sealing up the vessel. An injection port 16 for the microorganism introduction, a discharge port 17 and a port 18 for sampling were provided on the lid 15 and a Teflon tube was attached to the discharge port 17 and fixed by means of a Teflon seal. Teflon coated rubber was attached to the sampling port.
Gravel with a mean diameter of 1 cm was put in the stainless vessel to a thickness of about 4 cm. The gravel layer 22 was formed so that its moisture content and porosity (void ratio) were zero and 53% respectively. Then, the microorganism injection pipe 19 was driven into the gravel layer 22 . Next, 2932 g of fine sand of a specific gravity of 2.7 was filled so that the moisture content and the void ratio of the sand layer be 14% and 40% respectively. A layer of gravel with a mean diameter of 1 cm was further formed on the sand layer up to the top face of the stainless steel vessel. The gravel layer also had a moisture content of zero and a void ratio of 53%. The void volume of the soil in the stainless steel vessel is determined as follows:
For the sand layer 21 , the following equation can be applied where its moisture content is 14% and 2932 g of sands of a specific gravity of 2.7 were used.
Weight of fine sand (Ws)+Weight of moisture in the fine sand layer (Ww)=2932 g
Moisture content (ω=100Ww/Ws)=14
Specific gravity (Ws/Vs) 2.7
From the above, the volume (Vs) of fine sand particles in the fine sand layer is calculated:
Vs= 2932×100/(2.7(100+14))=952.57(cm 3 )
The void ratio is expressed by: Total volume of the fine sand layer (V)−Vs)/Total volume of the fine sand layer and (V−Vs)/V=0.4, then;
V=Vs/0.6=952.57/0.6=1587.6 (cm 3 ) and
The void volume (Vv) of the sand layer=0.4 V=0.4×1587.6=635 (cm 3 )
Since the volume of the gravel layer is expressed by the difference between the volume of the stainless steel vessel and the volume of the fine sand layer, the volume is calculated as: 2000−1587.6=412.4 (cm 3 ).
Since the void ratio of the gravel layer is 53%, the volume of the void is calculated as: 412.4×0.53=218.5 (cm 3 ). Therefore, the total void volume of the soil in the stainless steel vessel is: 635+218.5=853.5 (cm 3 ).
The lid 15 was then set up on the stainless steel vessel 14 . The microorganism-injection pipe 19 was passed through the microorganism-injection port 16 on the lid 15 , and the connection part was sealed with a Teflon seal. The lid was fixed with vises to ensure sealing of the vessel.
A reservoir 25 containing 500 ml of an aqueous solution of 50 ppm TCE 26 and a pump 24 were prepared. After connecting a Teflon tube extending from the discharge port 17 through the reservoir 25 to the microorganism-injection port 16 by means of a pipe joint 27 as shown in FIG. 3, the fine sand in the vessel 14 was contaminated with a vapor of TCE sent from the reservoir by means of the pump 24 , at a rate of 1 litter/min. for 25 hours. After disconnecting the TCE reservoir, a cultivation tank (not shown) of a pollutant-decomposing strain JM1 (FERM BP-5352) was connected to the microorganism-injection pipe 19 and the liquid culture of strain JM1 was slowly injected by means of compressed air. The injection volume (938.9 ml) was set to be 1.1 times as much as the total void volume of the sand and injection was continued until overflow of 445.4 ml (the presumed inherent soil water present in the void of the sand: Ww=0.14 Ws=0.14×2.7 Vs=360 ml) +superfluous amount of the culture liquid medium (0.1 Vv=85.3 ml) flowed out from the discharge port 18 . The JM1 cultivation tank was removed after injection and the injection port and discharge port were sealed. All of the overflow was collected.
Immediately after the injection and every 3 hours after, a 0.5 ml liquid sample was taken from each of three sampling ports by inserting a syringe. Sampling points were the bottom (1 cm above the bottom gravel layer), the middle (5 cm above the bottom sampling point) and the top (5 cm above the middle sampling point) of the sand layer. Each liquid sample was immediately placed in a bottle containing 5 ml of n-hexane and, after stirring for 3 minutes, the n-hexane layer was collected to determine TCE concentration by ECD gas-chromatography. The results are shown in FIGS. 5 to 7 (FIG. 5 : Top, FIG. 6 : Middle, FIG. 7 : Bottom of the sand layer). The conditions of the culture of pollutant-degrading microorganism are as follows:
A 3 day culture of strain JM1 (4.8×108 cell/ml) was diluted 2-fold with M9 medium and used for the injection.
M9 medium
Na 2 HPO 4
6.2
g/l
KH 2 PO 4
3.0
g/l
NaCl
0.5
g/l
NH 4 Cl
1.0
g/l
Sodium L-glutamate
20
g/l
TCE concentration of the trapped overflow measured by the same method as described above was 20 ppm, indicating that the overflow contained TCE.
Comparative Example 1
A stainless steel vessel containing the soil polluted with TCE was prepared as described in Example 1. The experiment was carried out in the same manner as in Example 1, except that M 9 medium was used instead of JM1 culture. The results are also shown in FIGS. 5 to 7 .
Comparative Example 2
A stainless steel vessel containing the soil polluted with TCE was prepared as shown in Example 1 and the experiment was carried out in the same manner as in Example 1 except that the injection of JM1 culture fluid was stopped when the liquid just come out from the discharge port to prevent overflow, that is, the injected amount of the culture was 493 ml ( the soil void volume (853.5 cm 3 ) subtracted with the volume of the void water (360 ml)). TCE concentrations in the sand layer in the stainless steel vessel were also measured by the same method as in Example 1. The results are shown in FIGS. 5 to 7 .
EXAMPLE 2
Formation of Pollutant-decomposition System in Simulated Polluted soil—Decomposition of TCE
A preliminary experiment was carried out for determining the void volume of the soil to be used in the experimental system shown in FIG. 4. A 36.6 liter stainless steel vessel 28 with a lid was prepared. The contact faces of the vessel 28 and lid 29 were mirror-polished and a Teflon O-ring 30 was used for sealing up the vessel. A soil hardening agent-injection port 31 , microorganism-injection port 32 and TCE-introduction port 33 , and two discharge ports 34 and 35 were provided on the lid 29 . A Teflon tube was fixed to each discharge port with a Teflon seal. A stainless steel pipe of 13 mm diameter, tapered and provided with many holes of 1 mm diameter at its lower end, was use as the soil hardening agent-injection pipe 36 . An L-shaped stainless steel pipe of 14 mm diameter, tapered at the end, was used as the TCE-introduction pipe 37 , where several holes of about 1 mm diameter were provided in the lower part so as to inject TCE from the bottom of the stainless steel vessel. A stainless steel pipe with a diameter of 13 mm was also provided as the microorganism-introduction pipe 38 .
Gravel was spread at the bottom of the stainless steel vessel to a height of about 4 cm to form a gravel layer 39 . After setting the TCE-introduction pipe 37 in the layer, fine sand 40 was put in the stainless steel vessel 28 up to 200 mm from the top of the stainless steel vessel 28 , and an iron pipe 41 of 112 mm diameter and 200 mm long was driven into the sand layer. To the same depth as with the iron pipe 41 , was driven a soil hardening agent-injection pipe 36 into the sand layer. After further filling the vessel with sand to a height of 180 mm from the top of the stainless steel vessel 28 , a microorganism-introduction pipe 38 was driven into the sand layer parallel to the soil hardening agent-injection tube 36 . Finally, the vessel was filled with sand up to the rim. Gypsum 43 was injected around the soil hardening agent-injection pipe 36 , microorganism-introduction tube 38 and TCE-introduction pipe 37 to fix them not to leave any space between the sand and pipes. An iron lid 42 was set on the iron pipe 41 so that the soil hardening agent injection tube 36 and microorganisms injection tube 38 come through the lid, and the Joints were fixed with gypsum. Each pipe was inserted into the port provided on the lid 29 of the stainless steel vessel and sealed with a Teflon seal. The lid was fixed with vises and the tight sealing was confirmed. The soil hardening agent-injection tube 36 was then connected to the soil hardening agent tank 50 via a valve 47 and a booster pump 46 . A soil hardening agent of water glass type (made by Nitto Kagaku Co.) was used as a soil hardening agent. After injecting 400 ml of the soil hardening agent from the soil hardening agent tank 50 operating the booster pump 46 at a pressure of 5 kg/cm 2 , the valve was closed and the stainless steel vessel was left standing for 24 hours. Then, the lid 29 was removed and the iron pipe 41 was withdrawn to find that the bottom of the iron pipe was sealed with a hardened product of the water glass type hardening agent. It was also confirmed that neither gaseous TCE, the liquid medium containing the microorganism to be used in this example nor water would not leak from the iron pipe 41 .
The void volume of the soil region isolated from the surrounding environment by the iron pipe 41 was first determined. The soil volume was calculated as follows: (11.2/2) 2 ×3.14×20=1969 cm 3 . The specific gravity, moisture content and weight of the unit volume of the soil were also determined using the samples randomly collected from three points in the isolated soil region. The results were a specific gravity of 2.7, a moisture content of 14% and an weight of the unit volume of 1.86 g/cm 3 . There were no significant difference among these values due to the difference of the sampling points. Therefore, the total soil void volume of the isolated soil region was calculated to be 779.1 cm 3 from the foregoing equation (1).
The test system shown in FIG. 4 was assembled by the same method as described above. 500 ml of an aqueous solution of 400 ppm TCE was put in a reservoir 44 and this reservoir 44 was connected to the TCE-introduction port 33 via a pump 45 using a Teflon tube.
The reservoir 44 was also connected to the discharge ports 34 and 35 using Teflon tubes. Then, the pump 45 was operated to circulate gaseous TCE at a rate of 1 liter/min. for 24 hours to contaminate the sand in the vessel. After that, the Teflon tubes connected to the two discharge ports were removed and an air sample was taken by inserting a syringe through each discharge port into the sand layer to a depth of 100 mm. TCE gas concentration was assayed by FID gas chromatography (trade name: GC-14B, made by Shimadzu Co.). The result showed that the gas concentrations were 985 ppm and 950 ppm at the discharge ports 34 and 35 , respectively.
After closing the valves 48 and 49 at the TCE-introduction port 33 and microorganism-injection port 32 , the soil hardening agent-injection tube 36 was connected to the soil hardening agent tank 50 via the valve 47 and booster pump 46 . A water glass type soil hardening agent (made by Nitto kagaku Co.) was used as the soil hardening agent. After sending 400 ml of the soil hardening agent from the soil hardening agent tank 50 with a booster pump 46 at 5 kg/cm 2 , the valve was closed. The vessel was left standing for 24 hours. Then, the Teflon tubes connecting the discharge ports 34 and 35 and the reservoir 44 were disconnected from the reservoir tank 44 by switching the valve 56 and 57 . The Teflon tube extending from the discharge port 34 was connected to a decomposition apparatus 53 containing 500 ml of the liquid culture of strain JM1 (FERM BP-5352). The strain JM1 used in the decomposition apparatus was grown by the same method as used for soil injection. The Teflon tube connected to the discharge port 35 was connected to the activated carbon column 52 .
Then the liquid culture of strain JM 1 (FERM BP-5352) in the tank 51 , grown in the same manner as in Example 1, was injected into the isolated region from the pipe 38 . The injection volume was 934.9 ml which is 1.2 times as much as the soil void volume. Upon seeing the overflow of the liquid from the discharge port 34 , injection of the liquid was stopped. The gas exhausted from the decomposition apparatus during injection was sampled from the sampling port 55 and the TCE concentration in the gas was assayed using an FID gas-chromatograph (trade name: GC 14B, made by Shimadzu Co.), showing a concentration of below the detection limit. After finishing the culture fluid injection, the valve 48 of the microorganism-injection tube was closed and the Teflon tube connected to the activated carbon column was removed, and Teflon rubber stoppers were attached to ports 34 and 35 to make them sampling ports.
An aliquot of 0.5 ml of the soil water was taken every 3 hours after the culture injection, by inserting a syringe from the sampling port 34 into a depth of 100 mm, and TCE concentration was assayed by the same method as in Example 1. Gaseous samples were also collected from the sampling port 35 every 3 hours for TCE assay by FID gas chromatography. The results are shown in FIGS. 8 and 9.
At the end of the experiment, an aliquot of 0.5 ml of the liquid culture 54 in the decomposition apparatus 53 was collected and, after extracting with n-hexane, TCE concentration was determined by gas-chromatography. The TCE concentration was 0.01 ppm.
EXAMPLE 3
Two sets of simulated TCE polluted soil were prepared in the same manner as in Example 1.
A colony of strain JM1 (FERM BP-5352) grown on M9 agar medium containing 1 wt % of malic acid was transferred to M9 liquid medium containing 1 wt % of sodium glutamate and cultured with shaking at 15° C. for 2 days. The cell concentration of the liquid culture after 2 days' shaking culture was 6×10 8 CFU/ml. This culture was diluted 2- and 4-fold with M9 medium containing no carbon source and the dilutions were aerated with oxygen gas for 10 minutes. Dilutions were injected into the soil in the above prepared two vessels respectively, by the same method as described in Example 1.
After the injection, the injection and discharge ports were sealed and the vessel was left standing for 48 hours at 20° C. Using a syringe, samples of 0.5 ml soil water were taken from three sampling points each provided 1 cm above the lower gravel layer, 5 cm above the bottom sampling point and 5 cm above the middle sampling point. Each of the samples was immediately placed in vessels containing 5 ml n-hexane and stirred for 3 minutes. Then the hexane layer was collected to determine the TCE content by ECD gas-chromatography (trade name: GC 14B, made by Shimadzu Co.) The results are shown in Table 1 and Table 2.
EXAMPLE 4
Two sets of simulated TCE polluted soil were prepared as in Example 3. The culture liquid medium of the strain JM1 cultivated under the same condition as in Example 3 was diluted 2- and 4-fold with M9 culture medium containing no carbon source and aerated with air for 10 minutes. These dilutions were injected into the vessels containing the TCE polluted soil, and the TCE concentration in the soil was measured by the same method as described in Example 3. The results are shown in Table 1 and Table 2.
EXAMPLE 5
An experiment was carried by the same method as in Example 4, except that the culture dilutions to be injected were not aerated. The results are shown in Table 1 and Table 2.
EXAMPLE 6
An experiment was carried by the same method as in Example 4, except that the injected culture dilutions of JM1 did not overflow from the discharge port, and injection was stopped at the point when the injected liquid appeared from the discharge port. The results are shown in Table 1 and Table 2.
TABLE 1
JM1 culture (2-fold dilution)
Example 4
Example 3
(exposed
(exposed to
to air for
Example 5
Sampling
oxygen for
10
(no
point
10 minutes)
minutes)
aeration)
Example 6
Top
0.03 (ppm)
0.08 (ppm)
0.23 (ppm)
1.10 (ppm)
Middle
0.02
0.06
0.09
0.34
Bottom
not
0.03
0.1
0.10
detected
TABLE 2
JM1 culture (4-fold dilution)
Sampling
point
Example 3
Example 4
Example 5
Example 6
Top
0.05 (ppm)
0.09 (ppm)
0.12
2.15 (ppm)
Middle
0.03
0.08
0.08
0.41
Bottom
0.03
0.05
0.07
0.15
It was confirmed from the results in Table 1 and Table 2 that a higher degree of soil remediation could be attained by previously aerating the bacterial suspension to be injected into the soil with oxygen or air. Moreover, by previously aerating the culture fluid with oxygen or air and injecting the culture fluid at a volume 1.2 times as much as the void volume of the soil to be remedied, the top layer of which remediation is often difficult can be more efficiently purified. | The present invention provides a method for remedying soil containing a region polluted with a pollutant which comprises a step of injecting into the soil a liquid containing a microorganism having an activity to decompose the pollutant or a liquid containing the microorganism and an activation agent for the microorganism decomposing the pollutant, wherein the step comprises isolating the region from surrounding soil with a barrier made of a material that does not allow the pollutant, the microorganism, the activation agent or water to pass through, and replacing void water in the isolated region with the liquid. | 1 |
[0001] Priority to German Patent Application No. 102 09346.6-24, filed Mar. 2, 2002 and hereby incorporated by reference herein, is claimed.
BACKGROUND INFORMATION
[0002] The present invention relates to a manufacturing method for a connection between a valve head and a valve stem of a multi-part valve, to a connection made using the method, and to an automotive engine valve made using the method.
[0003] Valves used in mass production are mostly based on high-temperature resistant steel, at least in the valve head area. The valve stem is made of less highly alloyed steel and is connected to the valve head by friction welding. In the valve seat area, valve heads are either plasma-coated with a wear-resistant material or hardened. From racing, valves are known that are made of titanium and TiAl. Currently, it is being considered to manufacture and use powder-metallurgically produced or cast solid valves of TiAl.
[0004] However, cast solid valves can be manufactured using by centrifugal casting or using a kind of a pressure diecasting or injection method. In order to avoid pores in the stem area which is difficult to feed, appropriate preheating must be provided in the permanent molds used. For this purpose, correspondingly expensive permanent mold materials are needed, such as niobium or tantalum. Moreover, the preheating operations increase cycle the times during production. Heretofore, however, it has not yet been possible to avoid residual porosity in the stem, even under optimum temperature control.
[0005] In the case of multi-part valves, different requirements are placed on the head and the stem. In particular, valve heads must be highly resistant to temperature and wear, whereas the valve stem must have a high strength in conjunction with a high resistance to abrasion at the stem end. The most convenient material is chosen in each case according to the requirements placed on the valve parts. When using valve heads, for example, of TiAl, the stem can be chosen to be made of suitable steel.
[0006] Conventional approaches to produce multi-part valves are limited to manufacturing the valve head and the stem separately from each other and to interconnect them in a subsequent process step.
[0007] U.S. Pat. No. 4,834,036 describes a method for making an interconnection between a valve head and a valve stem which is hollow inside. During manufacture, the stem end which is inserted in the head is expanded and connected thereto in a positive-locking manner under the influence of heat with the aid of a pressure medium which is pressed into the hollow valve stem.
[0008] Apart from single-part models, multi-part valves have the disadvantage of having to ensure a suitable connection of the individual parts.
BRIEF SUMMARY OF THE INVENTION
[0009] An object of the present invention is to manufacture and connect the parts of multi-piece valves in a simple and reliable manner.
[0010] The present invention provides for a method for making an interconnection between a valve head ( 1 ) and a valve stem ( 2 ) of a multi-part valve, in particular for motor vehicle engines, wherein the interconnection between these parts is made by pouring a casting intermetallic compound of titanium aluminide around a valve stem end made of steel.
[0011] Using this method, the present invention also provides a connection of a valve stem ( 1 ) to a valve head ( 2 ) of a multi-part valve, wherein the connection is accomplished by friction fit or positive fit or integral connection or by a combination, as well as an automotive engine valve, which is composed of a valve stem ( 1 ) and a valve head ( 2 ), wherein the valve stem ( 1 ) is composed of a steel alloy and the valve head ( 2 ) is composed of an intermetallic compound of the system Ti/Al.
[0012] The present invention thus describes a method for manufacturing a multi-part valve for motor vehicles on the basis of an in-situ connection of the valve head and stem using a casting process.
[0013] In the method according to the present invention for making an interconnection between a valve head and the stem, the interconnection between these parts is made by pouring a casting alloy around one stem end.
[0014] The connection of the head and the stem is accomplished in that, during the manufacture of the valve using a casting process, the stem is already integrated in a permanent mold, and thus directly cast-in.
[0015] It is important for a proper connection that no hot cracks occur during casting. These hot cracks result from tensions due to the volume contraction during solidification in the solid-liquid interval which exceed the strength of the solidifying material and which cannot heal due to lack of secondary feeding.
[0016] Therefore, the present invention proposes two measures to prevent these hot cracks. According to the present invention, first of all, the temperature control of the permanent mold and of the valve stem located therein is implemented such that a controlled solidification in a direction opposite to the mold filling direction is carried out, preferably including appropriate secondary feeding.
[0017] According to the present invention, moreover, a secondary feeding of the cast alloy is carried out at high filling pressure during casting to heal formed cracks.
[0018] The casting pressure required to fill the mold is reached, for example, due to the centrifugal force occurring during centrifugal casting.
[0019] The use of the permanent mold centrifugal casting process appears to be suitable for this purpose.
[0020] Technically, the process provides the particular advantage of achieving a very rigid connection of the valve head and stem due to the press-fit connection. Moreover, it is also possible to achieve optimum positive fit and, possibly even an integral connection.
[0021] The manufacturing process advantageously stands out compared to other joining techniques because of its economic efficiency, since the manufacture of multi-part valves is carried out in one step. This eliminates the need for subsequent processing steps to connect these two components.
[0022] In the method according to the present invention, the connection between the valve head and stem is accomplished by pouring the cast alloy around one stem end.
[0023] The connection of a valve head to the valve stem is primarily a friction fit due to the frictional forces between the head and the stem resulting from the press-fit connection.
[0024] The fundamental basis of the press-fit connection is provided by the shrinking of the cast alloy on the stem. Upon solidification, the cast alloy has a considerably higher temperature than the stem. The volume contraction associated with the cooling of the cast alloy is therefore greater, independently of whether the stem has a smaller or larger coefficient of thermal expansion than the cast alloy. The valve head made of the cast alloy shrinks on the stem during cooling.
[0025] A further subject matter of the present invention is the configuration of the valve stem end in order to accomplish a positive fit. For example, the stem end can be designed with a circumferential groove so as to produce an undercut around which flows the cast alloy, resulting in a kind of an interlocking of the head and the stem. Moreover, the stem end should, if possible, be designed such that the stem and the head are prevented from rotating relative to each other during later operation. This can be achieved, for example, by a groove or notch which extends perpendicular to the stem axis on the stem end, the groove or notch breaking the rotational symmetry of the stem and being infiltrated during the filling of the mold. Furrows or notches parallel to the stem axis are conceivable as well.
[0026] The metallurgical joint or integral connection, that is, the fusion or joining by fusion of the head and the stem material, can be achieved by a suitable material combination and selective temperature control of the stem and of the permanent mold. In this context, moreover, any form of groove or notch increases the contact area between the stem and the casting material, and represents an additional bonding surface in the combination with a desired metallurgical joint.
[0027] However, if the intention is to deliberately avoid such a metallurgical joint, then a diffusion barrier can be applied between the casting material and the stem, at least at the stem end which is cast-in. Such a diffusion barrier can be composed of a molybdenum film or of a molybdenum layer which is applied to the stem and prevents joining by fusion during the mold-filling period.
[0028] The valve stem is preferably composed of steel, of titanium or titanium alloys, or of an intermetallic alloy of the systems titanium-aluminum, in particular based on gamma-TiAl; iron-aluminum, for example, based on FeAl; and of the system nickel-aluminum, for example, based on NiAl.
[0029] Preferably, a cavity is formed inside the valve stem, the cavity being either empty or filled with sodium.
[0030] The valve head and stem can be made of the same material. However, it is preferred to use a material for the head that has a lower density than the stem material. The materials or intermetallic alloys proposed are those of the systems titanium-aluminum, in particular based on gamma-TiAl; iron-aluminum, for example, based on FeAl; and of the system nickel-aluminum, for example, based on NiAl. According to the present invention, it is also possible to use conventionally employed steels using the casting method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] In the following, the present invention will be described and illustrated in greater detail with reference to several selected exemplary embodiments in connection with the accompanying drawings, in which
[0032] [0032]FIG. 1 is a cross-section of a permanent mold having a mold insert, including an integrated valve stem;
[0033] [0033]FIG. 2 depicts a section through a valve composed of a stem and a head;
[0034] [0034]FIG. 3 shows the configuration of the stem end which is surrounded by the valve head.
DETAILED DESCRIPTION
[0035] Permanent mold 5 with integrated valve stem 1 , which is shown in FIG. 1, is used to manufacture the valves. According to the present invention, it is proposed for permanent mold 5 to be manufactured preferably from a high-temperature resistant steel, and to insert a mold insert 4 into the permanent mold, the mold insert being made of a high-temperature resistant steel or of niobium or tantalum and forming the mold cavity for valve head 2 . The permanent mold is provided with a bore whose end is connected to the mold cavity. Valve stem 1 is inserted into this bore. In this context, the length of the bore is selected such that one end of the stem extends from the bore into the mold cavity for valve head 2 .
[0036] The connection between valve head 2 and valve stem 1 is accomplished by pouring the casting alloy around valve stem 1 (FIG. 2).
[0037] The temperature control of permanent mold 5 and of stem 1 located therein is to be implemented such that a controlled solidification in a direction opposite to mold filling direction 6 is carried out, including appropriate secondary feeding.
[0038] [0038]FIG. 2 shows the completed valve composed of valve stem 1 and of valve head 2 , which surrounds the stem. The connection between the stem and the head is primarily the press-fit connection shown. In addition, it is possible to accomplish a positive fit. Depending on the selected alloy, in particular in the case of identical or similar stem and head materials, the connection can additionally be of a chemical or metallurgical nature, that is, represent an integral connection.
[0039] In the view of FIG. 3 is shown, in particular, the configuration of the stem end. For example, the stem end can be designed with a circumferential groove 11 so as to produce an undercut around which flows the casting alloy, resulting in a kind of an interlocking of the head and the stem, thus providing a positive fit. Moreover, the stem end should, if possible, be designed such that the stem and the head are prevented from rotating relative to each other during later operation. This can be achieved, for example, by groove or notch 12 shown in the drawing which extends perpendicular to the stem axis on the stem end, the groove or notch breaking the rotational symmetry of the stem and being infiltrated during the filling of the mold. Furrows or notches parallel to the stem axis are conceivable as well.
[0040] The filling of the mold is preferably carried out using a permanent mold casting method which allows pressure-assisted mold filling and solidification. Centrifugal casting appears to be particularly suitable. However, it is also conceivable to use pressure casting processes, such as classical pressure diecasting or squeeze casting. Furthermore, it is conceivable to use semi-solid metal (“SSM”) casting (or semi-solid metal forging). This term, which is used in scientific language, is understood to mean a method in which, unlike conventional pressure casting methods, metal, in this case the alloy for the valve head, is processed in the semi-solid state instead of liquid metal. The use of SSM casting has various advantages in the context of the idea according to the present invention. If an undesired reaction between the stem material and the valve material is expected, this reaction is considerably reduced by using a semi-solid melt which has a lower thermal energy compared to liquid material. In addition, the use of semi-solid material reduces the thermal shrinkage in such a manner that the valve head has an initial shape which nearly corresponds to the final dimensions (so-called “near-net-shape quality”) and the risk of cracking is reduced.
[0041] List of Reference Numerals
[0042] [0042] 1 valve stem
[0043] [0043] 2 valve head
[0044] [0044] 3 valve head cavity
[0045] [0045] 4 mold insert
[0046] [0046] 5 permanent mold
[0047] [0047] 6 mold filling direction
[0048] [0048] 11 groove
[0049] [0049] 12 transverse groove/notch | For making an interconnection between a valve head and stem, the interconnection between these parts is made by pouring a cast alloy around the stem end. A connection and a valve are also provided. | 5 |
CROSS-REFERENCED RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/873,712 filed Dec. 8, 2006 which is hereby incorporated by reference in it's entirety.
[0002] The present invention relates to a product and method of making such a device for encapsulating a wireless component and securing it to a thermoplastic surface of a desired device. More particularly, it relates to a product and method of making such a device for encapsulating a wireless component, such as an RFID tag, and securing it to a thermoplastic surface of a desired device such as a filter or filter capsule, biobag and the like.
BACKGROUND OF THE INVENTION
[0003] Due to many factors including increased use of manufacturing control and documentation systems, lot traceability, ease of use and item identification, customers require item specific information such as catalog number, lot and serial identification for each filter, media and component used in their process. Currently, techniques such as printing, engraving, laser marking, labeling and bar-coding are used to transfer this information to customers.
[0004] For filter cartridges and other products which are wholly in the fluid path during use, adhesives, inks or any foreign matter are extremely undesirable as they may leach extractable matter into the final product which needs to be identified, quantified and if at too high a level removed. Therefore engraving and laser marking are currently preferred to identify filter cartridges. Unfortunately, this requires the end user to manually read and write down or key in information. This process is subject to error because the engraving is difficult to read on the translucent part. Because of number of times a cartridge needs to be tracked through receiving, multiple uses, storage and disposal, customers are in need of a better way.
[0005] The use of wireless tags such as RFID tags is just being explored as a potential solution. Such tags generally comprise a wireless transponder of some type and an antenna, both of which are mounted to a card or other substrate and generally encapsulated in epoxy or urethane. These tags have been adhered to products through the use of adhesives, especially self-stick adhesives. The issue of adhesives especially in the fluid path remains. Additionally, adhesives tend to degrade over time and may fail losing the tag and making the entire system unworkable.
[0006] Recent advances in in-mold labeling combined with wireless identification technology offer a solution to the problem by eliminating traditional adhesive wireless tags and embedding wireless tags into the device itself, isolating it from the fluid streams. However, the tooling to make such a change is costly and needs to be specific to each part modified with a tag, thus slowing adoption and implementation.
SUMMARY OF THE INVENTION
[0007] The invention described herein solves this problem by providing an embedded wireless device, such as a RFID tag or Zigbee device, molded into separate housing formed of any thermoplastic material which is compatible with the plastic material of the device to which the tag and housing is to be attached. Subsequently, the tag assembly can be bonded such as by thermal bonding, solvent bonding or adhesive bonding, onto the device as is well known in the industry.
[0008] Preferably one surface of the housing has two or more spaced apart protrusions which center and aid in the attachment of the housing to the device. More preferably, these protrusions act as energy directors that are preferentially melted and used to attach the housing to the device. In addition, these protrusions also form the bulk of the necessary sacrificial material for mechanical attachment.
[0009] The end result is that the user has to accept no new materials into their processes and can leverage all the benefits of wireless technology on a multitude of products.
[0010] A further advantage to this device is that next generation wireless tags will provide customers with real time process information by incorporating sensors into the tag. These tags will need to be in the fluid path and having a universal means of attachment with the fewest new materials of construction will be a great advantage.
[0011] In one embodiment, the protrusions are made of thermoplastic and are bonded by an energy based heating such as ultrasonic or vibration welding. The protrusions act as energy directors and preferentially absorb the energy at their surfaces adjacent the device against which they have been placed to form a molten thermoplastic plastic bond between the housing and the device. In this embodiment, the thermoplastic of the housing and the device to which it is attached must be compatible and be capable of bonding to each other. In another embodiment, they are compatible and one has a lower melting point than the other. In a further embodiment, they are compatible and the protrusions have a lower melting point than the device surface. In an additional embodiment the plastics are the same.
[0012] Suitable thermoplastics include but are not limited to polyethylene, polypropylene, EVA copolymers, alpha olefins and metallocene copolymers, PFA, MFA, polycarbonate, vinyl copolymers such as PVC, polyamides such as nylon, polyesters, acrylonitrile-butadienestyrene (ABS), polysulphone, polyethersulphone, polyarylsulphone, polyphenylsulphone, polyacrylonitrile, polyvinylidene fluoride (PVDF), and blends thereof.
IN THE DRAWINGS
[0013] FIG. 1 shows a portion of the device containing the recess in perspective view.
[0014] FIG. 2 shows a portion of the device containing the recess and the wireless component in the recess in perspective view.
[0015] FIG. 3 shows one embodiment of the housing with the wireless component in the recess and covered by the second piece of the housing in cross-sectional view.
[0016] FIG. 4 shows one preferred embodiment of an outer surface of the device containing the protrusions in perspective view.
[0017] FIG. 5 shows one preferred embodiment of the present invention mounted against a surface to which it is to be bonded in perspective view;
[0018] FIG. 6A-6E show other embodiments of the outer surface of the device containing the protrusions in perspective view.
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1 shows a molded housing 2 with a first closed surface 4 and a recess 6 for the receipt of a wireless device (not shown).
[0020] FIG. 2 shows a wireless device 8 in the recess 6 of the housing 2 . In this particular example, the wireless device is a RFID tag and antenna assembly although it could be any device that uses wireless protocols like Zigbee, Bluetooth, or WUSB.
[0021] The recess is then sealed by a cover 10 preferably formed of the same plastic as the housing 2 although all the cover 10 need be is compatible with the plastic of the housing 2 so it can be sealed in a liquid tight manner to the housing. The cover 10 of the housing can be a separately molded or pre-formed piece that is attached to the housing 2 at the rim 12 by heat, ultrasonic or vibration welding, adhesive, solvent bonding and the like. Alternatively and preferably, it can be molded directly over the wireless device and recess such as by injection molding.
[0022] Preferably, one surface of the device, either the first closed surface 4 of the housing 2 or a surface 14 of the cover 10 as shown in FIG. 4 (in this instance as shown it is the cover 14 ) has two or more protrusions 16 formed on it and these protrusions 16 extend away from the surface 14 .
[0023] In the embodiment of FIG. 4 is shown one preferred style in which there are three protrusions 16 A, B and C, two of which 16 A and C are the same size, shape and other dimensions. The third protrusion 16 B is of different size and other dimensions, in this embodiment, by height and length. This style of device allows one to place the encapsulated wireless component (not shown) in the housing 2 against either a flat 18 or a rounded surface 20 of a device (not shown) to which the wireless component is to be attached, as shown in FIG. 5 , and still maintain good contact and center the wireless device and housing on that surface.
[0024] The wireless device in the housing is attached to the surface of the device on which it is mounted by any conventional means such as solvent bonding, adhesives, thermal bonding, such as by ultrasonic or vibration welding or by radiant heat or inductive heat of the plastic of the protrusions and/or the plastic of the device.
[0025] Preferably, the protrusion are made of thermoplastic and are bonded by an energy based heating such as ultrasonic or vibration welding. The protrusions in addition to being stabilizers or centering devices also act as energy directors and preferentially absorb the energy at their surfaces adjacent the device against which they have been placed to form a molten thermoplastic plastic bond between the housing and the device. In this embodiment, the thermoplastic of the housing and the device to which it is attached must be compatible and be capable of bonding to each other. In another embodiment, they are compatible and one has a lower melting point than the other. In a further embodiment, they are compatible and the protrusions have a lower melting point than the device surface. In an additional embodiment the plastics are the same.
[0026] The protrusions are further distinguished in that they are the sacrificial material used to mechanically bond to the mating surface. Their dimensions, shape, and spacing can be customized to supply the sufficient amount of sacrificial material necessary to bond. This sacrificial material is the only deformed component of the embodiment, where the electronics and immediately surrounding enclosing material is not directly used in the bonding. Likewise the surface to which it bonds such as the outer surface of a filter housing or filter capsule, or a biobag or a disposable probe, valve or connector is not deformed or distorted.
[0027] Suitable thermoplastics include but are not limited to polyethylene, polypropylene, EVA copolymers, alpha olefins and metallocene copolymers, PFA, MFA, polycarbonate, vinyl copolymers such as PVC, polyamides such as nylon, polyesters, acrylonitrile-butadiene styrene (ABS), polysulphone, polyethersulphone, polyarylsulphone, polyphenylsulphone, polyacrylonitrile, polyvinylidene fluoride (PVDF), and blends thereof.
[0028] Other shapes can be used for the protrusions 16 some of which are shown in FIGS. 6A-D . They may be formed in the shape of a circle 16 D of FIG. 6A , oval, 16 E of FIG. 6B , pyramids, 16 F of FIG. 6C or rectangular or square 16 G of FIG. 6D . Other shapes and combinations will be obvious to one of ordinary skill in the art. As shown in FIGS. 6A and D there can be 4 protrusions, while in FIGS. 6B and C there are only 2. One could also use 5 protrusions as shown in FIG. 6E . Other numbers of protrusions can be used and would be obvious to one of ordinary skill in the art.
[0029] The device can be made by several methods.
[0030] A first method is to preform a thermoplastic device formed of a housing having a first closed substantially planar inner surface and a first outer surface and at least one recess for holding the component. A wireless component, such as an RFID chip and antenna is then placed into the at least one recess. It may simply be laced in loosely or if desired it be adhered in place using an adhesive such as a hot melt thermoplastic, if desired. A cover is then overmolded to at least one recess and component with a thermoplastic to encapsulate the component and form a second outer surface of the housing. Either first outer surface or the second outer surface of the housing has two or more spaced apart protrusions extending away from the selected outer surface.
[0031] A second method is to preform a thermoplastic device formed of a housing having a first closed substantially planar inner surface and a first outer surface and at least one recess for holding the component. A wireless component, such as an RFID chip and antenna is then placed into the at least one recess. It may simply be laced in loosely or if desired it be adhered in place using an adhesive such as a hot melt thermoplastic, if desired. A cover is then overmolded to the at least one recess and component with a thermoplastic to encapsulate the component and form a second outer surface of the housing. Either first outer surface or the second outer surface of the housing has two or more spaced apart protrusions extending away from the selected outer surface. One then holds the two or more protrusions of the device against a thermoplastic assembly such as a cartridge outer housing and at least partially melt the two or more protrusions to form a bond between the thermoplastic assembly and the thermoplastic protrusions of the device.
[0032] A third method is to mold a thermoplastic device formed of a housing having a first closed substantially planar inner surface and a first outer surface and at least one recess for holding the component. A wireless component, such as an RFID chip and antenna is then placed into the at least one recess while still in the mold. A cover is then overmolded to the at least one recess and component with a thermoplastic to encapsulate the component and form a second outer surface of the housing. Either first outer surface or the second outer surface of the housing has two or more spaced apart protrusions extending away from the selected outer surface of the device.
[0033] A fourth method is to preform a thermoplastic device formed of a housing having a first closed substantially planar inner surface and a first outer surface and at least one recess for holding the component. A wireless component, such as an RFID chip and antenna is then placed into the at least one recess. It may simply be laced in loosely or if desired it be adhered in place using an adhesive such as a hot melt thermoplastic, if desired. A preformed cover is then placed over the at least one recess and component with a thermoplastic and bonded to it by a thermal bond between the housing and cover such as by radiant heat, vibration or ultrasonic welding or by a hot melt adhesive or the like to enclose the component and form a second outer surface of the housing. Either first outer surface or the second outer surface of the housing has two or more spaced apart protrusions extending away from the selected outer surface of the device.
[0034] A fifth method is to preform a thermoplastic device formed of a housing having a first closed substantially planar inner surface and a first outer surface and at least one recess for holding the component. A wireless component, such as an RFID chip and antenna is then placed into the at least one recess. It may simply be laced in loosely or if desired it be adhered in place using an adhesive such as a hot melt thermoplastic, if desired. A preformed cover is then placed over the at least one recess and component with a thermoplastic and the housing and cover are overmolded to bond the cover and housing together and to enclose the component and form a second outer surface of the housing. Either first outer surface or the second outer surface of the housing has two or more spaced apart protrusions extending away from the selected outer surface of the device.
[0035] Other methods can also be used as part of the present invention and would be obvious to one of ordinary skill in the art.
EXAMPLE
[0036] A wireless device, in this example a RFID tag formed of read/write chip and an antenna, available from Tagsys S.A. of France as catalog item Ario™ SM-ISO RFID tag was selected for this example. The wireless device had dimensions of 14 mm wide by 14 mm long and 2 mm high.
[0037] A housing having a cavity with inner cavity dimensions slightly larger than the dimensions of the wireless device was formed of polypropylene.
[0038] The wireless device was tested before insertion into the housing by reading the device with a handheld reader available from Tagsys.
[0039] A cover was formed over and into the cavity of the housing to encapsulate the wireless device within the cavity by an injection molding machine.
[0040] The outer surface of the housing opposite the cavity opening contained three projections in the form of rounded rectangular shapes similar to those shown in FIG. 4 .
[0041] The housing was placed against a thermoplastic (polypropylene) outer surface of a SHF filter available from Millipore Corporation of Billerica, Mass. and bonded to the outer surface of the filter by heating the projections and the housing with standard vibration thermal welder for a period of approximately 1 minutes while applying pressure between the two. The vibration was then stopped, the filter and housing allowed to cool and the wireless device was then tested and found to be capable of both reading and writing information. | The invention described herein provides an embedded wireless device such as a RFID tag molded into separate housing formed of any thermoplastic material compatible to that of the plastic material as the device to which the housing is to be attached. Subsequently, the housed tag assembly can be thermally bonded onto the device through many means which are well known and accepted in the industry. | 1 |
BACKGROUND OF THE INVENTION
[0001] Optical coherence analysis relies on the interference phenomena between a reference wave and an experimental wave or between two parts of an experimental wave to measure distances and thicknesses, and calculate indices of refraction of a sample. Optical Coherence Tomography (OCT) is one example technology that is used to perform high-resolution cross sectional imaging. It is often applied to imaging biological tissue structures, for example, on microscopic scales in real time. Optical waves are reflected from an object or sample and a computer produces images of cross sections or three-dimensional volume renderings of the sample by using information on how the waves are changed upon reflection.
[0002] There are several different classes of OCT, but Fourier domain OCT currently offers the best performance for many applications. Moreover, of the Fourier domain approaches, swept-source OCT has distinct advantages over techniques such as spectrum-encoded OCT because it has the capability of balanced and polarization diversity detection. It has advantages as well for imaging in wavelength regions where inexpensive and fast detector arrays, which are typically required for spectrum-encoded OCT, are not available.
[0003] In swept source OCT, the spectral components are not encoded by spatial separation, but they are encoded in time. The spectrum is either filtered or generated in successive optical frequency sampling intervals and reconstructed before Fourier-transformation. Using the frequency scanning swept source, the optical configuration becomes less complex but the critical performance characteristics now reside in the source and especially its frequency sweep rate and tuning accuracy, along with its coherence length characteristics.
[0004] The swept sources for OCT systems have typically been tunable lasers. The advantages of tunable lasers include high spectral brightness and relatively simple optical designs. A tunable laser is constructed from a gain element, such as a semiconductor optical amplifier (SOA) that is located within a resonant laser cavity, and a tuning element such as a rotating grating, grating with a rotating mirror, or a Fabry-Perot tunable filter.
[0005] Currently, some of the highest tuning speed/sweep rate lasers are based on the laser designs described in U.S. Pat. No. 7,415,049 B1, entitled Laser with Tilted Multi Spatial Mode Resonator Tuning Element, by D. Flanders, M. Kuznetsov and W. Atia. The use of micro-electro-mechanical system (MEMS) Fabry-Perot tunable filters combines the capability for wide spectral scan bands with the low mass, high mechanical resonant frequency deflectable MEMS membranes that have the capacity for high speed tuning/sweep rates.
[0006] Another laser architecture is termed a Fourier-domain mode-locked laser (FDML). This type of laser stores light in a long length of fiber for amplification and recirculation in synchronism with the laser's tuning element. See “Fourier Domain Mode Locking (FDML): A new laser operating regime and applications for optical coherence tomography”, R. Huber, M. Wojtkowski, and J. G. Fujimoto, 17 Apr. 2006/Vol. 14, No. 8/OPTICS EXPRESS 3225. The drawback of these devices is their complexity, however. Moreover, the ring cavity including the long storage fiber creates its own performance problems such as dispersion and instability.
[0007] An important metric for swept sources is coherence length. This refers to the propagation distance over which the source's optical signal maintains a specified degree of coherence. In OCT systems, longer coherence lengths enable imaging over longer depth ranges.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to an OCT method and system and swept laser designs that can be used to improve coherence length of the swept optical signal. This is accomplished using an intra-cavity element that extracts the tunable optical signal at the optimal location within the laser's resonant cavity. Generally this location is between the intracavity tuning element and the cavity's gain element so that light coming from the tuning element is extracted. The present invention also concerns the simultaneous or selective generation of a tunable optical signal with different coherences lengths.
[0009] In general in lasers, the cavity gain element adds noise and/or distorts the spectral content of the light in the laser cavity. For example, the gain element often adds amplified spontaneous emissions (ASE) and this noise degrades the tunable optical signal's coherence length. This noise, however, is removed by the tuning element. The distortion that is added by the gain element arises from a different source. High speed swept lasers such as those often used in OCT systems exhibit a form of mode-locking, termed swept mode locking See e.g., U.S. Pat. Appl. Pub. No. US 2012/0162662 A1, which is incorporated herein by this reference. As a consequence, during operation, light within the laser cavity circulates in the form of one or more pulses, which strongly modulate the gain. Each pulse “hops” to a new optical frequency with the laser tuning, but there is also considerable chirp to the pulses. The chirp is added by the gain element. When these pulses are filtered, the pulses are longer and have smaller chirp than those that have just passed through the gain element.
[0010] Thus, by extracting the tunable optical signal post filtering but before amplification, the coherence length is improved.
[0011] In general, according to one aspect, the invention features a swept laser that generates a swept optical signal. The laser comprises a laser cavity in which the swept optical signal is generated, a tuning element for a controlling an optical frequency of the swept optical signal, a gain element for amplifying light in the laser cavity, and an optical signal extraction element located between the tuning element and the gain element for coupling the swept optical signal from the laser cavity after being filtered by the tuning element but before amplification by the gain element.
[0012] In embodiments, the laser cavity is a linear cavity and the signal extraction element is located downstream of the tuning element but upstream of the gain element. In one case, the signal extraction element is a beam splitter and the tuning element is a Fabry Perot tunable filter. In examples, quarter wave plates on either side of the tuning element are used to rotate the polarization of the optical signal within the laser cavity so that light transmitted through the tunable filter has a polarization that is appropriate for amplification by the gain element whereas light that is rejected by the tunable filter has a polarization that is orthogonal to the polarization at which the gain element amplifies light. The gain element can be a reflective semiconductor optical amplifier.
[0013] In one embodiment, a low coherence signal extraction port is provided that generates a lower coherence version of the swept optical signal.
[0014] In another embodiment, the laser cavity is a ring cavity.
[0015] In general, according to one aspect, the invention features an optical coherence tomography system comprising: an interferometer that combines a swept optical signal from a sample and from a reference path to generate an interference signal, a detection system that detects the interference signal, and a swept laser. This laser generates the swept optical signal and comprises a laser cavity, a gain element for amplifying light in the laser cavity, and an optical signal extraction element located within the laser cavity for coupling the swept optical signal from the laser cavity prior to amplification by the gain element.
[0016] The above and other features of the invention including various novel details of construction and combinations of parts, and other advantages, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular method and device embodying the invention are shown by way of illustration and not as a limitation of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the accompanying drawings, reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale; emphasis has instead been placed upon illustrating the principles of the invention. Of the drawings:
[0018] FIG. 1 is a schematic diagram illustrating a swept laser (linear cavity) according to the present invention;
[0019] FIG. 2 is a schematic diagram illustrating a linear cavity swept laser according to a second embodiment of the present invention;
[0020] FIG. 3 is a schematic diagram illustrating a linear cavity swept laser according to a third embodiment of the present invention;
[0021] FIG. 4 is a schematic diagram illustrating a linear cavity swept laser according to a fourth embodiment of the present invention;
[0022] FIG. 5 is a schematic diagram illustrating a linear cavity swept laser according to a fifth embodiment of the present invention;
[0023] FIG. 6 is a schematic diagram illustrating a ring cavity swept laser according to a sixth embodiment of the present invention;
[0024] FIG. 7 is a schematic diagram illustrating a ring cavity swept laser according to a sixth embodiment of the present invention; and
[0025] FIG. 8 is a schematic diagram of an optical coherence tomography system using the inventive swept laser.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0027] Turning now to the drawing, FIG. 1 shows a swept laser source system 100 according to a first embodiment of the present invention.
[0028] In a preferred embodiment, a majority or all of the components of the swept laser 100 are installed on a common bench 105 . The bench 105 is termed a micro-optical bench and is preferably less than 10 millimeters (mm) in width and about 25 mm in length or less. This size enables the bench to be installed in a standard, or near standard-sized, butterfly or DIP (dual inline pin) hermetic package. In one implementation, the bench 105 is fabricated from aluminum nitride. A thermoelectric cooler is disposed between the bench and the package (attached/solder bonded both to the backside of the bench and inner bottom panel of the package) to control the temperature of the bench 105 .
[0029] As is characteristic of lasers, the swept laser 100 includes a laser (resonant) cavity 125 . Light within the cavity 125 is coupled from it via a high coherence output port defined by output lens 118 . In the illustrated example, the light or tunable signal is transmitted from the laser 100 and off of the bench 105 on an optical fiber 110 . Typically the optical fiber 110 extends through a fiber feedthrough in the hermetic package.
[0030] In other examples, the output port is defined by a window in the hermetic package. The tunable signal is coupled from the bench 105 and through the package as a beam, thus avoiding the use of the fiber.
[0031] A gain element 126 is provided in the cavity 125 . In a typical example, the gain element 126 is a semiconductor optical amplifier (SOA), which is mounted to the bench 105 via a submount. In other examples, a rare earth doped optical fiber gain element is used. Still other examples are solid-state optical gain media. The gain element 126 amplifies light within the cavity 125 .
[0032] In the current embodiment, the input facet 128 of the SOA chip 126 is angled relative to the axis of the cavity and anti-reflection (AR) coated. The back facet 130 is coated to be reflective to define one end of the laser cavity 125 . In the illustrated example, an edge emitting chip is used with a curved or arcuate ridge waveguide 115 .
[0033] The other end of the laser cavity 125 is defined by mirror 102 . Preferably, this mirror 102 also functions as a polarizing filter to remove light that is orthogonal to the gain polarization of the cavity 125 . The gain polarization of the cavity at the location of the mirror 102 is actually orthogonal to the gain polarization of the SOA 126 due to a pair of quarter waveplates 114 , 118 .
[0034] The material system of the chip 126 is selected based on the desired spectral operating range. Common material systems are based on III-V semiconductor materials, including binary materials, such as GaN, GaAs, InP, GaSb, InAs, as well as ternary, quaternary, and pentenary alloys, such as InGaN, InAlGaN, InGaP, AlGaAs, InGaAs, GaInNAs, GaInNAsSb, AlInGaAs, InGaAsP, AlGaAsSb, AlGaInAsSb, AlAsSb, InGaSb, InAsSb, and InGaAsSb. Collectively, these material systems support operating wavelengths from about 400 nanometers (nm) to 2000 nm, including longer wavelength ranges extending into multiple micrometer wavelengths. Semiconductor quantum well and quantum dot gain regions are typically used to obtain especially wide gain and spectral emission bandwidths. Currently, edge-emitting chips are used although vertical cavity surface emitting laser (VCSEL) chips are used in different implementations.
[0035] In one implementation, the gain element 126 amplifies light at only one polarization, the gain polarization. It provides little or no gain at the orthogonal polarization.
[0036] Also within the cavity 125 is a tuning element 116 , which is preferably mounted to the bench 105 . The tuning element typically has a tunable passband (in reflection or transmission) that scans over a scan band. This passband overlaps with the gain spectrum of the gain element 126 . This configuration allows optical energy within the passband to be amplified within the laser cavity 125 and thus coupled onto optical fiber 110 via the output port.
[0037] In some embodiments, the tuning element 116 is a micro mechanical system (MEMS) Fabry Perot tunable filter. In other examples, grating based tuning elements are used. Still other examples are acousto optic tunable filters.
[0038] The swept source system 100 is generally intended for high speed tuning to generate swept optical signals that repeatedly scan over the scan band(s) at rates of greater than 1 kiloHertz (kHz). In current embodiments, the laser system 100 tunes at speeds greater than 20 or 100 kHz. In very high speed embodiments, the multi-sweep rate swept source system 100 tunes at speeds greater than 200 or 500 kHz.
[0039] Typically, the width of the tuning or scan band is greater than 10 nanometers (nm). In the current embodiments, it is usually between 50 and 150 nm, although even wider tuning bands are contemplated in some examples. On the other hand, the bandwidth of the narrowband emission has a full width half maximum (FWHM) bandwidth of less than 20 or 10 GigaHertz (GHz), and is usually 5 GHz or less. For optical coherence tomography, this high spectral resolution implies a long coherence length and therefore enables imaging deeper into samples, for example deeper than 5 millimeters (mm). On the other hand, in lower performance applications, for example OCT imaging less than 1 mm deep into samples, broader FWHM passbands are sometimes appropriate, such as passbands of about 200 GHz or less.
[0040] The tuning speed can also be expressed in wavelength per unit time. In one example, for an approximately 110 nm tuning band or scanband and 100 kHz scan rate, assuming 60% duty cycle for substantially linear up-tuning, the peak sweep speed would be 110 nm*100 kHz/0.60=18,300 nm/msec=18.3 nm/μsec or faster. In another example, for an approximately 90 nm tuning range and 50 kHz scan rate, assuming a 50% duty cycle for substantially linear up-tuning, the peak sweep speed is 90 nm*50 kHz/0.50=9,000 nm/msec=9.0 nm/μsec or faster. In a smaller tuning band example having an approximately 30 nm tuning range and 2 kHz scan rate, assuming a 80% duty cycle for substantially linear tuning, the peak sweep speed would be 30 nm*2 kHz/0.80=75 nm/msec=0.075 nm/μsec, or faster.
[0041] Thus, in terms of scan rates, in the preferred embodiments described herein, the sweep speeds are greater than 0.05 nm/μsec and preferably greater than 5 nm/μsec. In still higher speed applications, the scan rates are higher than 10 nm/μsec.
[0042] According to the invention, the laser cavity 125 further comprises an optical signal extraction element 122 . The signal extraction element 122 is located downstream of the tuning element 116 but upstream of the gain element 126 and extracts light from the tuning element 116 before it is transmitted to the gain element 126 .
[0043] The advantage of extracting the tunable optical signal from this location within the laser cavity 125 is that the light has just been transmitted through the Fabry Perot tunable filter tuning element 116 , in fact twice in the illustrated embodiment since its last amplification. Thus, its bandwidth corresponds to the passband of the tuning element 116 . This extraction of the tunable optical signal, however, occurs prior to its amplification in the gain element 126 . Typically, a gain element adds noise in addition to amplifying light at the passband. In the case of a semiconductor optical amplifier, this noise includes amplified spontaneous emissions.
[0044] Moreover, as discussed previously, the gain element 126 also tends to modulate the light circulating within the cavity 125 . When operated as a swept source, with the tuning element 116 tuning over the scan band at a high rate, light circulates within the cavity as one or more pulses and the gain element chirps these pulses. The spectral broadening of the light circulating within the cavity by this chirping is counteracted by the double passing of the light through the tuning element 116 prior to extraction by the signal extraction element 122 .
[0045] Thus, by extracting the tunable optical signal prior to amplification, the tunable optical signal is relatively free of the noise and spectral distortion that would be added by the gain element 126 .
[0046] In the illustrated embodiment, the signal extraction element 122 is a beam splitter such as a partial beam splitter or a polarization beam splitter. It reflects light such as at a 90° angle. Often, it only couples approximately 1% to 10% of the light as the output tunable optical signal 160 . In illustrated embodiment, this tunable optical signal is coupled by the lens 118 into the optical fiber 110 .
[0047] Light that is outside the passband of the Fabry Perot tunable filter tuning element 116 is reflected by this filter. This light should not be amplified by the gain element 126 to ensure laser operation. As result, two quarter wave plates 114 , 118 are located on either side of the Fabry Perot filter 116 . These wave plates 114 , 118 rotate the polarization of the optical signal within the laser cavity 125 so that light transmitted through the tunable filter has a polarization that is appropriate for amplification by the gain element 126 . That is, the light is polarized parallel to the gain polarization in the case of a semiconductor optical amplifier gain element 126 . In contrast, light that is rejected by the tunable filter 116 has a polarization that is orthogonal to the polarization at which the gain element 126 amplifies light.
[0048] In the illustrated example, a series of lenses 112 , 120 , and 124 are used to couple light between the various elements within the laser cavity 125 and on the bench 105 . Specifically, lens 112 couples light between the mirror 102 , through the first quarter wave plate 114 and into the tuning element 116 . Lens 120 couples light between the tuning element 116 , the second quarter wave plate 118 , and the signal extraction element 122 . Finally, lens 124 couples light between the front facet 128 of the gain element 126 and the signal extraction element 122 .
[0049] FIG. 2 shows a swept laser 100 according to a second embodiment of the present invention. This embodiment includes a low coherence high power extraction port defined by lens 132 . Specifically, light that is returning from the gain element 126 on a path to the tuning element 116 is also reflected by the signal extraction element 122 to provide a low coherence version 162 of the tunable optical signal. Since this light includes the noise and spectral distortion contributed by the gain element 126 , it generally has a lower coherence length than the tunable optical signal 160 , but a much higher power since it comes directly from the gain element 126 . This light is collected by lens 132 and coupled into an optical fiber 134 in one example. In other examples, it is coupled from the bench 105 as a beam.
[0050] FIG. 3 shows a swept laser according to a third embodiment of the present invention. This embodiment further includes a medium coherence extraction port defined by lens 164 . In general, the coherence length of the tunable signal 165 generated at this port will be lower than the tunable signal 160 but higher than tunable signal 162 since it has been filtered by one pass through the filter 116 .
[0051] Specifically, mirror 102 , which possibly further functions as the polarizing filter, is partially reflective/transmissive to allow the light that has been filtered by the tuning element 116 to pass through the partial mirror 102 to be collimated by lens 164 as a medium coherence version 165 of the tunable optical signal. This medium coherence version 165 of the tunable optical signal is coupled into optical fiber 166 in the illustrated embodiment.
[0052] FIG. 4 shows a swept laser according to a fourth embodiment of the present invention. This embodiment also includes a medium coherence extraction port. Specifically, lens 112 couples light of the cavity 125 into fiber 166 . A fiber mirror 102 f , such a grating or partially reflective fiber splice, functions as a partially reflective/transmissive mirror to define the end of the cavity 125 and also as the medium coherence extraction port. The medium coherence version 165 of the tunable optical signal being transmitted through the fiber mirror 102 f on fiber 166 . The advantage of this embodiment is that longer laser cavities can be created that consequently have spectrally smaller longitudinal mode spacing.
[0053] FIG. 5 shows a swept laser 100 according to a fifth embodiment of the present invention. This embodiment also includes a reflective cavity extender 170 between lens 112 and the mirror 102 . It includes two antireflection coated facets 134 , 136 to allow the light from the cavity 125 to be coupled into and out of the extender 170 . In the extender, light propagates in a zig-zag pattern which increases the effective optical length of the laser cavity 125 . Here again, longer laser cavities can be created that consequently have spectrally smaller longitudinal mode spacing.
[0054] FIG. 6 shows a swept laser 100 according to a sixth embodiment of the present invention.
[0055] This swept laser 100 has a ring cavity configuration. Specifically, the laser cavity 125 transmits light counterclockwise through the laser cavity 125 that is implemented on bench 105 .
[0056] In more detail, light is amplified in the gain element 126 . In the illustrated example, a semiconductor optical amplifier is used in which both the front facet 128 and the rear facet 130 are antireflection coated. Currently an edge-emitting chip with a linear ridge waveguide is preferred.
[0057] The light that exits from the gain element 126 is collected by a lens 140 . The light is then reflected by a first fold mirror 142 and a second fold mirror 144 . A third lens 146 couples the light into the tuning element 116 . The light exiting from the tuning element 116 is collected by a third lens 148 . The light is then reflected by two fold mirrors 150 and 152 to be directed back to the gain element 126 .
[0058] This embodiment utilizes an angle-isolated tuning element 116 . Specifically, light that is transmitted through the tuning element 116 , such as a Fabry Perot tunable filter, stays within the laser cavity 125 . Light that is outside the passband, and reflected by the tunable filter 116 , is reflected at an angle relative to the axis of the laser cavity 125 and in this way does not return back to the gain element 126 to be amplified.
[0059] A signal extraction element 122 is located between the tuning element 116 and the gain element 126 . It is specifically located downstream of the tuning element 116 and upstream of the gain element 126 within the ring cavity 125 . In this way, the signal extraction element 122 functions as a high coherence optical signal output port and diverts a portion of the light circulating within the optical cavity 125 as the output tunable optical signal 160 . This tunable optical signal in the illustrated example is collected by the output lens 118 and coupled into the optical fiber 110 .
[0060] FIG. 7 shows a swept laser 100 according to a seventh embodiment of the present invention.
[0061] This swept laser 100 also has a ring cavity configuration. Specifically, the laser cavity 125 transmits light counterclockwise through the laser cavity 125 , which is implemented on bench 105 .
[0062] In more detail, light is amplified in the gain element 126 . In the illustrated example, a semiconductor optical amplifier is used in which both the front facet 128 and the rear facet 130 are antireflection coated.
[0063] The light that exits from the gain element 126 is collected by a lens 140 .
[0064] The lens 140 collimates the light so that it is transmitted through a first polarization beam splitter 180 . The configuration of the polarization beam splitter 180 and the polarization of the light exiting from the gain element 126 is such that the light is transmitted directly through the polarization beam splitter 180 . For example, if the light from the gain element 126 is polarized in a direction that is parallel to the plane of the bench 105 , then the first polarization beam splitter is transmissive to that parallel polarization.
[0065] The light exiting from the first polarization beam splitter 180 is then focused by a lens 146 to be coupled into the tuning element 116 . Light exiting from the tuning element 116 is been collected by lens 148 and collimated. The light is then transmitted through a second polarization beam splitter 182 . Again, the polarization of the light and the second polarization beam splitter 182 are configured so that the light is transmitted directly through the second polarization beam splitter 182 .
[0066] Light exiting from the second polarization beam splitter 182 is then coupled into a beam splitter 184 . The beam splitter 184 is configured to reflect a portion of the light and allow the other portion to pass directly through the beam splitter 184 . In one example, the beam splitter will 184 reflects about 50% of the light. In other examples, it reflects 80% or more of the light.
[0067] The light that is reflected by the beam splitter 184 remains within the laser cavity 125 , in the illustrated embodiment. Specifically it is reflected by a first fold mirror 144 . It is then reflected by a second fold mirror 150 , followed by a subsequent fold mirror 152 . These fold mirrors complete the ring cavity.
[0068] The light passing through the ring cavity is then collected by lens 145 and coupled into the entrance facet 128 of the gain element 126 .
[0069] The light that is transmitted through the beam splitter 184 is reflected to be returned back to pass through the tuning element 116 . Its polarization, however, on this return path is rotated 90°. As a result, it is reflected by both the second polarization beam splitter 182 and the first polarization beam splitter 180 .
[0070] In more detail, the light that is transmitted through the first polarization beam splitter 184 is reflected by a series of fold mirrors 185 , 186 , and 187 or other optical elements such as fiber to form a return path. On this return path through the series of mirrors, a half wave plate 188 is used to rotate the polarization of the light by 90°.
[0071] As a result, with this rotated polarization, the light reflected by fold mirror 187 and received by the second polarization beam splitter 182 is reflected to be collected by lens 148 and again coupled into the tuning element 116 . Its direction of propagation is counter to the predominant direction of propagation for the light in the laser cavity 125 .
[0072] Light exiting from the tuning element 116 , propagating in the contra propagation direction, is collimated by lens 146 and coupled into the first polarization beam splitter 180 . With its polarization, this returning light is reflected by the polarization beam splitter 180 , which also functions as the light extraction element, to be coupled to the output port. Specifically, in the illustrated embodiment, the light is collected by the lens 118 and coupled into the optical fiber 110 .
[0073] The advantage of this embodiment is that the light that is produced at the output port has been twice filtered by the tuning element 116 to counteract the spectral broadening from the chirp introduced by the gain element 126 , for example.
[0074] FIG. 8 shows an optical coherence analysis system 10 using the swept laser 100 , which has been constructed according to the principles of the present invention.
[0075] The swept laser 100 generates the tunable or swept optical signal on optical fiber 110 that is transmitted to interferometer 200 . The swept optical signal scans over a scan band with a narrowband emission.
[0076] In some embodiments, the light with other coherence lengths is provided such as on optical fibers 134 and 166 in the previously described embodiments.
[0077] In other cases, longer coherence length versions of the tunable signal are provided to a k-clock system 202 . In one example, the tunable signals provided on fibers 110 or 166 are used by the k-clock system 202 to generate the kclock, whereas the higher power versions of the tunable signal on fibers 134 are provided to the interferometer 200 and the sample 5. This system filters the tunable signal as produced k-clock signals that are used to trigger the sampling of the data acquisition system 255 at evenly spaced increments of the scanning of the tunable signal through the scan band.
[0078] A controller 290 generates a drive waveform that is supplied to a digital to analog converter 272 . This generates a tunable optical element drive signal 108 that is amplified by amplifier 274 and applied to the tuning element of 116 of the swept laser 100 .
[0079] The swept laser 100 is generally intended for high speed tuning to generate swept optical signals that repeatedly scan over the scan band(s) at rates of greater than 1 kiloHertz (kHz). In current embodiments, tuning element drive signal 108 that is applied to the tuning element 116 of the swept laser 100 repeatedly tunes the element 116 over the scanband at speeds greater than 20 or 100 kHz. In very high speed embodiments, the swept laser 100 tunes at speeds greater than 200 or 500 kHz.
[0080] Typically, the width of the tuning or scan band provided by the tuning element 116 is greater than 10 nanometers (nm). In the current embodiments, it is preferably between 50 and 150 nm, although even wider tuning bands are contemplated in some examples.
[0081] In the current embodiment, a Mach-Zehnder-type interferometer 200 is used to analyze the optical signals from the sample 5. The swept optical signal from the swept optical source system 100 is transmitted on fiber 110 to a 90 / 10 optical fiber coupler 210 . The swept optical signal is divided by the coupler 210 between a reference arm 220 and a sample arm 212 of the system.
[0082] The optical fiber of the reference arm 220 terminates at the fiber endface 224 . The tunable optical signal light 160 R (or alternatively 162 R or 164 R) exiting from the reference arm fiber endface 224 is collimated by a lens 226 and then reflected by a mirror 228 to return back, in some exemplary implementations.
[0083] The external mirror 228 has an adjustable fiber to mirror distance, in one example. This distance determines the depth range being imaged, i.e. the position in the sample 5 of the zero path length difference between the reference arm 220 and the sample arm 212 . The distance is adjusted for different sampling probes and/or imaged samples. Light returning from the reference mirror 228 is returned to a reference arm circulator 222 and directed to a 50 / 50 fiber coupler 240 .
[0084] The fiber on the sample arm 212 terminates at the sample arm probe 216 . The exiting swept optical signal 160 S (or alternatively 162 S or 164 S) is focused by the probe 216 onto the sample 5. Light returning from the sample 5 is returned to a sample arm circulator 214 and directed to the 50/50 fiber coupler 240 .
[0085] The reference arm signal and the sample arm signal are combined in the fiber coupler 240 to generate an interference signal.
[0086] The interference signal is detected a detection system 250 . Specifically, a balanced receiver, comprising two detectors 252 , is located at each of the outputs of the fiber coupler 240 . The electronic interference signal from the balanced receiver 252 is amplified by amplifier 254 .
[0087] A data acquisition system 255 of the detection system 250 is used to sample the interference signal output from the amplifier 254 . In one embodiment, the sampling is performed in response to the k-clock from the k-clock system 202 .
[0088] Once a complete data set has been collected of the sample 5 by spatially raster scanning the focused probe beam point over the sample, in a Cartesian geometry, x-y, fashion or a cylindrical geometry theta-z fashion, and the spectral response at each one of these points is generated from the frequency tuning of the swept laser 100 , the rendering/display system 280 performs a Fourier transform on the data in order to reconstruct the image and perform a 2D or 3D tomographic reconstruction of the sample 5. This information generated by the rendering system 280 can then be displayed on a video monitor.
[0089] In one application, the probe 216 is inserted into blood vessels and used to scan the inner wall of arteries and veins. In other examples, other analysis modalities are included in the probe such as intravascular ultrasound (IVUS), forward looking IVUS (FLIVUS), high-intensity focused ultrasound (HIFU), pressure sensing wires and image guided therapeutic devices. In still other applications, the probe is used to scan different portions of an eye or tooth or other structure of a patient or animal.
[0090] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | An optical coherence tomography system utilizes an optical swept laser that has improved coherence length in the swept optical signal. This is accomplished using an intra-cavity element that extracts the tunable optical signal at the optimal location within the laser's resonant cavity. Generally this location is between the intracavity tuning element and the cavity's gain element so that light coming from the tuning element is extracted. In general in lasers, the gain element adds noise and chirp and this degrades the tunable optical signal's coherence length. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to thermal printers and apparatuses having a thermal printer, and more particularly, to a thermal printer in which a platen roller is detachable from a frame.
2. Description of the Related Art
Regarding thermal printers mounted in hand-held devices and POS terminals, a clamshell type that allows easy setting of a paper roll is becoming the mainstream. In the clamshell type, when a cover is rotated and closed, a platen roller is pressed against a thermal head via paper and is fit and fixed to a frame. Thus, it is necessary to provide a lock mechanism so that the fixed platen roller not be easily separated from the frame.
FIG. 1 shows a thermal printer 10 of a conventional clamshell type. In FIG. 1, the thermal printer 10 includes a frame 11 , a platen roller 12 , a thermal head 13 , a paper roll 14 , paper 15 (a part of the paper roll 14 ), a lock arm 16 , a cam 17 , an operation lever 18 , and a spring 19 .
The platen roller 12 is moved downward from above, and pressed against the thermal head 13 via the paper 15 . On this occasion, a shaft 12 a of the platen roller 12 provided at an end of the platen roller 12 is fit into a U-shaped slot 11 a of the frame 11 and locked by the lock arm 16 .
For setting a new paper roll 14 , an operator operates the operation lever 18 so as to rotate the cam 17 and rotate the lock arm 16 for a little in the clockwise direction. Consequently, the lock of the shaft 12 a is released (for example, refer to Japanese Laid-Open Patent Application No. 2000-318260, paragraph No. 0015, FIG. 2 ).
The thermal printer 10 shown in FIG. 1 is additionally provided with three dedicated components, that is, the lock arm 16 , the cam 17 , and the operation lever 18 , in order to lock and release the platen roller 12 . Thus, there is a problem in that the increase in the number of components increases the manufacturing cost, the assembly processes, and the size and weight of the thermal printer.
SUMMARY OF THE INVENTION
It is a general object of the present invention to provide an improved and useful thermal printer, and an apparatus having the thermal printer, in which the above-mentioned problems are eliminated.
In order to achieve the above-mentioned object, according to one aspect of the present invention, there is provided a thermal printer that includes:
a thermal head;
a platen roller;
a frame having platen roller receiving parts that receive the platen roller in a detachable manner; and
a thermal head supporting member to which the thermal head is fixed, the thermal head supporting member being operatively coupled to the frame,
the thermal head supporting member including platen roller lock parts that lock the platen roller received by the platen roller receiving parts so as to resist or prevent the platen roller from exiting the platen roller receiving part.
Accordingly, components dedicated to locking the platen roller are not required, which is advantageous for reducing the size of a thermal printer. Moreover, since the number of assembly processes is decreased, it is possible to reduce manufacturing costs.
Also, in a thermal printer, the thermal head supporting member may include platen roller lifting parts that move the platen roller in the direction in which the platen roller exits the platen roller receiving parts when the thermal head is moved in the direction in which the thermal head is separated from the platen roller.
Accordingly, components dedicated to lifting (pushing up) the platen roller in the direction in which the platen roller exits the platen roller receiving parts are not required, which is advantageous for reducing the size of a thermal printer. Moreover, the number of assembly processes is decreased. Thus, it is possible to reduce manufacturing costs.
In addition, in a thermal printer, the thermal head supporting member may include an operation part that displaces the thermal head in a direction in which the thermal head is separated from the platen roller.
Accordingly, it is possible to simplify the construction of a part operated so as to displace the thermal head supporting member.
Further, the thermal head supporting member may include a head pressure biasing spring portion that biases head pressure whereby the thermal head presses the platen roller.
Accordingly, head pressure biasing spring members are not required, which is advantageous for reducing the size of a thermal printer. Moreover, the number of assembly processes is decreased. Thus, it is possible to reduce manufacturing costs
Additionally, a thermal printer may further include:
a head pressure biasing spring member for pressing the thermal head supporting member so as to bias head pressure whereby the thermal head presses the platen roller, and
the head pressure biasing spring member may include a spring portion that is pressed and deflected by the platen roller received in the platen roller receiving parts, and when the lock of the platen roller is released, restored so as to move the platen roller in the direction in which the platen roller exits the platen roller receiving part.
Accordingly, it is possible to realize, with a small number of components, a thermal printer in which the platen roller pops up when the lock of the platen roller is released.
Furthermore, according to another aspect of the present invention, there is provided an apparatus that includes:
a thermal printer including:
a thermal head;
a platen roller;
a cover supporting the platen roller, the cover being rotatably opened and closed;
a frame having platen roller receiving parts that receive the platen roller in a detachable manner, the platen roller being received by the platen roller receiving parts when the cover is closed; and
a thermal head supporting member to which the thermal head is fixed, the thermal head supporting member being operatively coupled to the frame,
the thermal head supporting member including platen roller lock parts that lock the platen roller received by the platen roller receiving part so as to resist or prevent the platen roller from exiting the platen roller receiving part.
Accordingly, since the size of the thermal printer is reduced, the size of the apparatus is also reduced.
Other objects, features and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view showing a conventional thermal printer;
FIG. 2 is a perspective view showing a hand-held device according to one embodiment of the present invention;
FIGS. 3A and 3B are side views showing the operation of closing a cover of a clamshell type thermal printer;
FIGS. 4A and 4B are side views showing the operation of opening the cover of the clamshell type thermal printer;
FIG. 5 is a perspective view showing a thermal printer unit;
FIGS. 6A and 6B are perspective views showing a thermal head supporting member;
FIG. 7 is a side view showing the shapes of a lock part and a lifting part in an enlarged manner;
FIGS. 8A, 8 B, 8 C, and 8 D are side views showing an operation in which a platen roller is locked when closing the cover;
FIGS. 9A, 9 B, 9 C, and 9 D are side views showing the operation in which a lock of the platen roller is released and the platen roller is lifted;
FIGS. 10A and 10B are a perspective view and a side view, respectively, showing a first variation of the thermal head supporting member;
FIGS. 11A and 11B are a perspective view and a side view, respectively, showing a second variation of the thermal head supporting member;
FIG. 12 is a perspective view showing a third variation of the thermal head supporting member;
FIGS. 13A, 13 B, and 13 C are side views showing a thermal printer unit in which the thermal head supporting member shown in FIG. 12 is incorporated; and
FIG. 14 is a perspective view showing a fourth variation of the thermal head supporting member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 shows a hand-held device 30 according to one embodiment of the present invention. In FIG. 2, X 1 -X 2 indicates the width direction, Y 1 -Y 2 indicates the longitudinal direction, and Z 1 -Z 2 indicates the height direction. The hand-held device 30 is provided with a line thermal printer 40 of a clamshell type on Y 1 side and includes a liquid crystal display part 31 , key switches 32 , and an operation knob 33 at the top surface.
FIGS. 3A and 3B show a closing operation of the clamshell type thermal printer 40 , and FIGS. 4A and 4B show an opening operation of the clamshell type thermal printer 40 . As shown in FIG. 3A, the clamshell type thermal printer 40 is formed by a case 42 , a cover 44 that can be opened/closed and is supported by the case 42 via a shaft 43 at one end, and a thermal printer unit 50 (shown in greater detail in FIG. 5) fixed to the case 42 . A paper roll holding part 41 holding a paper roll is formed in the case 42 . The cover 44 covers the paper roll holding part 41 . A platen roller 60 is supported at the head of the cover 44 .
As is shown in FIG. 5, in the thermal printer unit 50 , a motor 52 and a gear box 53 are fixed to a frame 51 . Moreover, a thermal head supporting member 55 to which a thermal head 54 shown in FIGS. 6A and 6B is fixed, and a head pressure biasing spring member (hereinafter referred to as a “spring member”) 56 that is a leaf spring are operatively coupled to the frame 51 of the thermal printer unit 50 , for example, in the manner illustrated in FIG. 5 . Further, a flexible print cable 57 extends from the thermal head 54 , and a platen roller 60 is fixed to the frame 51 in a detachable manner. The thermal head supporting member 55 serves to support the thermal head 54 and serves as a heat sink that diffuses heat generated in the thermal head 54 . It should be noted that the present invention includes the thermal printer unit 50 .
As is shown in FIG. 3A, the lower side of the thermal head supporting member 55 is interposed between and supported by pivots 51 a and 51 b . Pin parts 55 a and 55 b shown in FIG. 6A, provided on both upper sides of the thermal head supporting member 55 , are fit to slots 51 c and 51 d (only one of which is shown). The spring member 56 forms a V-shape, is mounted between the thermal head supporting member 55 and the frame 51 , and presses the thermal head 54 against the platen roller 60 .
The platen roller 60 includes shaft parts 60 a and 60 b at its opposite ends and includes a gear 60 c on one end. The platen roller 60 is supported by the frame 51 such that the shaft parts 60 a and 60 b are fit to respective platen roller receiving parts 51 e and 51 f of the frame 51 , the receiving parts 51 e and 51 f each being formed into a U-shape slot. The gear 60 c is engaged with an output gear (not shown) of the gear box 53 .
In accordance with the present invention, the thermal head supporting member 55 can be pivoted, as illustrated, over a predetermined range of angles with respect to the frame 51 via the pin parts 55 a and 55 b sliding within the corresponding slots 51 c and 51 d , and a bottom portion of the thermal head supporting member 55 being guided by the pivots 51 a and 51 b . The thermal head supporting member 55 is formed by performing press work on a metal plate. The thermal head supporting member 55 includes arm parts 70 and 75 extending in the direction indicated by Y 1 (hereinafter referred to as the “Y 1 direction”) at both ends and also includes an arm part 80 in the middle as an operation part extending in the Y 2 direction. As shown in FIG. 3A, the operation knob 33 is fit to a rising part 81 at an end of the arm part 80 . Bifurcate portions 71 and 76 are provided at the tips of the arm parts 70 and 75 , respectively. The bifurcate portion 71 includes an upper platen roller lock part (hereinafter referred to as a “lock part”) 72 and a lower platen roller lifting part (hereinafter referred to as a “lifting part”) 73 . The bifurcate portion 76 includes an upper platen roller lock part (hereinafter referred to as a “lock part”) 77 and a lower platen roller lifting part 78 . The lock part 72 and the lifting part 73 are located at the position corresponding to the platen roller receiving part 51 e . The platen roller lock part 77 and the platen roller lifting part 78 are located at the position corresponding to the platen roller receiving part 51 f.
In the description that follows, the operation of the thermal printer is described with reference to the X 1 portion of the thermal printer (for example, the shaft part 60 a , the bifurcate portion 71 , and the platen roller receiving part 51 e ). For sake of brevity, the description relating to the X 2 portion (for example, the shaft part 60 b , the bifurcate portion 76 , and the platen roller receiving part 51 f ) is omitted.
FIG. 7 shows the shapes of the lock part 72 and the lifting part 73 in an enlarged manner, in conjunction with the shaft part 60 a and the platen roller receiving part 51 e.
The platen roller receiving part 51 e includes an arcuate bottom portion 51 e 1 having a point O 1 as the center. The reference numeral 90 designates the center line of the platen roller receiving part 51 e , which center line is drawn through the point O 1 and extends in the directions indicated by Z 1 -Z 2 . The reference numeral 91 designates a line drawn through the point O 1 and orthogonal to the center line 90 . The line 91 extends in the directions indicated by Y 1 -Y 2 . In FIG. 7, the two-dot chain line indicates the shaft part 60 a assuming that the platen roller 60 is mounted.
The lock part 72 extends into the platen roller receiving part 51 e in the Y 1 direction at a position above the shaft part 60 a . That is, the lock part 72 extends alongside the platen roller receiving part 51 e and into a X 1 -X 2 projecting path of the platen roller receiving part 51 e . A tip 72 a of the lock part 72 is displaced in the Y 1 direction relative to the center line 90 by a distance ΔY. A tangent line 72 b is declined downward to the right, that is, declined in the direction indicated by Z 2 (hereinafter referred to as the “Z 2 direction”) as the tangent line 72 b extends in the Y 1 direction. The tangent line 72 b intersects the line 91 at an angle θ. The upper surface of the lock part 72 is referred to herein as an inclined surface 72 c.
The lifting part 73 extends in the Y 1 direction to form an upward sloping arc-like shape that is lower in the Z 2 direction than the platen roller receiving part 51 e . A tip 73 a of the lifting part 73 is located farther in the Y 1 direction than the platen roller receiving part 51 e . Moreover, the tip 73 a of the lifting part 73 is displaced in the direction indicated by Z 1 (hereinafter referred to as the “Z 1 direction”) relative to the lowermost portion of the bottom portion 51 e 1 of the platen roller receiving part 51 e by a distance Δz. A spacing 100 in the directions indicated by Y 1 -Y 2 exists between the lifting part 73 and the platen roller receiving part 51 e . The spacing 100 enables lock release and lifting (pushing up)(that are described below) to be performed with desired timing.
Next, a description will be given of the opening and closing operations of the cover 44 of the clamshell type thermal printer 40 , and the operations of the bifurcate portions 71 and 76 then.
The paper roll 110 is set inside the paper roll holding part 41 , and the cover 44 is pivoted to be closed with the paper 111 pulled out. The cover 44 is rotated from the state shown in FIG. 3A to a substantially closed position as shown in FIG. 3B as an initial stage in which the shaft part 60 a of the platen roller 60 enters the platen roller receiving part 51 e from the Z 1 side, and contacts and is supported by the upper surface of the lock part 71 . In this state, the operator manually presses the cover 44 . With this operation, the cover 44 is pivoted to a final position shown in FIG. 4A, at which the cover 44 is completely closed, and locked by the lock part 71 at the position then as a final stage. On this occasion, the spring member 56 causes the thermal head 54 and the platen roller 60 to press towards each other with the paper 111 interposed therebetween. In addition, in a last stage of the pivot of the cover 44 , the spring member 56 is temporarily elastically deformed as shown in FIG. 4B, and the thermal head supporting member 55 is rotated in the counterclockwise direction.
FIGS. 8A through 8D show the operation of the bifurcate portion 71 then in an enlarged manner. As is shown in FIG. 8A, the shaft part 60 a of the platen roller 60 enters, from the Z 1 side, the platen roller receiving part 51 e . Then, as shown in FIG. 8B, the shaft part 60 a contacts the inclined surface 72 c of the lock part 72 and urges the lock part 72 in the direction indicated by Y 2 (hereinafter referred to as the “Y 2 direction”). Thereafter, as shown in FIG. 8C, the shaft part 60 a makes the lock part 72 retract from the platen roller receiving part 51 e . The shaft part 60 a slides by the lock part 72 and reaches the bottom portion 51 e 1 as shown in FIG. 8 D.
After the shaft part 60 a slides by the lock part 72 , the bifurcate portion 71 is displaced in the Y 1 direction by the spring force of the spring member 56 , and as shown in FIG. 8D, the lock part 72 comes above the shaft part 60 a and locks the shaft part 60 a . That is, the lock part 72 restricts the shaft part 60 a from being displaced in the Z 1 direction and locks the shaft part 60 a with respect to the bottom portion 51 e 1 of the platen roller receiving part 51 e . Similarly, the bifurcate portion 76 , which is on the other side, locks the shaft part 60 b.
Here, the tip 72 a of the lock part 72 locks the shaft part 60 a at a position Q 1 that is displaced from the peak P in the Y 1 direction. Thus, even if a force in the Z 1 direction, urging the shaft part 60 a to exit from the platen roller receiving part 51 e , is exerted due to dropping impact, for example, a component force in the Y 2 direction is not generated in the lock part 72 . That is, the lock part 72 fully locks the shaft part 60 a.
Hence, the platen roller 60 is locked such that the shaft parts 60 a and 60 b on both ends are locked by the lock parts 72 and 77 , respectively. Thus, even if the hand-held device 30 is erroneously dropped, for example, the cover 44 is not opened.
In addition, since the lock part 72 is temporarily retracted by the shaft part 60 a , the thermal head 54 is temporarily separated from the platen roller 60 , and then contacts the platen roller 60 . However, since the platen roller 60 is made of rubber, the impact then is small and insignificant.
When the paper roll 110 is used up and a new paper roll 110 needs to be set, the operator pulls the operation knob 33 in the Y 2 direction in the state shown in FIG. 4 A. With this operation, as shown in FIG. 4B, the thermal head supporting member 55 is translated in the counterclockwise direction, that is, in the direction in which the thermal head supporting member 55 becomes substantially perpendicular. Thus, the lock of the shaft part 60 a is released and the cover 44 can be opened. Moreover, the shaft part 60 a is lifted (pushed up) by the lifting part 73 , and the cover 44 is lifted a relatively small amount. In this state, the operator manually opens the cover 44 .
FIGS. 9A through 9D show the operation then of the bifurcate portion 71 in an enlarged manner. The bifurcate portion 71 is moved substantially in the Y 1 direction from the state shown in FIG. 9 A. As shown in FIGS. 9B and 9C, on one hand, the lock part 72 is displaced such that the lock part 72 exits from the platen roller receiving part 51 e in the Y 2 direction, and thus the lock of the shaft part 60 a is gradually released. On the other hand, the lifting part 73 is displaced in the Y 2 direction, enters the platen roller receiving part 51 e , and contacts and lifts the lower portion of the shaft part 60 a . Finally, as shown in FIG. 9D, the lock part 72 exits from the platen roller receiving part 51 e and the lock of the shaft part 60 a is released. Moreover, the tip 73 a of the lifting part 73 lifts the shaft part 60 a for ΔZ.
As described above, the lock parts 72 and 77 , and the lifting parts 73 and 78 are parts of the thermal head supporting member 55 . Thus, components dedicated to locking of the platen roller 60 are not used. Accordingly, compared with conventional printers, it is possible to manufacture the thermal printer 40 with a smaller size and less weight without increasing the number of components, thus, with less assembly processes and at lower manufacturing cost.
It should be noted that the thermal printer 40 may be applied to not only the hand-held device 30 , but also stationary apparatuses.
Next, a description will be given of variations of the thermal head supporting member 55 .
FIGS. 10A and 10B show a thermal head supporting member 55 A according to a first variation of the thermal head supporting member 55 .
The thermal head supporting member 55 A differs from the thermal head supporting member 55 shown in FIGS. 6A, 6 B, and 7 in lock parts 72 A and 77 A. The lock parts 72 A and 77 A are shorter than the lock parts 72 and 77 . As shown in FIG. 10B, the tip 72 Aa of the lock part 72 A locks the shaft part 60 a at a position Q 2 that is displaced from the peak P in the Y 2 direction by a distance ΔY. In other words, the lock part 72 A locks the shaft part 60 a in a state where a component force in the Y 2 direction is generated in the lock part 72 A if a force in the Z 1 direction is exerted on the platen roller 60 . The lock part 77 A thereby locks the shaft part 60 a in a similar manner.
When a strong force is exerted on the platen roller 60 in the Z 1 direction, the shaft part 60 a pushes away the lock part 72 A in the Y 2 direction and is separated from the platen roller receiving part 51 e . That is, the platen roller 60 is locked by simple locking.
FIGS. 11A and 11B show a thermal head supporting member 55 B according to a second variation of the thermal head supporting member 55 .
The thermal head supporting member 55 B differs from the thermal head supporting member 55 shown in FIGS. 6A, 6 B, and 7 in that the thermal head supporting member 55 B does not include the lifting parts 73 and 78 . The thermal head supporting member 55 B includes the lock parts 72 and 77 . The lock part 72 locks the shaft part 60 a as shown in FIG. 11 B. The lock part 77 locks the shaft part 60 a in a similar manner.
FIG. 12 shows a thermal head supporting member 55 C according to a third embodiment of the thermal head supporting member 55 .
The thermal head supporting member 55 C is formed such that head pressure biasing coil springs (head pressure biasing spring members) 120 and 121 are fixed to the back surface of the thermal head supporting member 55 B shown in FIGS. 11A and 11B. The head pressure biasing coil springs 120 and 121 include wire-like spring portions 120 a and 121 a extending in the Y 1 direction, respectively. The wire-like spring portions 120 a and 121 a possess functions of popping up the shaft parts 60 a and 60 b , respectively.
As is shown in FIG. 13A, the thermal head supporting member 55 C is incorporated in a thermal printer unit 50 A. The wire-like spring portions 120 a and 121 a cross the platen roller receiving part 51 e.
As is shown in FIG. 13B, in the state where the platen roller 60 is locked and fixed, the wire-like spring portion 120 a is elastically deformed (deflected) in the Z 2 direction. When the lock is released as shown in FIG. 13C, the platen roller 60 is popped up by the spring force of the wire-like spring portion 120 a.
FIG. 14 shows a thermal head supporting member 55 D according to a fourth variation of the thermal head supporting member 55 .
In the thermal head supporting member 55 D, in addition to the lock parts 72 and 77 , the lifting parts 73 and 78 , and the arm part 80 , a pair of leaf spring portions 130 and 131 are formed out of the back surface, as by cutting, and project from the back surface at a non-zero angle relative thereto. The leaf spring portions 130 and 131 bias head pressure. Thus, the spring member 56 in FIG. 3A is not required. Accordingly, the number of components of the thermal printer 40 is further reduced.
Additionally, in order to form the leaf spring portions 130 and 131 , the material of the thermal head supporting member 55 D preferably is relatively thinner than normal (for example, the material of the aforementioned thermal head supporting members 55 , 55 A, 55 B or 55 C). Moreover, since the leaf spring portions 130 and 131 are formed, the area where the thermal head 54 contacts the thermal head supporting member 55 D is decreased, resulting in slight degradation of the function of the thermal head supporting member 55 D as a heat sink. The degradation of the function as a heat sink, however, does not present a problem in thermal printers that are not used continuously.
The present invention is not limited to the specifically disclosed embodiments, and variations and modifications may be made without departing from the scope of the present invention.
The present application is based on Japanese priority application No. 2002-367091 filed on Dec. 18, 2002, the entire contents of which are hereby incorporated by reference. | A thermal printer including a thermal head, a platen roller, a frame having platen roller receiving parts that receive the platen roller in a detachable manner, is disclosed. The thermal head is fixed to a thermal head supporting member that is operatively coupled to the frame. The thermal head supporting member includes platen roller lock parts that lock the platen roller received by the platen roller receiving part so as to resist or prevent the platen roller from exiting the platen roller receiving part. | 1 |
TECHNICAL FIELD
The present invention generally relates to hydraulic actuators of the type designed to be hydraulically independent from other units and from any main hydraulic systems aboard an aircraft or rocket and particularly, to a pneumohydraulic actuator in which a hydraulic actuator, that is hydraulically independent, is driven by a pneumatic gear motor.
BACKGROUND OF THE INVENTION
Hydraulic actuators of the type designed to be hydraulically independent are well known in the aerospace field and are used for a variety of applications such as to provide vectoring of a rocket's exhaust nozzle or to move control surfaces aboard an aircraft. These actuators generally comprise a hydraulic pump, a linear or rotary actuator that converts the pressure energy of the pumped hydraulic fluid into mechanical energy in the form of linear or rotary motion, and means for driving the hydraulic pump, and generally come in two configurations. The first configuration is the hydrostatic actuator in which the hydraulic pump is in direct fluid communication with the actuator. This system is static because, except for the pumping required to make up for leakage flow in the system, the hydraulic pump only operates when a command to move the actuator is received. The second configuration is the recirculating hydraulic actuator in which a servo-valve is used to control the flow of hydraulic fluid from the hydraulic pump to the actuator and from the actuator to a reservoir. Also, excess flow from the pump is dumped through a relief valve into the reservoir. In this recirculating configuration the hydraulic pump operates continuously, circulating the hydraulic fluid between itself and the reservoir. Only when actuation is required is hydraulic fluid sent to the actuator.
In the hydrostatic configuration, the hydraulic pump is commonly driven by a brushless electric motor. A detailed description of an electrohydrostatic actuator can be found in Chamberlain, U.S. Pat. No. 4,630,441. The use of electric motors to drive the pump has a number of disadvantages. First, the electric motor requires a turbogenerator and circuitry to supply it with adequate electric current. The use of a turbogenerator and circuitry not only adds weight and electronic noise to the vehicle but also reduces the reliability of the system by adding additional failure modes associated with these components. Furthermore, due to size and weight constraints imposed for aircraft and rocket applications, these electrically driven actuators have been limited to outputs of about 45 horsepower. However, there are some applications on airplanes and rockets that require outputs greater than what electrically driven configurations can provide.
Some vehicles have a readily available source of pressurized gas. In these cases, high pressure ratio, impulse type turbine wheels have been used to drive the hydraulic pump on a recirculating configuration. Pressurized gas is bled from the vehicle's gas supply and expanded across the turbine wheel which converts the pressure energy of the gas into rotary motion that drives the hydraulic pump. This configuration is capable of generating up to about 100 horsepower. A disadvantage to using these turbine wheels is their high inertia. Because of their high inertia, the turbine wheels are very slow in accelerating to operating speed. In modern aircraft and rockets, actuators must be able to respond quickly. As a result, in order to meet this quick response time the turbine wheel must be kept running at full operating speed even when no actuation is required. This constant running generates large amounts of heat which requires an elaborate cooling mechanism to dissipate. Also, because the turbines must run continuously, they cannot be used with hydrostatic systems.
Therefore, where pressurized gas is available, there is a need for a hydraulic actuator that could be driven using the pressurized gas and also, could generate sufficient horsepower, satisfy the fast response times required of the actuator, and not generate large amounts of heat during those periods in which actuation is not required. Further, the hydraulic actuator should be packaged in a unitary structure so that it can be mounted in tight spaces aboard the rocket or aircraft and mounted near the rocket or aircraft member that is to be actuated.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a hydraulic actuator of the type that is hydraulically independent that can be driven using available high pressure gas aboard a vehicle.
Another object of the present invention is to provide a pneumatic means for driving a hydraulic actuator that can accelerate rapidly to operating speed and satisfy the quick response time required of actuators on rockets and aircraft.
Yet another object of the present invention is to provide a pneumatic means for driving a hydraulic actuator that does not generate large amounts of heat when actuation is not required.
Yet still another object of the present invention is to provide a pneumatically driven hydraulic actuator having closely coupled components in a single unitary package so that the unit is easily installed or removed.
The present invention achieves the above-stated objects by providing a hydrostatic actuator and a recirculating hydraulic actuator each driven by a low inertia, pneumatic gear motor wherein the components are closely coupled and are disposed within a single unitary package.
These and other objects, features and advantages of the present invention, as well as the preferred embodiment, will be more fully understood from the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a closely coupled pneumohydrostatic actuator constructed in accordance with the preferred embodiment of the present invention;
FIG. 2 is a front view of the closely coupled pneumohydrostatic actuator of FIG. 1;
FIG. 3 is a side and partly cross-sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 2;
FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 4; and
FIG. 6 is a schematic of a closely coupled pneumorecirculating hydraulic actuator which is constructed in accordance with the alternative embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, FIGS. 1-5 show a pneumohydrostatic actuator generally indicated by the numeral 10. The pneumohydrostatic actuator 10 is comprised of a pneumatic gear motor assembly 20, a torque motor 30, a hydraulic pump 40, an actuator 50, a reservoir 60, an anti-cavitation system 70, and an electronic control unit 80.
The pneumatic gear motor assembly 20 has a housing 21 having a pneumatic inlet 22 and a pneumatic exhaust 23. A directional control valve 24 is rotatably supported in the housing 21 by a set of contact bearings 25, (see FIG. 4). Also, mounted within the housing 21 is a pneumatic gear motor 26 comprising two helical rotors 27 in self-timed engagement. The pneumatic gear motors, of the type used herein, have low inertias which allows them to be rapidly accelerated to operating speed. Each of the helical rotors 27 is supported by contact bearings 28 and can rotate both clockwise and counterclockwise. Also, each helical rotor 27 has a three lobed construction to eliminate output torque ripple. Two opposed conduits 18 and 19 fluidly couple the directional control valve 24 to the pneumatic gear motor 26. In operation, pressurized gas entering through the inlet 22 is directed, by the directional control valve 24 through one of the conduits 18 or 19 to the helical rotors 27 in which the pressure energy of the pressurized gas is extracted and converted into rotary motion of an output shaft 29, (see FIG. 4). The gas then passes to the exhaust 23 via the other of the conduits 18 or 19.
One particular application in which the pneumohydrostatic actuator 10 may be used is to provide pitch and yaw vectoring of the exhaust nozzle of a rocket that uses liquid hydrogen and liquid oxygen as fuel. In this application, the liquid hydrogen changes to gas when it is used to cool the rocket engine. The pressurized hydrogen gas is then used to drive the pneumatic gear motor 26. The temperature of the hydrogen gas can range from about -400° F. to 90° F. To avoid hydrogen embrittlement of the components of the gear motor assembly 20, the material for the housing 21, directional control valve 24, and the helical rotors 27, preferably has a face centered cubic crystal structure and can be selected from the following: Nitronic 60, Nickel based alloys 718 and 709; superalloys, cobalt based alloys HS25 and HS6B, Aluminum alloys, Copper alloys, Titanium alloys, Austentic stainless steels 304L and 316L, and stainless steel A286. However, the preferred material for these components is stainless steel A286. Also, the preferred material for the bearings 25 and 28 is stellite.
A torque motor 30 is mounted to the pneumatic, gear motor assembly 20, (see FIG. 3). The torque motor 30 has two electrically conducting coils 31 that when subjected to an electric current will cause the wand 32 to move. The degree of motion of the wand 32 is proportional to the magnitude of the electric current. The movement of the wand 32 proportionally block or unblocks the conduit 33. Conduit 33 fluidly communicates with a vane valve driver 34 via conduits 37 and 38. Two orifices 36 are operably disposed within the conduit 33 to control the flow of gas therein. The vane valve driver 34 can rotate over a +45 degree range and is coupled via a centering spring 35 to the directional control 24. When gas flows within the unblocked conduit 33 the gas pressure in conduits 37 and 38 is equal and the vane valve driver is at its pre-set position as shown in FIG. 1. As the wand 32 blocks the gas flow in conduit 33 the gas pressure in conduit 38 rises creating a pressure differential across the vane valve driver 34. In response to this pressure differential the vane valve driver will rotate thereby rotating the directional control valve 24. If the wand 32 is removed from conduit 33, the pressure differential disappears and the centering spring 35 will pull the vane valve driver 34 and the directional control valve 24 back to their pre-set position. The gas exiting conduit 33 (not shown) is returned to the inlet 22 upstream of the control valve 24.
A hydraulic pump 40 is provided. The pump 40 is a high speed, fixed displacement, rotating cylinder block type piston pump. The pump 40 is comprised of a housing 41 having a shaft 42 rotatably mounted therein. One end of the shaft 42 is coupled to the output shaft 29 of the pneumatic motor 26. The other end of the shaft 42 has a cylinder block 44 having a circular array of axial pumping chambers 45 for slideably receiving pistons 47. Only two of these chambers and pistons are shown in FIG. 1. A cam plate 46 is mounted on the heads of each piston 47 and causes the pistons 47 to reciprocate within the chambers 45 in response to rotation of the shaft 42. The bottom of each of the chambers 45 alternately opens into one of two conduits 47 and 48 through which hydraulic fluid flows. The shaft 42 has a plurality of static seals 39 and a rotary seal 49.
An actuator 50 is a linear output piston type actuator comprised of a housing 51 integral with the pump housing 41. The housing 51 is coupled at one end 54 to a supporting structure not shown. A piston 55 is slideably mounted within the housing 51 dividing the interior of the housing 51 into two chambers 52 and 53 of equal area. The chamber 52 is in fluid communication with the conduit 47 and the chamber 53 is in fluid communication with the conduit 48. A pressure differential between the chambers 52 and 53 will cause the piston 55 to move laterally relative to the housing 51. Coaxially mounted through the piston 55 is a hollow rod 56. One end of the rod 56 extends beyond the housing 51 and is coupled to the rocket nozzle or other member, (not shown), that is required to be moved. The rod 56 moves laterally in response to the lateral movement of the piston 55 and simultaneously moves the nozzle or member being acted upon. The lateral position of the rod 56 is monitored by a linear variable displacement transducer (LVDT) mounted thereon, which develops an electric signal indicative of the actuation status of the nozzle or other member.
A hydraulic fluid reservoir 60 is disposed within the pump housing 41. The reservoir 60 comprises a bellowed chamber 61 having a spring 62 counterbalancing a piston 65 upon which a pressure differential is acting. The reservoir 60 has an exit port 63 and an inlet port 64.
An anti-cavitation system 70 is disposed within the housing 41 between the reservoir 60 and the hydraulic pump 40 and is in fluid communication with both of these components. The system is comprised of a plurality of conduits and valves. The system prevents cavitation in both the actuator 50 and the pump 40. A conduit 71 connects conduit 48 with the exit port 63 and has a one-way check valve 72 that allows hydraulic fluid to flow only from the exit port 63 to the conduit 48. A conduit 73 connects the inlet port 64 to a shuttle valve 74. Connecting the shuttle valve 74 to conduit 71 is conduit 75. A conduit 76 connects conduit 47 to conduit 71 and has a one-way check valve 77 that allows hydraulic fluid to flow only from the exit port 63 to the conduit 47. A conduit 78 couples the conduit 76 to the shuttle valve 74. The shuttle valve 74 is a two-position valve that operates to open and close conduits 75 and 78.
To fully understand how this anti-cavitation system works it is best to look at a particular operating sequence Referring to FIG. 1, hydraulic fluid is being pumped through conduit 47 to the chamber 52 of the actuator 50 and returned from the chamber 53 through conduit 48. The pressure differential thereby created between the chambers 52 and 53 cause the rod 56 to extend. Simultaneously, the pressurized hydraulic fluid from the pump 40 flows through conduit 76 closing check valve 77 and also through conduit 78 opening the shuttle valve 74, closing conduit 75 and passing through conduit 73 to the inlet port 64 of the reservoir 60. Upon entering the reservoir 60 the hydraulic fluid moves the piston 63 laterally compressing the spring 62 and pressurizing the hydraulic fluid therein. When an external force acting on the piston rod 56 of the piston actuator 50 force it to extend faster than the hydraulic pump 40 can pump, the pressure of the hydraulic fluid will drop in chamber 52 and in conduits 47, 76, 78 and 73 and will increase in conduits 48, 71 and 75. When the pressure in the reservoir 60 and conduit 75 becomes greater than the pressure in conduit 78 the shuttle valve 74 will close conduit 7B and the check valve 77 will open. The spring 62 will then decompress and hydraulic fluid stored therein will flow from the exit port 63 through conduits 76 and 47 to the chamber 52 thereby preventing cavitation of the actuator 50.
An electronic control unit (ECU) 80, of the type well known in the art, is provided for coordinating the flow of pressurized gas to the pneumatic gear motor assembly 20 and torque motor 30 with the extension and retraction of the actuator rod 56. The ECU 80 also receives an electric signal from the LVDT and sends commands to the torque motor 30 to increase or decrease the amount of pressurized hydrogen gas entering the pneumatic motor assembly by opening or closing the directional control valve 24. The ECU 80 interfaces with the vehicles control system.
In operation, when movement of the rod 56 is not required, the pneumohydrostatic actuator 10 operates at a low power operating speed of about 10 rpm which is just sufficient to make up for leakage of hydraulic fluid in the system and does not generate large amounts of heat. When movement of the rod 56 is required, a command is sent from the vehicle to the ECU 80. The ECU 80 then commands the torque motor to position the directional control valve 24 depending on whether clockwise or counterclockwise rotation is required. The rotating of the valve 24 permits the pressurized gas to flow from its source in the vehicle to the pneumatic motor 6. With gas at a pressure of about 180 psi, the rotors 27 will accelerate to their operating speed of about 20,000 rpm in about 100 milliseconds. The rotors 27 simultaneously drive the hydraulic pump 40 which pumps hydraulic fluid to one of the chambers 52 or 53. The pressure differential between these chambers causes the piston 55 and the rod 56 to move laterally. The position of the rod is monitored by the LVDT which sends a signal back to the ECU 80. When the rod 56 has moved far enough to accomplish the necessary actuation, the ECU 80 sends a signal to the torque motor to partly close the valve 24 and the pneumohydrostatic actuator 10 returns to its low power operating condition.
FIG. 3 shows the components of the pneumohydrostatic actuator 10 in a closely coupled relationship to each other within a compact unitary package. The pneumatic motor 26 is mounted vertically on the actuator 50 resulting in a taller but narrower configuration. Alternatively, the pneumatic motor can be rotated about its output shaft 29 and the reservoir 60 can be packaged besides the pump 40 instead of at the end of the pump 40.
An alternative embodiment of the present invention is the pneumo-recirculating hydraulic actuator schematically illustrated in FIG. 6. The pneumo-recirculating hydraulic actuator 110 is comprised of a pneumatic gear motor assembly 120, a hydraulic pump 140, a piston actuator 150, a reservoir 160, an electronic control unit 180, and a hydraulic fluid conduit 170. Like the preferred embodiment, the components of the pneumo-recirculating hydraulic actuator 110 are in a close coupled relationship to each other. Many of the features of these components are the same as the features of the corresponding component in the pneumohydrostatic actuator 10 and therefore the detailed description of these components is not repeated here. Instead, the emphasis of the following description is on those features of the pneumo-recirculating hydraulic actuator 110 that are different from the pneumohydrostatic actuator 10.
Because the piston actuator 150 is controlled by a servo-valve 155, there is no need for the pneumatic gear motor assembly 120 to be reversible. Consequently, in the gear motor assembly 120 the directional control valve 24 is replaced by a hydraulically actuated uni-directional control valve 124 and is positioned downstream of the pneumatic inlet 122. A torque motor is no longer required to control the gas flow. Only a single conduit 123 runs from the valve 124 to the helical rotors 127. Also, if hydrogen gas is used as the operating fluid than the preferred materials for gear motor assembly 120 are the same as for the gear motor assembly 20.
The hydraulic pump 140 is the same as the hydraulic pump 40 except that conduit 147 runs from a piston chamber to the servo-valve 155 and the hydraulic fluid in this line always flows in this direction. Likewise, a conduit 148 runs from a piston chamber to the reservoir 160 which is structurally the same as the reservoir 60. The hydraulic fluid conduit 170 runs from conduit 147 back to control valve 124 and controls the opening and closing of the valve 24. The servo-valve 155 is disposed between the hydraulic pump 140 and the piston actuator 150. The piston actuator 150 being structurally the same as the piston actuator 150 and has a hollow rod 156. A conduit 157 runs from the servo-valve 155 to the reservoir 160. Anti-cavitation valves are not required. The ECU 180 is the same as the ECU 80, but controls the pneumo-recirculating actuator 110 by controlling the flow of hydraulic fluid through the servo-valve 155.
In operation, when movement of the arm 156 is not required the pneumo-recirculating actuator 110 operates at a low power setting of about 10 rpm to make up for leakage of hydraulic fluid. At this low power setting very little heat is generated. When the ECU 180 receives a command to move the actuator rod 156, it commands the servo-valve 155 to direct flow to the proper chamber in the actuator 150. The proper chamber depends on whether the rod 156 is to be extended or retracted. The servo-valve 155 opens causing the pressure in the conduits 147 and 170 to drop. The drop in pressure in the conduit 170 forces the control valve 124 to open allowing the high pressure hydrogen gas at about 180 psi to enter and expand across the helical rotors 127. The rotors 127 accelerate in about 100 milliseconds to full operating speed of about 20,000 rpm. The rotors 127 then drive the hydraulic pump 140 which in turn pumps hydraulic fluid into the conduit 147. The servo-valve 155 channels the hydraulic fluid from conduit 147 into the appropriate chamber in the piston actuator 160, thereby causing the rod 156 to extend or retract. A LVDT mounted on the rod 156 sends a signal to the ECU 180 and permits the ECU to monitor the lateral position of the rod 156. When the rod 156 has completed its movement, the ECU 180 sends a signal to the servo-valve 155 to shut off the flow to the piston actuator 160. Once the flow is shut off the pressure in lines 147 and 170 will rise. In response to this pressure rise, the control valve 124 closes down and reduces the flow of pressurized gas to the gear motor 126. The gear motor 126 returns to its low power operating point.
A method is also provided for actuating a member on an aircraft or a rocket having an on board source of pressurized gas. The first step in this method is to couple a pneumatic motor to a hydraulic pump that is fluidly coupled to a piston actuator having an actuator arm extending therefrom. The actuator arm is then coupled to the member of the rocket or aircraft that requires actuation. High pressure gas, stored aboard the vehicle, is brought from it storage compartment to the pneumatic motor. The pneumatic motor extracts the pressure energy of the gas and converts this energy into rotary motion. This rotary motion drives the hydraulic pump which in turn pumps hydraulic fluid to the piston actuator causing the actuator arm to laterally move and thereby move the member requiring actuation.
Accordingly, the foregoing portion of the description, which includes the accompanying drawings, is not intended to restrict the scope of the invention to the illustrated embodiments or to specific details which are ancillary to the teaching contained herein. The invention should be construed in the broadest manner which is consistent with the following claims. | A pneumatically driven hydrostatic actuator and a pneumatically driven recirculating hydraulic actuator are provided. Each of these actuators consists of a hydraulic pump fluidly coupled to an actuator. The pump is driven by a low inertia pneumatic motor that extracts pressure energy from pressurized gas and converts it to rotary motion. The pneumatic motor is preferably made from stainless steel A286 so that it can operate using pressurized hydrogen gas. The components of both actuators are in a closely coupled relationship so that they can be arranged in a compact unitary package. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OF DEVELOPMENT
[0002] Not Applicable
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable
REFERENCE TO A SEQUENCE LISTING
[0004] Not Applicable
STATEMENT REGARDING PRIOR DISCLOSURES BY INVENTOR OR JOINT INVENTOR
[0005] Not Applicable
BACKGROUND OF INVENTION
[0006] Field of the Invention
[0007] This invention relates to the hanging or supporting of picture frames, mirrors or the like (all of which will hereafter be referred to as “frame” or “frames”) comprising a wall member cooperating with a corresponding frame member being adjustable and securable.
[0008] Currently when hanging frames there are problems (1) precisely locating where the frame will hang on the wall, (2) precisely aligning the frame vertically and horizontally, (3) securing the frame to the wall so that it cannot be dislodged or misaligned unintentionally and (4) securing the frame to the wall so it that cannot be removed easily by a person who does not have a right to remove it.
[0009] Description of Related Art.
[0010] There are various systems and methods available that can locate and align a frame on a wall.
[0011] These include use of a stand that holds or supports a frame. The stand with the frame can be placed in a selected position along a wall at the desired horizontal location where the stand then can be extended to raise the frame to the desired vertical position on the wall. The location of the frame or the hangers for the frame can be marked on the wall. The hangers are then attached to the wall by reference to the marks.
[0012] There are also devises that hold a frame by its wire and allow an installer to suspend that frame to a position on a wall and then mark the location of the placement of the hooks or nails on the wall. This is the system and method employed by Hang and Level™ produced by Under the Roof Decorating.
[0013] A frame can be located on a wall by installing a rail on that wall above the location of the frame and suspending wires from the rail that attach to hooks on that frame with the length of the suspended wire being adjustable to permit the frame to be level and at the desired height.
[0014] There are also systems that employ Velcro® (or similar fabric hook and loop fasteners) strips with adhesives on the side without Velcro. The two strips are attached on their Velcro sides, one strip is attached to a frame by the adhesive, the frame is then attached to the wall with the adhesive on the other strip. That permits an installer to directly place a frame on the desired location on the wall. Command™ Picture Hanging Strips produced by 3M uses this system and method.
[0015] There are various systems and methods available for hanging a frame on a wall.
[0016] These include the traditional use of hooks or hangers attached to a frame. Wire can be then secured to the hooks or hangers attached the frame. The frame is then suspended by the wire that hangs from hooks, hangers, screws or nails attached to a wall.
[0017] Brackets or sawtooths can be attached to a frame and a frame can be suspended by hanging the brackets or sawtooths on hooks, hangers, screws or nails attached to a wall.
[0018] There is also a system that employs double rails with one rail attached to the back of a frame and the other rail attached to the wall. The frame is suspended by nesting the rail attached to the frame inside the rail attached to a wall.
[0019] Velcro strips attached by adhesive to a frame and a wall as described above for Command™ Picture Hanging Strips is another system for hanging a frame.
[0020] There are various systems and methods available for securing a frame on a wall.
[0021] These include a bracket attached to the bottom of a frame that is secured to a wall by a special “T”-shaped screw placed in a wall. When the frame is placed on the wall the T-shaped screw fits through the bracket and when the T-shaped screw is turned 90° by a special tool the frame cannot thereafter be removed without use of the special tool.
SUMMARY OF INVENTION
[0022] The devices in this wall hanging system allow the level installation of a frame on a precise location on a wall or other vertical surface (all of which will hereafter be referred to as “wall”). This is accomplished by using two identical devices with one device attached to each side of a frame. Each device has two halves: an upper half which is attached to a frame by screws or like fasteners (all of which will hereafter be referred to as “screw” or “screws”) and a lower half that is initially attached to a wall by adhesive and then secured permanently to a wall by screws.
[0023] Once a frame is installed on a wall the devices can be minutely adjusted by an installer to compensate for any minor error in installation as to height or horizontal alignment.
[0024] The use of set screws and flutes securing the upper half of each device to the lower half fastens a frame to a wall in a manner that prevents accidental dislodging or mis-aligning of that frame by accident and prevents the unauthorized removal of that frame.
DESCRIPTION OF VIEWS OF DRAWINGS
[0025] The invention, as illustrated in the drawings, consists of the following components and features. The invention uses pairs of identical devices with one of each pair attached to each side of a frame and those devices are then attached to a wall. Each device has two halves, the top half that is attached to the frame and the lower half that is attached to the wall. The top half is attached to the frame by screws which are placed through countersinked holes so that the screw heads are flush with the device when fully attached.
[0026] The upper half has a male part or tongue that is flanged at its end that mates or nests with the corresponding female slot of the lower half of the device. The side of the tongue has a flute on each side the tongue. The diameter of those flutes match the dimensions of the hemispherical ends of the set screws in the side of the lower half of the device.
[0027] The lower half of the device is attached to the wall by screws which are placed through countersinked holes so that the screw heads are flush with the device when fully attached. The screw holes of the lower half are drilled at an 11° angle from the horizontal. The lower half of the device has a female slot with a flange that mates with the tongue of the upper half. The lower half has two set screws with hemispherical ends that go into threaded holes on the sides of the lower half. The other ends of the set screws have slots that will accept a tool such as a wrench or screw driver with a unique shape that can tighten the set screws. The lower half has a set screw on the bottom that can extend into the slot where the tongue of the upper half nests such that the set screw contacts the bottom of the tongue and can raise the upper half of the device. The lower half of the device has an adhesive strip on the side that abuts the wall when installed. The adhesive strip has a low tack glue on each side. The adhesive strip extends a small distance onto the upper half where the upper and lower halves meet.
[0028] Various embodiments of the invention are shown by the following drawings:
[0029] FIG. 1 has isometric depictions of the upper and lower halves of the device showing the side that attaches to a wall.
[0030] FIG. 1A shows the upper and lower halves assembled together with the side set screws tightened.
[0031] FIG. 1B shows the upper and lower halves separated with the set screws removed from the lower half. FIG. 1B shows the flute on one side of the tongue with a concave dimension that matches the hemispherical diameter of the end of set screw on the sides of the lower half. FIG. 1B shows the groove in the flange on the female slot of the lower half that is an extension of the threaded hole for the bottom set screw on the lower half. That groove permits the lower set screw to extend into the female slot and raise the upper half of the device by pushing the tongue upward.
[0032] FIG. 1C shows the halves assembled with the adhesive strip attached to the lower half where there is a small overlap of the adhesive strip onto the upper half.
[0033] FIG. 1D shows the device halves separated with the adhesive strip attached to the lower half.
[0034] FIGS. 1E and 1F are wireframe isometric depictions of the device halves assembled and separated respectively showing the interior features of the device. FIG. 1F also shows the three set screws removed from the threaded holes.
[0035] FIG. 2 has isometric depictions of the upper and lower halves of the device showing the side that attaches to a frame.
[0036] FIG. 2A shows the upper and lower halves assembled together and FIG. 2B shows the upper and lower halves separated.
[0037] FIGS. 2C and 2D are wireframe depictions of the halves assembled and separated respectively showing the interior features of the device.
[0038] FIGS. 2B and 2D show the three set screws removed from the threaded holes.
[0039] FIG. 3 has depictions of the plan views of two devices showing the upper halves attached to a frame.
[0040] FIG. 3A shows a device attached to each side of a frame with the upper and lower halves assembled but omits the adhesive strip attached to the lower half with an overlap onto the upper half.
[0041] FIG. 3B shows a device attached to each side of a frame with the upper and lower halves separated but omits the adhesive strips attached to the lower halves.
[0042] FIG. 3C shows a device attached to each side of a frame assembled and shows the adhesive strips attached to the lower halves with an overlap onto the upper halves.
[0043] FIG. 3D shows a device attached to each side of a frame with the halves separated and shows the adhesive strips attached to the lower halves.
[0044] FIGS. 3E and 3F are wireframe depictions of the halves assembled and separated respectively showing the interior features of the devices when the upper halves are attached to a frame and omits the adhesive strips. FIG. 3F also shows the three set screws removed from the threaded holes.
[0045] FIG. 4 has depictions of the plan views of two devices showing the lower halves attached to a wall in alignment with the upper halves when the upper halves are attached to a frame. The outline of the frame is shown in FIG. 4 but the frame is otherwise transparent in the drawings.
[0046] FIG. 4A shows two devices attached to a wall with the upper and lower halves assembled.
[0047] FIG. 4B shows two devices attached to a wall with the upper and lower halves separated.
[0048] FIGS. 4C and 4D are wireframe depictions of the halves assembled and separated respectively showing the interior features of the devices when the lower halves are attached to a wall. FIG. 4D also shows the three set screws removed from the threaded holes.
[0049] FIG. 5 has wireframe depictions of the side view of the upper and lower halves of the device showing the interior features of the device and the use of screws and adhesive strip to attach the upper half of the device to the frame, the lower half to the wall and the assembling of the halves of the devices together thereby securing the frame to the wall.
[0050] FIG. 5A shows the halves of the device separated in a location between the frame and the wall where the device is be installed. The figure shows the horizontal angle of the screw holes drilled in the upper half of the device where screws would be directed into the frame and the 11° downward angle of the screw holes drilled in the lower half of the device where screws would be directed into a wall. FIG. 5A shows the flute in the male part of the upper half of the device and the set screw on the side of the lower half that is to be tightened into the flute. It shows the flange feature of the male part of the upper half of the device and the corresponding flange feature of the female part of the lower half. For illustration purposes, FIG. 5A also shows the adhesive strip separated from the lower half of the device, although an installer would not remove the strip from the device during installation.
[0051] FIG. 5B shows the upper half of the device screwed into the frame and the lower half being held onto the upper half by the overlap of the adhesive strip.
[0052] FIG. 5C shows the lower half of the device held onto the wall by the adhesive strip with the upper half of the device separated from the lower half.
[0053] FIG. 5D shows the upper half of the device screwed into the frame and the lower half screwed into the wall and positioned vertically in preparation of assembling the two halves together.
[0054] FIG. 5E shows the upper and lower halves of the device assembled together and held in place by the flanges of the male part of the upper half nested into the female part of the lower half and by the set screw on the side of the lower half tightened against the edge of the flute in the upper half.
DETAILED DESCRIPTION OF INVENTION
[0055] The following is a detailed description of exemplary embodiments to illustrate the principles of the invention, which scope can encompass numerous alternatives, modifications and equivalents. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. Frames are the typical item this invention hangs on a wall but other items including mirrors, signs, shelves, decorations, trophies can be hung on a vertical surface using this invention. Walls are the typical vertical surface, but other surfaces such as fences can be used to hang items using this invention. Screws are the typical fastener used to attach the device to a frame or vertical surface but other fasteners could be employed. In this Detailed Description of Invention, references will be made to “frames”, “walls” and “screws” but the invention applies to their like.
[0056] This invention typically uses two identical devices each of which consists of two parts: an upper half and a lower half as shown in FIGS. 1 and 2 . Two devices are employed to hang a frame, one affixed to each side of a frame as shown in FIG. 3 . If the vertical load or weight of the frame warrants additional devices, then one or more pairs of devices can be employed, with one of each pair being installed on each side of the frame. Once the devices are affixed to the frame then the frame is located on the wall where the adhesive strip holds the lower halves of the devices in place. The frame is then lifted vertically thus separating the upper and lower halves of the devices with the lower halves remaining attached to the wall held by the adhesive strips where they can then be permanently attached to the wall by screws. Once the lower halves are attached to the wall by screws the frame is returned to the desired position and desired alignment by nesting the upper and lower halves of the devices. A minor adjustment to the vertical position and alignment of the frame may be accomplished by the set screws and flute in the device. The side set screws are tightened so that they extend into the flutes of the upper halves resulting in two halves of the devices being secured together and the frame secured to the wall. A more detailed description of the invention follows.
[0057] The devices are presented to an installer with each half together as shown in FIGS. 1A and 2A with low-tack adhesive strips attached to the lower halves of the devices with a small overlap onto the upper halves of the devices as shown in FIG. 1C . The presentation of devices to an installer has the set screws screwed into the threaded holes on the sides of the lower halves of the devices but the heads of the set screws do not extend into the fluted cavities of the male parts of the upper halves; the set screws in the bottoms of the lower halves are screwed into the threaded holes but do not extend into female parts of the lower halves. This is illustrated in FIGS. 1E and 2C . It is the overlap of the adhesive strips onto the upper halves that keeps the upper and lower halves together until the halves are intentionally separated during installation. The adhesive strips are presented with non-stick liners on the side not attached to the device; the liners are removed during the installation process as described below.
[0058] This invention is employed by first aligning the outer edges of the devices with the outer edges of the frame. Although each device should be affixed to the respective side of a frame at a similar distance from the top of the frame this invention does not require that the distances be precisely identical. The upper halves of the devices are then affixed to the frame by screws through holes drilled in the upper halves. The lower halves of the devices will remain held to the upper halves by the overlap of the adhesive strips. The screws are placed in the holes drilled in the upper halves and then tightened into the frame until the heads of the screws are flush with sides of the devices. The result of this first step is shown in FIGS. 3C and 5B .
[0059] Once the devices are affixed to the frame, the installer then removes the non-stick liners from the adhesives strips on the lower halves of the devices exposing the adhesive layer facing the wall side of the frame. The installer then places a level on the top (or some other rectilinear part) of the frame so the installer can determine horizontal or vertical alignment. Such a level can either rest on the frame surface or can be temporarily attached by a number of means, including the use of glue, tape or clamps. With the level on the frame and the adhesive exposed on the wall side of the lower halves of the devices, the installer then locates that frame on the desired location on a wall with the proper horizontal alignment achieved by referring to the level. When the desired location with proper alignment is found, the installer then firmly presses the frame against the wall and the adhesive then holds the lower halves of the devices in the selected place on the wall. The installer then raises the frame vertically separating the upper halves of the devices from the lower halves, with the lower halves remaining on the wall held by the adhesive. This is shown in FIG. 5C . The installer can then place the frame aside with the upper halves of the devices affixed to it.
[0060] The installer then permanently attaches the lower halves of the devices into the wall at the locations where they are held by the adhesive by placing screws through the holes drilled in the lower halves of the devices and installing the screws until the screws are flush with the edge of the device. The lower halves of the devices are drilled so that the screws are directed into the wall at an approximate 11° downward angle. The screws are tightened into the walls (and through the adhesive strips) until the heads of the screws do not protrude past the edge of the devices.
[0061] Once the lower halves of the devices are permanently attached to the wall then the frame is returned to the wall with the male parts of the upper halves of the devices placed into the female parts of the lower halves. This positioning of the upper and lower halves of the devices when they are affixed to the frame and attached to the wall is shown in FIGS. 3B (without adhesive strips depicted), 3 D (with adhesive strips depicted), 4 B and 5 D. Note that the set screws in the lower halves of the devices never extend into the female part of the lower halves until all adjustments are accomplished as an improperly extended set screw could prevent the complete nesting of the lower and upper halves of the devices.
[0062] Once a frame is hanging on the wall with the upper and lower halves of the devices nested together, the devices are designed to permit minor but significant adjustments to allow a more precise vertical location on the wall and a more squared alignment. This is accomplished by use of set screws in the bottom and side of the lower halves of the devices and the flutes in the sides of the male part of the upper halves that align with the side set screws of the lower halves. To raise an entire frame, an installer adjusts the set screws in the bottoms of both lower halves of the devices an equal distance. To adjust the alignment of a frame, an installer adjusts the set screw in the bottom of the lower half of the device for the side that needs to be raised to achieve horizontal alignment.
[0063] Once the height and alignment of a frame is accomplished, the installer then tightens the set screws on the sides of the lower halves of the devices. This holds the adjustment in place because the diameter of the hemispherical end of the set screws is the same as the diameter as the flute cavities in the male part of the upper halves of the devices. This matching of diameters achieves the maximum friction between the surface areas of the set screws and flutes. The set screws will then hold a frame at the adjusted height and alignment.
[0064] When the upper and lower halves of the devices are nested together the vertical load (or weight) of the frame is held by the assembled devices as affixed to the frame and attached to the wall. This configuration is shown in FIGS. 3A (without adhesive strips depicted), 3 C (with adhesive strips depicted), 4 A and 5 E. The manner of the fit of the flanges on the male part of the upper halves of the devices into the female part of the lower halves prevents a frame from moving horizontally away from a wall, as shown in FIGS. 5B and 5D . That design also prevents rotation along the latitudinal axis of the frame. Because the male parts of the upper halves of the devices have flutes and not simply grooves, the male parts cannot be lifted out from the female parts of lower halves as the bottom of the flutes will be stopped by the set screws and prevent removal without first loosening the set screws. The set screws have a unique head (i.e., not a hex or square shape) that can only be turned with a matching wrench or screw driver of the same shape and dimension thus preventing a person without the appropriate tool from loosening the set screws and removing the frame by separating the halves of the devices.
[0065] If the vertical load or weight of a frame is such that more than two devices are necessary then two or more additional device pairs can be used by affixing one of each pair to each side of a frame and then attaching them to a wall in the same manner as a single pair of devices.
[0066] This invention permits the installation of a frame on a wall using the devices and a level that without first making preliminary measurements or marks on a wall to achieve the desired location with proper alignment. The invention allows minor adjustment to correct any misalignment or mis-location that is too low. Once the alignment and location is accomplished the set screws and flutes secure the frame in place and prevent accidental misalignment or mis-positioning when hit or bumped into. The set screws and flutes prevent the removal of a frame from a wall without use of the appropriate unique tool.
[0067] The disclosed embodiments are illustrative but not restrictive. While specific configurations of this wall hanging system devices have been described, this invention can be applied to a variety of items that can be hung on a wall. There are alternative ways of implementing this invention. | A system with devices for hanging picture frames, mirrors or the like comprising a wall member cooperating with a corresponding frame member being adjustable and securable. The devices are installed in pairs, one device on each side of the frame or like. The devices have two mating halves, the upper halves affixed to the frame and the lower halves attached to a wall or other vertical surface. The devices are placed on a wall be use of adhesive and then permanently attached by screws or like fasteners. The devices permit adjustment to height and alignment by set screws and flutes. The devices prevent accidental misalignment and mis-location after installation and impede unauthorized removal. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage application of PCT/SG2008/000352 filed Sep. 17, 2008.
TECHNICAL FIELD
[0002] The present invention relates broadly to a battery pack burn-in test system and method.
BACKGROUND OF THE INVENTION
[0003] Presently, many portable devices such as cordless power tools, computer notebooks and mobile phones are shipped with a lithium-ion battery pack due to its advantages of high energy density, low self -discharge, no memory effect, longer run-time and light-weight compared to a conventional battery pack. However, lithium-ion battery packs may result in unsafe operation due to over-charging, over-discharging or over-heating conditions.
[0004] A lithium-ion battery pack is typically made up of one or a plurality of lithium-ion cells either in series or in parallel connection, depending on its output energy requirements. The battery pack also comprises a protection board for monitoring and ensuring that the lithium-ion cells operate within their safety limits. Some battery packs include fuel gauge integrated circuit (IC) to estimate the state of charge (SOC) and are also able to communicate with external devices via System Management Bus (SMBus) communication. This type of battery pack is commonly known as a Smart Battery Pack.
[0005] As part of the manufacturing process, battery pack manufacturers typically perform a battery pack burn-in test using a 3-phase cycle of full charging-full discharging-50% charging of each battery pack to weed out any initial faulty battery packs due to component defects, mismatched cells, poor spot-welding, poor solder joint and other functional defects. At the same time, the battery pack also performs a SOC calibration to accurately update its SOC during the full charging-full discharging cycle.
[0006] The battery pack burn-in test system is a relatively sophisticated electronic test system which supports multi-channel testing, user programmable burn-in test parameters and test data logging functions. The devices which provide the transfer of energy to and from the battery packs are the Constant Current Constant Voltage (CCCV) Charger and the Electronic Load (ELoad) respectively. During the discharge phase, the battery pack to be tested, here referred to as the Pack-Under-Test (PUT), is connected to an ELoad which discharges the PUT with a preset current. The PUT will terminate the discharging process when any of its cells goes below the over-discharge voltage threshold. In the charge phase, the PUT is connected to a CCCV Charger where the charger will terminate the charging process when the PUT's full-charge conditions are met. The burn-in test cycle typically begins with charging and the PUT will first be charged from an initial capacity of about 50% to a full-charge capacity of 100%. The PUT will then be completely discharged to 0%. Finally, the PUT is recharged to its shipping capacity of 50%. The initial capacity of the PUT is about 50% as this is the initial shipping capacity of the lithium-ion cells. Accordingly, the battery pack manufacturers have to recharge the PUT to 50% prior to shipment. The duration of the burn-in test cycle depends on the setting of the charging and discharging currents. More heat will be generated for a shorter burn-in period due to higher current requirements and vice versa. Typically, the burn-in test duration ranges from 3 hours to 5 hours.
[0007] The present method of battery pack burn-in test process has a problem of generating large amount of heat as the PUT exchanges energy between the ELoad and the CCCV charger. As an example, a standard 6-cell lithium-ion battery pack that is designed for a computer notebook typically dissipates around 35 W in the form of heat during the discharge phase. Consequently, a thousand PUTs discharging at the same time will result in 35 kW of power being converted into waste heat. It is relatively common for a battery pack manufacturing site to maintain burn-in processes of thousands of battery packs simultaneously. With such a large amount of heat generated as a result of the burn-in processes, it is a very costly operation to control the temperature of the burn-in process room to an acceptable operating temperature. Powerful air-conditioners and heat removal system may help to cool down the room but these consume additional electricity which can result in higher costs. Furthermore, failure to control the temperature of the burn-in process room may result in safety concerns as the lithium-ion battery packs may be operating outside their safety operating zone.
[0008] A need therefore exists to provide a battery pack burn-in test system and method that seek to address at least one of the abovementioned problems.
BRIEF SUMMARY OF THE INVENTION
[0009] According to a first aspect of the present invention there is provided a battery pack burn-in test system comprising first and second interconnection circuits for electrically interconnecting a first and a second battery pack respectively to the system; a data communication bus for coupling to respective battery management integrated circuits (ICs) of the first and second battery packs; and a system management unit coupled to the data communication bus. The system management unit may control a charging of the first battery pack during a burn-in test from a discharging of the second battery pack.
[0010] The system may further comprise a current limiter coupled to the data communication bus, the current limiter being electrically connected between the first and second battery pack to limit a charging current for charging the first battery pack from the discharging of the second pack for an initial charging of the first battery pack in a constant current charging state under the control of the system management unit.
[0011] The system may further comprise a first adjustable power supply electrically connected in series with the second electrical interconnection circuit and coupled to the data communication bus for maintaining a selected voltage difference between a series voltage of the second battery pack and the first adjustable power supply on the one hand, and a voltage of the first battery pack on the other hand under the control of the system management unit.
[0012] The system management unit may further maintain the series voltage of the second battery pack and the first adjustable power supply at a constant value and may allow the charging current to gradually decrease in a constant voltage charging state following the constant current charging state.
[0013] The system may further comprise a second adjustable power supply electrically connected in series with the first electrical interconnection circuit and coupled to the data communication bus for maintaining a selected voltage difference between a series voltage of the first battery pack and the second adjustable power supply on the one hand, and a voltage of the second battery pack on the other hand under the control of the system management unit during a constant current charging state of the second battery pack from a discharging of the first battery pack; and the system management unit may further maintain the series voltage of the first battery pack and the second adjustable power supply at a constant value and may allow the charging current to gradually decrease in a constant voltage charging state of the second battery pack following the constant current charging state of the second battery pack.
[0014] The system may further comprise first and second chargers electrically connected in parallel with the first and second interconnections respectively and coupled to the data communication bus, for auxiliary charging of the first and second battery packs under the control of the system management unit.
[0015] The system may further comprise first and second electronic loads electrically connected in parallel with the first and second interconnection circuits respectively and coupled to the data communication bus, for auxiliary discharging of the first and second battery packs under the control of the system management unit.
[0016] The system may further comprise a power switch electrically connected in series between the first and second interconnection circuits and coupled to the data communication bus, for disconnecting a series connection between the first and second battery packs during the auxiliary charging or discharging.
[0017] The system management unit may determine potential differences and temperatures of the first and the second battery packs respectively.
[0018] The system management unit may determine charge capacities of the first and the second battery packs respectively.
[0019] The system management unit may comprise a microcontroller.
[0020] The data communication bus may comprise a SMBus.
[0021] According to a second aspect of the present invention there is provided a method for burn-in testing of battery packs, the method comprising charging a first battery pack from a discharging of a second battery pack.
[0022] The method may further comprise limiting a charging current for charging the first battery pack from the discharging of the second pack for an initial charging of the first battery pack in a constant current charging state.
[0023] The method may further comprise providing an adjustable power supply in series with the second battery pack and maintaining a selected voltage difference between a series voltage of the second battery pack and the first adjustable power supply on the one hand, and a voltage of the first battery pack on the other hand.
[0024] The method may further comprise maintaining the series voltage of the second battery pack and the first adjustable power supply at a constant value and allowing the charging current to gradually decrease in a constant voltage charging state following the constant current charging state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Embodiments of the invention will be better understood and readily apparent to one of ordinary skill in the art from the following written description, by way of example only, and in conjunction with the drawings, in which:
[0026] FIG. 1 shows a schematic block diagram illustrating the functional blocks for a lithium-ion battery pack in accordance with one embodiment of the present invention.
[0027] FIG. 2 illustrates a Constant Current Constant Voltage (CCCV) charging profile of a lithium-ion cell in a lithium-ion battery pack in accordance with one embodiment of the present invention.
[0028] FIG. 3 shows a schematic block diagram illustrating a manual energy transfer process between two lithium-ion battery packs of an example embodiment.
[0029] FIG. 4 shows a schematic block diagram illustrating an automatic energy transfer system between two lithium-ion battery packs of an example embodiment.
[0030] FIG. 5 shows a flowchart illustrating a process of energy transfer for the automatic energy transfer system according to the embodiment of FIG. 4 .
[0031] FIG. 6 shows a schematic block diagram illustrating a recyclable energy lithium-ion battery pack's burn-in test system in accordance with one embodiment of the present invention.
[0032] FIG. 7 shows a flowchart illustrating the initial phase of the energy transfer process for the recyclable energy lithium-ion battery pack's burn-in test system according to the embodiment of FIG. 6 .
[0033] FIG. 8 shows a flowchart illustrating phase 2 of the energy transfer process for the recyclable energy lithium-ion battery pack's burn-in test system according to the embodiment of FIG. 6 .
[0034] FIG. 9 shows a flowchart illustrating the final phase of the energy transfer process for the recyclable energy lithium-ion battery pack's burn-in test system according to the embodiment of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0035] The example embodiments described hereafter may be able to overcome the shortcomings that have been described previously. The example embodiments may provide a battery pack burn-in test system and a method of transferring energy between battery packs. The transfer of energy between battery packs occurs via the use of the discharge of a first battery pack in the discharging state during the burn-in test to charge a second battery pack in the charging state. In example embodiments, the transfer of energy may be a unidirectional process from the first battery pack to the second battery pack. In alternate embodiments, the transfer of energy may be a bi-directional process involving the transfer of energy from the first battery pack to the second battery pack and vice versa.
[0036] FIG. 1 shows a schematic block diagram illustrating the functional blocks for a lithium-ion battery pack 100 in accordance with one embodiment of the present invention. The lithium-ion battery pack 100 comprises a Battery Management IC (BMIC) 102 , a Sense Resistor (RS 1 ) 104 , a P-channel Charge MOSFET (CFET) 106 , a P-channel Discharge MOSFET (DFET) 108 , a Rechargeable Battery 110 and a connector (CN 1 ) 112 . In example embodiments, Battery Management IC (BMIC) 102 may be a microcontroller.
[0037] The Rechargeable Battery 110 in accordance with embodiments of the present invention comprises one or more individual cells e.g. 114 arranged in series. It should be appreciated that the individual cells e.g. 114 can be arranged in series or in parallel in any configurations depending on the output energy requirements. In example embodiments, the P-channel Charge MOSFET (CFET) 106 is connected in series with the P-channel Discharge MOSFET (DFET) 108 between the positive electrode of the Rechargeable Battery 110 and the positive (+) terminal 118 of the battery pack 100 . The P-channel Charge MOSFET (CFET) 106 and the P-channel Discharge MOSFET (DFET) 108 are connected to the Battery Management IC (BMIC) 102 via corresponding electrical connection represented as lines 122 and 124 respectively. The battery pack 100 further comprises a Sense Resistor (RS 1 ) 104 arranged between the negative electrode of the Rechargeable Battery 110 and the negative (−) terminal 120 of the battery pack 100 . It should be appreciated that the P-channel Charge MOSFET (CFET) 106 , the P-channel Discharge MOSFET (DFET) 108 and the Sense Resistor (RS 1 ) 104 may be arranged in other configurations without departing from the spirit or scope of the invention as broadly described.
[0038] The Rechargeable Battery 110 comprising individual cells e.g. 114 of example embodiments are connected to the Battery Management IC (BMIC) 102 via corresponding electrical connection represented as lines e.g. 116 . The Battery Management IC (BMIC) 102 monitors the voltages and temperatures of the individual cells e.g. 114 of the Rechargeable Battery 110 to ensure that the cells e.g. 114 are operating within their safety limits. The cells e.g. 114 may be charged by an external Constant Current Constant Voltage (CCCV) charger (not shown) by connecting the corresponding terminals of the CCCV charger to the positive (+) terminal 118 and the negative (−) terminal 120 provided on the Connector (CN 1 ) 112 of the battery pack 100 . If any of the cells e.g. 114 is charged beyond a pre-determined over-charge voltage protection threshold or is operating outside a pre-determined safe charge temperature range, the Battery Management IC (BMIC) 102 will turn off the P-channel Charge MOSFET (CFET) 106 to disable charging, thus protecting the cells e.g. 114 from being over-charged or operating at a relatively unsafe temperature level. Typically, the over-charge voltage protection threshold for a lithium-ion cell is about 4.2 V.
[0039] The cells e.g. 114 of the battery pack 100 in example embodiments may be discharged by an external device load (not shown) by connecting the corresponding terminals of the device load to the positive (+) terminal 118 and the negative (−) terminal 120 provided on the Connector (CN 1 ) 112 of the battery pack 100 . If any of the cells e.g. 114 is discharged below a pre-determined over-discharge voltage protection threshold or is operating outside a pre-determined safe discharge temperature range, the Battery Management IC (BMIC) 102 will turn off the P-channel Discharge MOSFET (DFET) 108 to disable discharging, thus protecting the cells e.g. 114 from being over-discharged or operating at a relatively unsafe temperature level. Typically, the over-discharge voltage threshold for a lithium-ion cell is about 2.5 V.
[0040] In example embodiments, the Battery Management IC (BMIC) 102 additionally monitors the current flow in the battery pack 100 by detecting the potential difference, also referred to as voltage drop, across the Sense Resistor (RS 1 ) 104 via corresponding electrical connection represented as lines 126 and 128 connected at junctions 130 and 132 respectively. If the charge current or discharge current exceeds their respective pre-determined current thresholds, the Battery Management IC (BMIC) 102 will turn off the P-channel Charge MOSFET (CFET) 106 or the P-channel Discharge MOSFET (DFET) 108 to disable charging or discharging respectively. The Battery Management IC (BMIC) 102 according to embodiments of the present invention can additionally detect the status of the battery pack 100 and communicate this information to an external device using System Management Bus (SMBus) protocol via the SMBus CLK 134 and the SMBus DAT 136 terminals provided on the Connector (CN 1 ) 112 of the battery pack 100 .
[0041] FIG. 2 illustrates a Constant Current Constant Voltage (CCCV) charging profile 200 of a lithium-ion cell in accordance with one embodiment of the present invention. The Constant Current Constant Voltage (CCCV) charging profile 200 shows the characteristics of the charge capacity 202 , the charge voltage 204 and the charge current 206 against the charge time 208 . During the Constant Current (CC) state 210 , the lithium-ion cell is charged with a pre-determined constant current, represented by the current curve 218 , until the cell reaches about 75% of its full capacity as shown by the capacity curve 214 . In this Constant Current (CC) state 210 , the charge voltage during charging of the cell increases as shown by the voltage curve 216 . At the point of 75% full capacity, the voltage of the cell and the voltage drop across the internal resistance of the cell are equal to the maximum output voltage of the charger. The charging state then switches from the Constant Current (CC) state 210 to the Constant Voltage (CV) state 212 where the cell is now charged with a constant voltage as shown by the voltage curve 216 . As the cell gains in potential, the voltage difference across its internal resistance and the charge current 206 will reduce gradually until the charge current 206 , represented by the current curve 218 , falls below a pre-determined level which is generally set at about 5% to 10% of the CC current setting. This condition signals that the cell is now fully charged and the CCCV Charger turns off its output to stop the charging process.
[0042] FIG. 3 shows a schematic block diagram illustrating a manual energy transfer process 300 between two lithium-ion battery packs of example embodiments of the present invention. The process 300 transfers energy from the Battery Pack A 302 to the Battery Pack B 304 . The Battery Pack A 302 is connected in series with a Variable Power Supply (VPS 1 ) 306 and a Current Limiting Circuit (CL 1 ) 308 . The Battery Pack B 304 is connected in parallel to the Battery Pack A 302 , the Variable Power Supply (VPS 1 ) 306 and the Current Limiting Circuit (CL 1 ) 308 . The transfer of energy from the Battery Pack A 302 to the Battery Pack B 304 can be controlled by changing the level of the Total Series Voltage (TSV) 310 , determined collectively from the voltages of the Battery Pack A 302 and the Variable Power Supply (VPS 1 ) 306 . If the Total Series Voltage (TSV) 310 is set higher than the voltage of the Battery Pack B 304 , current will flow from the Battery Pack A 302 to charge the Battery Pack B 304 , as represented by the arrow 312 . The Current Limiting Circuit (CL 1 ) 308 maintains the charge current at a constant value so that the Battery Pack A 302 charges the Battery Pack B 304 in the Constant Current (CC) state. In order to protect against over charging the Battery Pack B 304 , the Total Series Voltage (TSV) 310 is monitored at regular intervals and where necessary, the Variable Power Supply (VPS 1 ) 306 is adjusted manually to limit the Total Series Voltage (TSV) 310 to the pre-determined permissible maximum voltage of the Battery Pack B 304 . Thus, when the Battery Pack B 304 is charged to its pre-determined permissible maximum voltage, the charge current starts to decrease and the Current Limiting Circuit (CL 1 ) 308 acts in a similar fashion to a bypass circuit as the system switches from the Constant Current (CC) state 210 to the Constant Voltage (CV) charging state 212 . The charging of the Battery Pack B 304 is stopped when its full charge condition is met.
[0043] FIG. 4 shows a schematic block diagram illustrating an automatic energy transfer system 400 between two lithium-ion battery packs of example embodiments. The automatic energy transfer system 400 comprises a System Management Unit (SMU) 402 arranged to control and communicate with a Programmable Power Supply A (PPSA) 404 , a Current Limiter (CL) 406 , a Power Switch (PSW) 408 , a Battery Pack A 410 and a Battery Pack B 412 via a network of System Management Bus (SMBus) connections represented as lines e.g. 416 in order to perform the energy transfer process. It should be appreciated that other communication interface, for example serial, parallel and wireless communication interface, may be employed instead of the SMBus communication interface. The Battery Pack A 410 and the Battery Pack B 412 are connected in parallel while the Programmable Power Supply A (PPSA) 404 , the Current Limiter (CL) 406 and the Power Switch (PSW) 408 are connected in series with the Battery Pack A 410 via a closed-loop electrical connection represented as line 426 . The process for the energy transfer of the energy transfer system 400 will now be described with reference to the flowchart 500 of FIG. 5 . After the start 502 of the energy transfer process, the System Management Unit (SMU) proceeds to communicate with the Battery Pack A and the Battery Pack B at step 504 to check the respective status of the voltage and temperature of the Battery Pack A and the Battery Pack B. At step 506 , the voltages and temperatures of the Battery Pack A and the Battery Pack B are checked against pre-determined safety limits to determine if they are within the safe limits for operations. If any of the voltages or temperatures of the Battery Pack A or the Battery Pack B are outside the safe limits, the process proceeds to step 520 to stop and subsequently ends 522 the energy transfer process. In the event that the Battery Pack A is not over-discharged and the Battery Pack B is not fully charged and that the temperatures of both the Battery Pack A and the Battery Pack B are within the safe operating temperature range, the process proceeds to step 508 where the System Management Unit (SMU) turns on the Power Switch (PSW) and subsequently the process continues to step 510 to set the output voltage of the Programmable Power Supply A (PPSA).
[0044] In example embodiments, the output voltage of the Programmable Power Supply A (PPSA) may be set based on the conditions as described below, by way of example and not limitation. The Total Series Voltage (TSV), determined collectively from the voltages of the Programmable Power Supply A (PPSA) and the Battery Pack A, is set for example 0.1 V higher than the voltage of the Battery Pack B to enable the energy transfer from the Battery Pack A to the Battery Pack B. If the Battery Pack A has a higher potential than the Battery Pack B, for example above 0.1 V, the Programmable Power Supply A (PPSA) is set to 0 V. The System Management Unit (SMU) then sets the Current Limiter (CL) to maintain a constant charge current to charge the Battery Pack B. Furthermore, the Total Series Voltage (TSV) is not set higher than the pre-determined permissible maximum voltage of the Battery Pack B to protect against over charging the Battery Pack B. Subsequently after the output voltage of the Programmable Power Supply A (PPSA) has been set, the process for the energy transfer proceeds to step 512 where the Battery Pack B is charged in the Constant Current Constant Voltage (CCCV) mode. During the charging step 512 , the charge current flows from the positive (+) terminal of the Battery Pack A towards the positive (+) terminal of the Battery Pack B to charge the Battery Pack B. The charge current subsequently flows from of the negative (−) terminal of the Battery Pack B through the Power Switch (PSW), the Current Limiter (CL) and the Programmable Power Supply A (PPSA) towards the negative (−) terminal of the Battery Pack A.
[0045] In example embodiments, the System Management Unit (SMU) continuously monitors the respective status of both the Battery Pack A and the Battery Pack B at regular intervals and progressively increases the Programmable Power Supply A (PPSA) output as the voltages of the Battery Pack A and the Battery Pack B decreases and increases respectively in order to maintain a constant charge current so that the Battery Pack B is charging in the Constant Current (CC) state. While the Battery Pack B is charging up to its pre-determined permissible maximum voltage, the charge current decreases progressively as the charging process switches from the Constant Current (CC) state to the Constant Voltage (CV) state. In example embodiments at step 514 , the Battery Pack A is checked to determine if it has been fully discharged. In the event that the Battery Pack A has been fully discharged, the energy transfer process is terminated by the sequential process of turning off the Power Switch (PSW) and the Programmable Power Supply A (PPSA) at step 518 and then stopping 520 and ending 522 the energy transfer process. If the Battery Pack A has not been fully discharged, the process proceeds to step 516 where the Battery Pack B is checked to determine if it has been fully charged. In the event that the Battery Pack B has been fully charged, the energy transfer process is terminated by the sequential process of turning off the Power Switch (PSW) and the Programmable Power Supply A (PPSA) at step 518 and then stopping 520 and ending 522 the energy transfer process. If the Battery Pack B has not been fully charged, the process returns to step 510 to reset the output voltage of the Programmable Power Supply A (PPSA). The subsequent steps after step 510 as described above are then repeated until either the Battery Pack A has been fully discharged as determined in step 514 or the Battery Pack B has been fully charged as determined in step 516 , whereby the energy transfer process is then terminated. Generally, the energy transfer process does not offer 100% efficiency as the Battery Pack A typically has its entire energy depleted before the Battery Pack B is fully charged.
[0046] It will be appreciated that the fully charged Battery Pack B can then be used in the same manner as Battery Pack A to charge another Battery Pack from a discharging of Battery Pack B using the system and method as described with reference to FIGS. 4 and 5 . Also, it will be appreciated that the system and method as described with reference to FIGS. 4 and 5 can also be used for the 50% re-charging as part of the overall burn-in test by stopping the charging when 50% re-charging is reached under the control of the System Management Unit.
[0047] FIG. 6 shows a schematic block diagram illustrating a recyclable energy lithium-ion battery pack's burn-in test system 600 in accordance with one embodiment of the present invention. The burn-in test system 600 is a further enhancement to the automatic energy transfer system 400 ( FIG. 4 ) described previously as the system 600 is able to support the process of bi-directional energy transfer and charging and discharging of the Battery Pack A 608 and the Battery Pack B 622 to the desired capacity in example embodiments. The burn-in test system 600 comprises a System Management Unit (SMU) 602 arranged to control and communicate with the different devices of the burn-in test system 600 via a network of System Management Bus (SMBus) connections represented as lines e.g. 628 to perform the energy transfer process. It should be appreciated that other communication interface, for example serial, parallel and wireless communication interface, may be employed instead of the SMBus communication interface. The burn-in test system 600 further comprises a Battery Pack A 608 and a Battery Pack B 622 connected in parallel, thereby allowing the transfer of energy from one battery pack to the other. In example embodiments, a Programmable Power Supply A (PPSA) 604 is connected in series with the Battery Pack A 608 and a Programmable Power Supply B (PPSB) 618 is connected in series with the Battery Pack B 622 . The voltage of the Programmable Power Supply A (PPSA) 604 may be set by the System Management Unit (SMU) 602 in order to control the Total Series Voltage A (TSVA) 606 and consequently the energy transfer from the Battery Pack A 608 to the Battery Pack B 622 . In a similar fashion, the voltage of the Programmable Power Supply B (PPSB) 618 may be set by the System Management Unit (SMU) 602 in order to control the Total Series Voltage B (TSVB) 620 and consequently the energy transfer from the Battery Pack B 622 to the Battery Pack A 608 .
[0048] The burn-in test system 600 of example embodiments further comprises a Current Limiter (CL) 614 connected in series with the Programmable Power Supply A (PPSA) 604 and the Battery Pack A 608 in order to control the Constant Current Constant Voltage (CCCV) charging of the Battery Pack A 608 and the Battery Pack B 622 and a Power Switch (PSW) 616 connected in series with the Current Limiter (CL) 614 to protect both the Battery Pack A 608 and the Battery Pack B 622 from over-discharging and over-charging by opening the current path between them. In example embodiments, the Battery Pack A 608 , the Battery Pack B 622 , the Programmable Power Supply A (PPSA) 604 , the Programmable Power Supply B (PPSB) 618 , the Current Limiter (CL) 614 and the Power Switch (PSW) 616 are connected to each other via a closed-loop electrical connection represented as line 630 .
[0049] In example embodiments, the burn-in test system 600 further comprises a Constant Current Constant Voltage (CCCV) Charger A 610 and an Electronic Load A (ELoad A) 612 connected in parallel to the Battery Pack A 608 and a Constant Current Constant Voltage (CCCV) Charger B 624 and an Electronic Load B (ELoad B) 626 connected in parallel to the Battery Pack B 622 . The Constant Current Constant Voltage (CCCV) Charger A 610 and the Constant Current Constant Voltage (CCCV) Charger B 624 enable the charging of the Battery Pack A 608 and the Battery Pack B 622 respectively while the Electronic Load A (ELoad A) 612 and the Electronic Load B (ELoad B) 626 enable the discharging of the Battery Pack A 608 and the Battery Pack B 622 respectively to a pre-determined capacity relatively accurately.
[0050] The energy transfer process of the system 600 will now be described with reference to the flowcharts of FIGS. 7-9 . FIG. 7 shows a flowchart 700 illustrating an initial phase of the energy transfer process for the recyclable energy lithium-ion battery pack's burn-in test system of example embodiments, for example the burn-in test system 600 . During the initial phase, the energy transfer process involves transferring energy from the Battery Pack A to the Battery Pack B. At step 702 , the System Management Unit (SMU) proceeds to communicate with the Battery Pack A and the Battery Pack B to check the respective status of the voltage and temperature of the Battery Pack A and the Battery Pack B. At step 704 , the voltages and temperatures of the Battery Pack A and the Battery Pack B are checked against pre-determined safety limits to determine if they are within the safe limits for operations. If any of the voltages or temperatures of the Battery Pack A or the Battery Pack B are outside the safe limits, the process stops at step 706 as a result of the protection features incorporated into the battery packs in example embodiments.
[0051] In the event that the Battery Pack A is not over-discharged and the Battery Pack B is not fully charged and that the temperatures of both the Battery Pack A and the Battery Pack B are within the safe operating temperature range, the process proceeds to step 708 where the System Management Unit (SMU) sets the Programmable Power Supply B (PPSB) to 0 V to act as a bypass to allow current to flow and turns on the Power Switch (PSW). The System Management Unit (SMU) then sets the output voltage of the Programmable Power Supply A (PPSA) at step 710 such that the Total Series Voltage A (TSVA), determined collectively from the voltages of the Programmable Power Supply A (PPSA) and the Battery Pack A, is set for example 0.1 V higher than the voltage of the Battery Pack B to enable the energy transfer from the Battery Pack A to the Battery Pack B. If the Battery Pack A has a higher potential than the Battery Pack B, for example above 0.1V, the Programmable Power Supply A (PPSA) is set to 0 V. The System Management Unit (SMU) then sets the Current Limiter (CL) to maintain a constant charge current to charge the Battery Pack B. Furthermore, the Total Series Voltage A (TSVA) is not set higher than the pre-determined permissible maximum voltage of the Battery Pack B to protect against over charging the Battery Pack B.
[0052] In example embodiments, the System Management Unit (SMU) continuously monitors the respective status of both the Battery Pack A and the Battery Pack B at regular intervals and progressively increases the Programmable Power Supply A (PPSA) output as the voltages of the Battery Pack A and the Battery Pack B decreases and increases respectively in order to maintain a constant charge current so that the Battery Pack B is charging in the Constant Current (CC) state. While the Battery Pack B is charging up to its pre-determined permissible maximum voltage, the charge current decreases progressively as the charging process switches from the Constant Current (CC) state to the Constant Voltage (CV) state.
[0053] Generally, the energy transfer process does not offer 100% efficiency as the Battery Pack A typically has its entire energy depleted before the Battery Pack B is fully charged. At step 712 , the Battery Pack A is checked to determine if it has been fully discharged. In the event that the Battery Pack A has depleted its energy (i.e. fully discharged) before the Battery Pack B has been fully charged, as determined in step 712 , the process proceeds to step 716 where the System Management Unit (SMU) turns off the Programmable Power Supply A (PPSA) and the Power Switch (PSW) to stop the charging of the Battery Pack B. Subsequently, the System Management Unit (SMU) enables the CCCV Charger B to continue the charging of the Battery Pack B. At step 720 , the Battery Pack B is checked to determine if it has been fully charged. If the Battery Pack B has not been fully charged, the CCCV Charger B continues the charging of the Battery Pack B. In the event that the Battery Pack B has been fully charged, the charging process is terminated at step 724 where at the end of this initial phase of the energy transfer process, the Battery Pack A is fully discharged (0% capacity) while the Battery Pack B is fully charged (100% capacity). Subsequently, the energy transfer process proceeds to phase 2 at step 726 .
[0054] In example embodiments, in the event that the Battery Pack A has not depleted its energy (i.e. not fully discharged), as determined in step 712 , the process proceeds to step 714 where the Battery Pack B is checked to determine if it has been fully charged. If the Battery Pack B has been fully charged, as determined in step 714 , the process proceeds to step 718 where the System Management Unit (SMU) turns off the Programmable Power Supply A (PPSA) and the Power Switch (PSW) to stop the charging of the Battery Pack B. Subsequently, the System Management Unit (SMU) enables the Electronic Load A (ELoad A) to start the discharging of the Battery Pack A. At step 722 , the Battery Pack A is checked to determine if it has been fully discharged. If the Battery Pack A has not been fully discharged, the Electronic Load A (ELoad A) continues the discharging of the Battery Pack A. In the event that the Battery Pack A has been fully discharged, the discharging process is terminated at step 724 where at the end of this initial phase of the energy transfer process, the Battery Pack A is fully discharged (0% capacity) while the Battery Pack B is fully charged (100% capacity). Subsequently, the energy transfer process proceeds to phase 2 at step 726 . In the event that the Battery Pack B has not been fully charged, as determined at step 714 , the process returns to step 710 to reset the output voltage of the Programmable Power Supply A (PPSA) and the subsequent steps after step 710 are then repeated until the Battery Pack A has been fully discharged (0% capacity) and the Battery Pack B has been fully charged (100% capacity) at step 724 .
[0055] FIG. 8 shows a flowchart 800 illustrating phase 2 of the energy transfer process according to embodiments of the present invention. During phase 2 , the energy transfer process involves transferring energy from the Battery Pack B to the Battery Pack A. At step 802 , the System Management Unit (SMU) sets the Programmable Power Supply A (PPSA) to 0 V to act as a bypass to allow current to flow and turns on the Power Switch (PSW). The System Management Unit (SMU) then sets the output voltage of the Programmable Power Supply B (PPSB) at step 804 such that the Total Series Voltage B (TSVB), determined collectively from the voltages of the Programmable Power Supply B (PPSB) and the Battery Pack B, is set for example 0.1 V higher than the voltage of the Battery Pack A to enable the energy transfer from the Battery Pack B to the Battery Pack A. If the Battery Pack B has a higher potential than the Battery Pack A, for example above 0.1 V, the Programmable Power Supply B (PPSB) is set to 0 V. The System Management Unit (SMU) then sets the Current Limiter (CL) to maintain a constant charge current to charge the Battery Pack A. Furthermore, the Total Series Voltage B (TSVB) is not set higher than the pre-determined permissible maximum voltage of the Battery Pack A to protect against over charging the Battery Pack A.
[0056] In example embodiments, the System Management Unit (SMU) continuously monitors the respective status of both the Battery Pack A and the Battery Pack B at regular intervals and progressively increases the Programmable Power Supply B (PPSB) output as the voltages of the Battery Pack B and the Battery Pack A decreases and increases respectively in order to maintain a constant charge current so that the Battery Pack A is charging in the Constant Current (CC) state. While the Battery Pack A is charging up to its pre-determined permissible maximum voltage, the charge current decreases progressively as the charging process switches from the Constant Current (CC) state to the Constant Voltage (CV) state.
[0057] Generally, the energy transfer process does not offer 100% efficiency as the Battery Pack B typically has its entire energy depleted before the Battery Pack A is fully charged. At step 806 , the Battery Pack B is checked to determine if it has been fully discharged. In the event that the Battery Pack B has depleted its energy (i.e. fully discharged) before Battery Pack A has been fully charged, as determined in step 806 , the process proceeds to step 810 where the System Management Unit (SMU) turns off the Programmable Power Supply B (PPSB) and the Power Switch (PSW) to stop the charging of the Battery Pack A. Subsequently, the System Management Unit (SMU) enables the CCCV Charger A to continue the charging of the Battery Pack A. At step 814 , the Battery Pack A is checked to determine if it has been fully charged. If the Battery Pack A has not been fully charged, the CCCV Charger A continues the charging of the Battery Pack A. In the event that the Battery Pack A has been fully charged, the charging process is terminated at step 818 where at the end of phase 2 of the energy transfer process, the Battery Pack A is fully charged (100% capacity) while the Battery Pack B is fully discharged (0% capacity). Subsequently, the energy transfer process proceeds to the final phase at step 820 .
[0058] In example embodiments, in the event that the Battery Pack B has not depleted its energy (i.e. not fully discharged), as determined in step 806 , the process proceeds to step 808 where the Battery Pack A is checked to determine if it has been fully charged. If the Battery Pack A has been fully charged, as determined in step 808 , the process proceeds to step 812 where the System Management Unit (SMU) turns off the Programmable Power Supply B (PPSB) and the Power Switch (PSW) to stop the charging of the Battery Pack A. Subsequently, the System Management Unit (SMU) enables the Electronic Load B (ELoad B) to start the discharging of the Battery Pack B. At step 816 , the Battery Pack B is checked to determine if it has been fully discharged. If the Battery Pack B has not been fully discharged, the Electronic Load B (ELoad B) continues the discharging of the Battery Pack B. In the event that the Battery Pack B has been fully discharged, the discharging process is terminated at step 818 where at the end of this phase 2 of the energy transfer process, the Battery Pack A is fully charged (100% capacity) while the Battery Pack B is fully discharged (0% capacity). Subsequently, the energy transfer process proceeds to the final phase at step 820 . In the event that the Battery Pack A has not been fully charged, as determined at step 808 , the process returns to step 804 to reset the output voltage of the Programmable Power Supply B (PPSB) and the subsequent steps after step 804 are then repeated until the Battery Pack A has been fully charged (100% capacity) and the Battery Pack B has been fully discharged (0% capacity) at step 818 .
[0059] FIG. 9 shows a flowchart 900 illustrating the final phase of the energy transfer process according to embodiments of the present invention. During the final phase, the energy transfer process involves transferring energy from the Battery Pack A to the Battery Pack B. At step 902 , the System Management Unit (SMU) sets the Programmable Power Supply B (PPSB) to 0 V to act as a bypass to allow current to flow and turns on the Power Switch (PSW). The System Management Unit (SMU) then sets the output voltage of the Programmable Power Supply A (PPSA) at step 904 such that the Total Series Voltage A (TSVA), determined collectively from the voltages of the Programmable Power Supply A (PPSA) and the Battery Pack A is set for example 0.1 V higher than the voltage of the Battery Pack B to enable the energy transfer from the Battery Pack A to the Battery Pack B. If the Battery Pack A has a higher potential than the Battery Pack B, for example above 0.1 V, the Programmable Power Supply A (PPSA) is set to 0 V. The System Management Unit (SMU) then sets the Current Limiter (CL) to maintain a constant charge current to charge the Battery Pack B. Furthermore, the Total Series Voltage A (TSVA) is not set higher than the pre-determined permissible maximum voltage of the Battery Pack B to protect against the over charging of Battery Pack B.
[0060] In example embodiments, the System Management Unit (SMU) continuously monitors the respective status of both the Battery Pack A and the Battery Pack B at regular intervals and progressively increases the Programmable Power Supply A (PPSA) output as the voltages of the Battery Pack A and the Battery Pack B decreases and increases respectively in order to maintain a constant charge current so that the Battery Pack B is charging in the Constant Current (CC) state. At step 906 , the Battery Pack B is checked to determine if it has been charged to 50% capacity. If the Battery Pack B has not been charged to 50% capacity, the process returns to step 904 in order to reset the output voltage of the Programmable Power Supply A (PPSA) to continue the charging of the Battery Pack B until a 50% capacity has been achieved. In the event that the Battery Pack B has been charged to 50% capacity, as determined in step 906 , the process proceeds to step 908 where the System Management Unit (SMU) turns off the Programmable Power Supply A (PPSA) and the Power Switch (PSW) to stop the charging of the Battery Pack B.
[0061] In example embodiments, the process subsequently proceeds to step 910 where the Battery Pack A is checked to determine if it is at more than 50% capacity. If the capacity of the Battery Pack A is less than 50%, as determined in step 910 , the process proceeds to step 912 where the System Management Unit (SMU) enables the CCCV Charger A to start the charging of the Battery Pack A. At step 916 , the Battery Pack A is checked to determine if it has been charged to 50% capacity. If the Battery Pack A has not been charged to 50% capacity, the CCCV Charger A continues the charging of the Battery Pack A. In the event that the Battery Pack A has been charged to 50% capacity, the charging process is terminated at step 920 where at the end of this final phase of the energy transfer process, both the Battery Pack A and the Battery Pack B are at 50% capacity charge. Subsequently, the energy transfer process ends at step 922 .
[0062] In the event that the capacity of the Battery Pack A is more than 50%, as determined in step 910 , the process proceeds to step 914 where the System Management Unit (SMU) enables the Electronic Load A (ELOAD A) to start the discharging of the Battery Pack A. At step 918 , the Battery Pack A is checked to determine if it has been discharged to 50% capacity. If the Battery Pack A has not been discharged to 50% capacity, the Electronic Load A (ELOAD A) continues the discharging of the Battery Pack A. In the event that the Battery Pack A has been discharged to 50% capacity, the charging process is terminated at step 920 where at the end of this final phase of the energy transfer process, both the Battery Pack A and the Battery Pack B are at 50% capacity charge. Subsequently, the energy transfer process ends at step 922 .
[0063] The lithium-ion battery pack's burn-in test system according to embodiments of the present invention can allow two battery packs to be tested at the same time. The test system enables the transfer of electrical energy or charges from one battery pack to the other battery pack and vice versa. In example embodiments, the energy transfer process utilises the electrical energy discharged from one battery pack which is in the discharging state to charge another battery pack which is in the charging state. This energy transfer process is able to transfer energy regardless of the electrical potential difference between the battery packs and it is able to recharge the lithium-ion battery packs in the Constant Current Constant Voltage mode.
[0064] The lithium-ion battery pack's burn-in test system according to embodiments of the present invention can advantageously minimise the generation of heat as waste from the series of tests and charging and discharging of the battery packs. Conventional burn-in test processes generate a large amount of heat as the battery packs transfer their electrical energy with chargers and loads by charging from the chargers and discharging to the loads connected to the battery packs. In contrast, the burn-in test system of example embodiments employs an energy transfer process which exchanges electrical energy between the battery packs. In the event that a battery pack has not been charged to the desired capacity from the energy transfer process, a Constant Current Constant Voltage (CCCV) charger is activated to continue the charging of the battery pack to the desired capacity. In the event that a battery pack has not been discharged to the desired capacity from the energy transfer process, an Electronic Load (Eload) is activated to continue the discharging of the battery pack to the desired capacity. The selective use of the Constant Current Constant Voltage (CCCV) charger and the Electronic Load (Eload) to charge and discharge the battery pack respectively after the energy transfer process between two battery packs helps to reduce the overall heat generated from the battery packs.
[0065] The lithium-ion battery pack's burn-in test system according to embodiments of the present invention can allow the testing, state of charge (SOC) calibration and charging of the battery packs simultaneously. The system enables the battery packs to be charged and discharged as a form of burn-in testing to ensure that the battery packs are not faulty due to component defects, mismatched cells, poor spot-welding, poor solder joint and other functional defects, for example. The testing is performed over a three-phase cycle as described above involving full charging, full discharging and charging to 50% capacity for the battery packs. At the same time, the battery pack can also perform a SOC calibration to accurately update its SOC during the full charging-full discharging cycle. At the end of this cycle, the battery packs are typically maintained at 50% capacity charge, which is the general capacity for battery packs prior to shipment of the battery packs to consumers.
[0066] It will be appreciated by a person skilled in the art that numerous variations and/or modifications may be made to the present invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects to be illustrative and not restrictive. | A battery pack burn-in test system comprising first and second interconnection circuits for electrically interconnecting a first and a second battery pack respectively to the system; a data communication bus for coupling to respective battery management integrated circuits (ICs) of the first and second battery packs; and a system management unit coupled to the data communication bus. The system management unit may control a charging of the first battery pack during a burn-in test from a discharging of the second battery pack. | 7 |
BACKGROUND OF THE INVENTION
The manufacture of paper pulp stock from wood by defibrating the wood raw material into fibers suitable for paper making can take place either chemically as a pulp cooking process or by subjecting the deciduous material to mechanical defibrating treatment.
There are two basic types of methods for the mechanical defibrating of wood. The oldest method is the grinding process in which wet logs of suitable length are pressed against the coarse surface of a rotating cylindrical grinding stone. Water in proper amount is also directed onto the grinding surface. The water is necessary because the grinding of totally dry wood leads to the production of useless wood flour. This process results in practically all of the wood material being converted into an aqueous fiber slurry, with the exception of splinters and slivers. This type of fiber pulp stock is generally used as raw material for newsprint.
A more modern mechanical pulp manufacturing method makes use of chipped wood, i.e. wood in the form of wet chips, which are defibrated for example between two disc-like grinding elements which rotate relative to each other and which have a suitable surface structure. This method also results in a pulp slurry which after screening is suitable for paper making.
As is well known, wood contains 20-30 percent of lignin which is an aromatic substance having a large molecular size. Lignin resembles glue to some degree and it acts to bond the wood fibers together. In pulp cooking or other chemical reactions on the pulp, the lignin is mainly dissolved. However, in mechanical defibration the lignin remains on the fibers.
Thus, it is a characteristic of mechanical pulp manufacturing methods that all of the constituents of the wood, that is the cellulose fibers and the lignin bonding the fibers together are present in the produced pulp fiber stock. Moreover, these mechanical pulp manufacturing methods produce an appreciable amount of heat during the defibration process because the mechanical energy is converted to heat and this results in the temperature of the pulp rising to a level which is sufficient to make the lignin soft and sticky.
In recent years a new type or grade of mechanical pulp, so called thermomechanical pulp has gained wide acceptance. This pulp is made from chips in a disc type refiner. In this manufacturing process heat is added in addition to that which is generated by the friction on the chips during the defibration process. Due to the increased temperature in the production of thermomechanical pulp the lignin is softened more thoroughly than in the conventional mechanical pulp processes. This means that the fibers are separated from each other quite easily and in comparatively intact condition so that the fibers are long and pliant. As a result, the quality of the thermomechanical pulp, from the standpoint of paper making, is in many respects higher than that of other mechanical pulps. Thus, in the manufacture of newsprint it is possible to produce paper entirely from thermomechanical pulp, whereas in the case of the use of conventional mechanical pulps (e.g. groundwood) for the production of newsprint it is necessary to add a considerable amount, up to 25%, of chemical pulp or cellulose in order to obtain the required strength for the paper.
It is in general necessary to improve the optical and printing properties of pulps in order to be able to use the same for newsprint and other purposes. Mineral fillers are used in particular to improve the printing properties and opacity of the paper. The introduction of the filler material may take place in one of two different ways, either by mixing the filler with the paper stock or by coating the paper web. In the mixing method the filler is added as a suspension into the pulp stock slurry before the stock enters the paper machine. This is accomplished by introducing the filler as an aqueous suspension of 30-40% solids into the mixing chest following the high consistency stock chest. However, the problem with the use of fillers has always been that they are very poorly retained by the fibers. While it is possible to mix the filler material in the pulp stock slurry so that a homogenous suspension of filler particles and fibers with the water is obtained, when the suspension is fed onto the paper machine wire, where it is dewatered and a continuous web formed from the fibers, a considerable portion of the filler material is removed with the water and the remaining portion of the filler material has a tendency to concentrate on only one surface layer of the web, which results in so called one-sidedness. The quantity of filler added to the paper stock may vary, depending upon paper grade, from 2 to 40% of the weight of the paper produced. The most common filler contents are 5-20%. Talc, clay (kaolin), chalk and other equivalent substances are usually used as fillers. In recent times there has been increased use of high quality fillers such as titanium oxide and zinc sulphide pigments for improvement in the opacity of the paper. Generally speaking the fillers are used for improving the opacity and brightness of the paper and for increasing its receptivity to printing ink, as well as for improving the smoothness and finish of the paper.
As indicated above, while the use of fillers is generally well known, the problem has remained, particularly in the production of mechanical pulp, of retention of the filler by the fibers.
U.S. Pat. No. 3,388,037 describes the production of mechanical pulp wherein the pulp is chemically acted upon, for example by sulfite solution and by sodium peroxide or hydrogen peroxide or hypochlorite. Some fillers may be added along with the chemical solutions in which case, in addition to the whitening effect of the chemical solution there is a further chemical reaction between the fibers and the filler material. In addition to the expense of chemical processing this process suffers from the disadvantage of the loss of newsprint yield because the chemical action consumes a portion of the wood, as well as of the lignin or the like which binds the wood fibers together.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the present invention, fillers are added to and mixed with the mechanical pulp stock during the production thereof at such time that the filler material is in contact with the pulp fibers while the plasticizable constituents thereof are in softened and sticky material and remain in contact therewith for a sufficient time during which the plasticizable constituents are in such condition so that the filler materials adheres to the fibers to a much greater degree than with known methods, and has the effect of improving the properties of the resulting mechanical pulp for paper making purposes without chemical reaction. Thus, for example, the fillers can be added to the raw material of the pulp before the same is frictionally acted upon in the mechanical defibration process so that is remains in contact therewith during the frictional heating when the plasticizable constituents become softened and sticky and thus adheres thereto. However, it is preferred to add the fillers during the mechanical defibration or very shortly thereafter while the plasticizable constituents of the pulp are still in softened and sticky condition.
Accordingly, it is a primary object of the present invention to provide a method whereby considerable quantities of filler material can be made to become fixed to the fibers of mechanical pulp without chemical reaction therewith.
It is another object of the present invention to provide a method which can result in increase in the brightness and opacity of paper made from mechanical pulp. It is yet another object of the present invention to reduce the blackening tendency of paper made from mechanical pulp when this paper is calendered at moisture contents higher than 10-11%.
It is still another object of the present invention to reduce the one-sidedness or assymmetry in the structure of paper made from pulp and the linting tendency of paper which is loaded with fillers.
A further object of the present invention is to improve the possibilities for the use of filler materials which are advantageous for the paper quality but which due to their relatively poor retention to fibers makes their use difficult in paper making.
Other objects and advantages of the present invention will be apparent from a further reading of the specification and of the appended claims.
With the above and other objects in view, the present invention mainly comprises in the production of mechanical paper pulp from natural vegetable fibers for material, particularly wood, by frictionally acting upon fibrous raw material containing plasticizable constituents which during the process are heated to a temperature sufficiently high to plasticize such constituents and soften and render the same sticky while at least partially separating the fibers from each other, which comprises adding at least one paper filler material which is chemically non-reactive with the fibrous pulp through the same at such time that when the plasticizable constituents thereof are in softened and sticky condition the filler is in contact therewith and remains in contact therewith for a sufficient time to adhere to the plasticizable constituents and thus to the fibers of the pulp, thus resulting in improvement of the properties of the mechanical pulp.
It is thus clear that in accordance with the present invention advantage is taken of the elevated temperature in the defibrating process and in the presence of lignin or an equivalent plasticizable substance on the defibrated fibers to improve the properties of the mechanical pulp without chemical reaction therewith. The fillers which are utilized primarily are used to improve the optical properties such as opacity and brightness and to increase the receptivity of the paper to printing ink, as well as to improve the smoothness and finish of the paper.
This is accomplished in accordance with the present invention by increased retention of the filler material onto the fibers in an inexpensive manner without using chemical reactions and is accomplished by making use of the natural lignin or the like in the fiber and the high temperature obtained during the mechanical defibration to cause the filler material to stick to the lignin and become fixed on the surface.
Although lignin is mainly mentioned as the plasticizable constituent of wood or the like, the same becoming plasticized at increased temperature for example 100°-170° C., it must be borne in mind that certain paper stocks may contain other plasticizable constituents such as hemicellulose which are plasticized in the same manner as lignin. For instance, hardwood pulps and paper stock made of bagasse contain large quantities of hemicellulose and these materials can be subjected to the process of the invention in the same manner as woods which contain lignin.
It should be understood that any filler material which is commonly used in paper stocks and which is not chemically reactive with the fibrous pulp may be utilized as filler for the purposes of the present invention, and although specific examples of filler materials are mentioned, it is to be understood that the invention is not limited thereto. Thus, for example, among the more commonly used fillers or loading materials for the manufacture of paper, all of which may be used for the purposes of the present invention, are kaolin, talc, calcined gypsum, chalk, precipitated calcium carbonate, barium sulfate in cylindrical granular form known as blanc fixe, barium sulfate in arthro-rhombic form known as baryte, silica, titanium dioxide (anatase or rutile), zinc sulfide, etc.
Also, the amount of filler which is added according to the present invention can vary depending upon the final use for which the paper is intended. The advantages obtained according to the present invention that there is less waste of filler material because it almost totally adheres to the fibers in the course of the process.
In general, the amount of filler, analyzed in terms of ash content in the finished paper, may vary between about 2-40% by weight, most common amounts varying between 5-20% by weight of the paper. As indicated above, the amount is dependent upon the intended use of the final product.
The filler material, as previously mentioned, may be introduced into the defibrating system while the fillers are suspended in water to form a filler slurry, i.e. an aqueous suspension which may have about 30-40% of solids. On the other hand, the consistency or the solid content with regard to fibers of the pulp varies greatly depending upon the defibrating method.
If defibrating is performed by means of a grinding stone, the resulting pulp consistency may be in the range of about 1-2% or even higher. Due to the great dilution (50-100 times) of the pulp slurry and the high consistency (30-40%) of the filler slurry the latter does not remarkably affect the resulting filler-mixed pulp stock consistency.
On the other hand, in the manufacturing of mechanical pulp from chips, particularly thermomechanical pulp, the most suitable solids content (of fibers) of the resulting pulp is approximately 20-25%. Maximum filler suspensions flow if all fillers are fed in the defibrating state may represent 20% of the pulp slurry flow corresponding to about 8% filler solids in the pulp slurry. Excessive amount of fillers means excessive dilution of the stock which could possibly disturb the defibration process.
Consequently, in some cases it may be advantageous to introduce only a portion, for example one half of the total filler amount, to the stock during the defibrating process proper, and another portion at a later stage. Addition of all the filler material simultaneously during defibration of the stock resulting in very firm adhesion affects the pulp quality in a manner which may not always be desired and it is thus possible to control the quality of the final pulp by varying the times of addition of the filler material. Thus, divided addition may be preferred in certain instances.
It is also possible according to the present invention to use more than one kind of filler with one being introduced in the system in the defibrating stage while the other filler may be introduced at another stage.
BRIEF DESCRIPTION OF DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 constitutes a block diagram illustrating the method of the present invention particularly with respect to the manufacture of thermomechanical pulp in two defibrating stages;
FIG. 2 diagrammetically illustrates an apparatus for carrying out the process of the FIG. 1; and
FIG. 3 diagrammetically illustrates an embodiment of the invention as applied to a defibrating process utilizing a conventional stone grinding machine.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring more particularly to the figures, in both FIGS. 1 and 2, the symbol M in refers to the entry of the raw material to be defibrated, and M out refers to the exit of the pulp.
In FIG. 2 block 20 represents the stage of preheating of the raw material e.g. wood chips, while block 21 represents the first defibrating stage and block 22 represents the second defibrating stage. The pulp from the second defibrating stage 22 is conducted to the screening and cleaning stage 23. The reject from the screening stage 23 is conducted to the reject refining stage 25 from which is is returned through conduit c to the screening and cleaning stage 23. After the second defibrating stage 22 proper a part of the pulp is returned through conduit b to the input side of the second defibrating stage 22.
According to the present invention, the filler material coming from block 24 can be introduced to the process through one or more of the conduits a 1 , a 2 , a 3 and a 4 .
According to the preferred embodiment of the present invention, the fillers are introduced into the process at 26 between the first defibrating stage 21 and the second defibrating stage 22 through conduit a 1 . Conduits a 2 and a 3 represented by the dotted lines illustrate embodiments of the invention according to which the filler material may in part or in whole be introduced through conduit a 2 directly into the first defibrating machine 21 or at its input side through conduit a 3 . According to still another embodiment of the invention, as discussed above, the fillers may also be introduced into the process immediately after the defibrating stages 21 and 22, for example through conduit a 4 . This alternative implies that the plasticizable constituent of the pulp must be in softened and sticky condition at the time of the addition of the filler through a 4 .
The apparatus and mtehod of producing mechanical pulp, particularly thermomechanical pulp, of improved properties according to the present invention is illustrated in greater detail in connection with FIG. 2.
As shown in FIG. 2 a disc refiner 10 is used in the process as the defibrating machine. The refiner 10 comprises two opposed, refining or grinding discs 11 and 12 which are rotated in mutually opposite directions driven by electric motors 15 and 16, respectively. The raw material in the form of wet wood chips or sawdust particles is introduced into the refiner by means of the screw conveyor 13. The selected filler material, for example, talc or clay in an amount corresponding to the desired filler content in the paper to be produced from the pulp is introduced into the screw conveyor 13 at 26, the filler being supplied from tank 24 through conduit a 1 .
As shown in FIG. 2, the raw material for the pulp, such as wood chips, is fed into the preheater 20 through rotary valve 29. In the preheater 20 the chips are heated to a temperature of about 100°-130° C. The preheater 20 includes a screw conveyor and the preheated wood chips leave the preheater 20 through the rotary valve 19 and are subsequently conducted through the steam separator 17 to the screw conveyor 13 by which the preheated chips are fed into the refiner 10. The screw conveyor 13 is so arranged that the steam from the refiner can be conducted in countercurrent with respect to the direction of movement of the chips.
Fresh steam is introduced into the process as required through the control valve 28 and the pressure in the preheater 20 is controlled by means of control valve 27. The pressure in steam separator 17 is controlled by a similar valve.
As is clear from FIG. 2, the wood chips and/or the sawdust particles are subjected to powerful mechanical treatment in the gap Δ between the refining discs 11 and 12 which rotate in opposite directions. Defibration of chips takes place partly by their contact with the rapidly rotating refining discs, and partly as a result of their mutual contact with each other, the friction resulting therefrom causing heating of the material under treatment. This temperature rise causes further softening and plasticizing of the lignin or other equivalent constituent of the raw material.
The fillers are admixed with the fibers in the refiner 10 and adhere to the softened lignin on the surface of the fibers.
The grinding machine shown in FIG. 3 includes a magazine 31 for the wood or logs 32 to be ground, a grinding stone 33 which rotates in the direction shown by the arrow and pulp pit 34 under the stone. By means of known devices, for instance by means of a hydraulically loaded plunger (not shown), logs 32 are pressed against the surface of the grinding stone. Water required for the grinding process is led to the surface of the stone through a shower pipe 35.
The pulp produced in the process is gathered in form of fiber-water suspension 39 in the pit 34 under the stone and flows over the overflow dam 38 to a trough 40, from which the pump 41 feeds the stock to the screening apparatus (not shown) to separate shives etc. and from there to the paper making process. The grinding stone and the stock pit are enclosed in an air tight chamber 42, where, if required, overpressure may be produced and maintained, for instance by means of compressed air fed through a pipe 44 equipped with a valve 43.
The lower portion of the chamber 42 is provided with a compartment 46 equipped with a mixer 45 in the stock pit 34, which is equipped with a partial dividing wall 47, which guides the pulp arriving continuously into the pit to flow through the compartment towards the overflow dam. The apparatus also includes a shower pipe 36, through which the filler slurry is introduced onto the surface of the grinding stone as a suspension with about 30-40% solid content. Another shower pipe 37 is arranged to feed filler material to be mixed with the pulp on the surface of the stone. The feeding of filler material can take place through either only one of the shower pipes, or both, depending on circumstances. There is connected to the pit 34 a steam pipe 49 equipped with a valve 48 to heat the pulp 39 in case increased temperature in the process is needed. The purpose of the mixer 45 is to maintain the flow of the pulp through the compartment 46 on the one hand and on the other hand to create an efficient mixing of the filler suspension with the stock.
The energy input through the shaft of the grinding stone is converted to heat during the grinding process and the temperature of the pulp produced may rise to a considerable level (100°-130°) similarly as in a process using a disc refiner. This results in the lignin or the like present in fibers becoming soft and sticky.
The pulp stock manufactured by grinding must be diluted to a consistency which permits further pumping of the pulp. Introducing the dilution water, which may take place through a hower pipe 35a, rapidly lower the temperature of the pulp suspension well below 100° C.
When it is desired to utilize the ability of the lignin-containing fibers to bind filler material on their surface at high tempaeratures, introduction of fillers must be carried out in connection with the grinding process or immediately thereafter. The filler suspension can be led onto the bare surface of the stone before the grinding zone. However, if this upsets the grinding process, it is possible to accomplish the filler addition immediately after the grinding zone on the grinding stone surface which is covered by the pulp.
For securing the sticking of the filler particles on the fibers, dwell time of the pulp in the grinder pit must be prolonged, which is achieved by increasing the pit volume with an additional compartment. The same purpose i.e. securing the filler fixing, is served by a mixer placed in said compartment which also provides the possibility of pulp heating by means of steam.
As is well known, production of high quality groundwood implies that the logs to be ground are wet and that during the grinding process sufficient water is present. The vast amount of heat generated in the process and the rise of the temperature to over 100° C. may cause a rapid evaporation of the water and drying of the wood material at the grinding zone. In order to prevent this the grinding process may be carried out in a pressure tight chamber in which the overpressure is maintained e.g. by means of compressed air. Overpressure may also be accomplished by the steam supply which is used for heating the pulp in the pit below the grinding stone.
As indicated above, all filler materials commonly used in the paper making may be used for the purposes of the present invention. One of the most suitable of such fillers is talc which in addition to its use in improving the optical and printing properties of the paper has been found particularly effective as an aid against so called pitch troubles which may appear when mechanical pulp is manufactured from certain raw materials e.g. pinewood.
The amounts of talc filler required for pitch control are slight, about 1-2% and this amount can be added into the system in or prior to the first defibrating stage, whereas ordinary usage for improving paper properties amounts to 5-10% depending on the paper or board grade produced, the latter amount being fed to the system in the second defibrating stage or, after the defibrating has been completed.
As indicated above, the plasticizable constituent of wood is mainly lignin and correspondingly reference is made generally to lignin as being this substance which undergoes softening and plasticizing due to the rise in temperature during the defibration process. However, it must be noted that certain paper pulps are not of woody origin or contain other constituents than lignin, which are plasticized in an equivalent manner as lignin, and from the standpoint of the present invention any such plasticizable constituent of the wood is affected in the same manner by the process of the invention, and the filler materials can be made to adhere thereto in accordance with this invention.
In general, the method of the present invention may be applied in all cases where mechanical pulps are produced and used particularly for such pulp grades in which fillers have already conventionally been used, though not introduced in the manner of the present invention. This includes the use thereof for photogravure and offset printing paper. In addition, the process of the present invention is suitable for the production of mechanical pulp for paper grades in which fillers have not hitherto been used but in which it is now possible to use fillers due to the particular advantages of the method of the present invention. Such applications include, for example, newsprint papers, particularly when it is desired to reduce the base weight of the paper which is of considerable importance at this time. This becomes possible with the method of the present invention due to the improved opacity of the produced paper.
While the invention has been illustrated in particular with respect to specific methods of production of mechanical pulp from woody raw material, it is apparent that variations and modifications as regards the raw material as well as the filler utilized and the treatment thereof can be made in accordance with the invention. | Properties of mechanical paper pulp which is produced by grinding or otherwise frictionally acting on natural fibrous raw material containing plasticizable constituents which become heated to a temperature sufficiently high to soften the plasticizable constituents thereof are improved by the addition of paper filler material which is chemically inert to the pulp at a time which results in the filler being in contact therewith while the plasticizable constituents are plasticized and thus softened and sticky. This causes the filler, without chemical reaction, to adhere to the plasticized constituents and thus to the fibers of the pulp to result in improved properties of a totally mechanical pulp. The properties which are improved include the optical and printing properties of the paper made from the pulp. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an inkjet printer and a suction apparatus used therefor.
2. Description of the Prior Art
In a closed ink tank, the amount of air inside increases due to evaporation of the ink or the like, and ink may not then be properly supplied. Therefore, the increased amount of air must be exhausted outside the tank. When the air is exhausted by a negative pressure suction source, ink is exhausted together with the air. For this reason, if air suction tubes for ink tanks of respective colors communicate with each other, the inks diffuse and mix with each other. In order to prevent this, a conventional arrangement as shown in FIG. 1 has been proposed. Referring to FIG. 1, a recording head 1 has an integral unit of a plurality of subtanks storing inks of different colors therein. Each subtank has an inkjet nozzle. Main tanks 2 (only one is shown in the figure for the sake of simplicity) are respectively connected to the subtanks. A cap 3 seals the surface of the recording head 1 in which the nozzles are embedded and serves to prevent drying of the inks. A negative pressure suction source 4 has independent air suction tubes 5 which are respectively connected to the subtanks.
With the arrangement as described above wherein the air suction tubes 5 are arranged for the respective subtanks, mixing of different color inks may be prevented to a certain degree. However, since the different color inks are still mixed in the negative pressure suction source, the inks diffuse and mix with each other as they are drawn into the air suction tubes 5.
When air layers are present in the air suction tubes 5, the different color inks mix with each other due to formation of an ink head or a change in the air volume, which are respectively caused by inclination of the air layers or changes in temperature.
In this manner, the conventional arrangement requires a separate negative pressure suction source for ink suction in addition to a negative pressure suction source for air suction. Furthermore, an air suction tube must be connected to each subtank. This has prevented easy mounting of the arrangement on the printer, and has thus prevented a compact arrangement. When the recording head 1 moves together with a carriage, the air suction tubes provide a resistance and adversely affect the movement of the recording head 1.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an inkjet printer which may not cause mixing of inks of different colors.
It is another object of the present invention to provide an inkjet printer which is capable of high-speed printing.
It is another object of the present invention to provide an inkjet printer which allows each mounting.
It is another object of the present invention to provide an inkjet printer of a simple structure.
The above and other objects of the present invention will become apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing the arrangement of a conventional device;
FIGS. 2 to 6 show a suction apparatus according to a first embodiment of the present invention, wherein FIG. 2 is a perspective view showing the outer appearance of the first embodiment;
FIG. 3 is a partially sectional view of the FIG. 2;
FIG. 4A is a sectional view of a suction path sealing mechanism;
FIG. 4B is a partial view showing the relationship between the vertical movement of an opening/closing cam and a hollow shaft;
FIG. 5 is a sectional view showing details of a negative pressure suction source used in the embodiment;
FIG. 6 is a timing chart for explaining the mode of operation of the embodiment;
FIGS. 7 to 9 show a suction apparatus according to a second embodiment of the present invention, wherein FIG. 7 is a partially sectional perspective view of the embodiment;
FIG. 8 is a sectional view of a sealing portion of a piston; and
FIG. 9 is a top view of a pump.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 2 to 6 show the first embodiment of the present invention. Referring to FIG. 2, a recording head 9 has ink supply tubes 8-1 to 8-4. A capping 12 having ink suction paths 11 and air suction paths 25 in an elastic cap 10 opposes the recording head 9. A pin 12A protrudes from the side surface of the capping 12. Suction path sealing mechanisms (A) and (B) are incorporated within the capping 12. A lever 13 moves vertically in the directions indicated by arrow 14. By the engagement of a groove cam 13B formed in the lever 13 with the pin 12A, the vertical movement of the lever 13 is converted to transverse movement of the capping 12 so as to control its attachment to or separation from the recording head 9. The lever 13 further has a cam 13A. The vertical movement of the cam 13A controls the movement of an ink suction hollow shaft 15 and an air suction hollow shaft 26 (FIG. 3) of the suction path sealing mechanisms in the directions indicated by arrow 16. A negative pressure suction source 17 is arranged immediately below one end of the lever 13. The vertical movement of the lever 13 vertically moves a piston 18 of the negative pressure suction source 17. The negative pressure suction source 17 and the capping 12 are connected by an ink suction tube 19 and an air suction tube 20, thereby transmitting a negative pressure.
FIG. 3 shows a partially sectional view of the apparatus shown in FIG. 2. In the recording head 9, four subtanks 9-1, 9-2, 9-3 and 9-4 are arranged next to each other in the direction parallel to the surface of a printing paper sheet (printing direction). The respective subtanks store inks of different colors and have inkjet nozzles 21, air suction holes 22, and resistance filters 23 at the distal ends of the holes 22. The inkjet nozzles 21 are of so-called ink-on-demand type; they inject inks in response to drive signals supplied from a printer circuit (not shown). The resistance filters 23 serve to keep the subtanks in a substantially sealed state, and to extract excess air in the subtanks, thereby keeping the ink levels constant. In order to perform these two functions, each resistance filter 23 comprises a material such as a membrane filter having pores of about 5 to 10μ `diameter. The resistance filters 23 serve to allow permeation of air only when no ink is attached to them, but do not allow permeation of air when a large quantity of ink is adhered to them. As shown in FIG. 3, when the ink level is kept at a normal ink level 24, the resistance filter 23 is soaked with the ink and therefore seals the interior of the subtank. When the amount of air in the subtank increases due to evaporation of the ink or the like, the ink level falls to reach a level 24A. Then, the resistance filter 23 is no longer soaked with the ink and the air can permeate therethrough to a certain degree. The capping 12 has four ink suction paths 11 and four air suction paths 25 in correspondence with the respective nozzles and air suction holes, respectively. The four ink suction paths 11 and respectively connected to the ink suction hollow shaft 15 inside the capping 12. The four air suction paths 25 are respectively connected to the air suction hollow shaft 26 inside the capping 12.
FIG. 4A shows a section of the ink suction hollow shaft 15.
The ink suction hollow shaft 15 has notches 15A corresponding to the respective ink suction paths 11. The open end of the shaft 15 communicates with the negative pressure suction source by means of the ink suction tube 19. In the state shown in FIG. 4A, the cam 13A of the lever 13 urges a contact member 15B of the shaft 15 to a position 15C in FIG. 4(B) so as to inject inks from the respective nozzles 21. When the contact member 15B of the shaft 15 returns to a position 15C' by means of a spring 27 upon upward movement of the lever 13, the respective ink suction paths 11 are sealed. More specifically, since the hollow shaft 15 moves upward in the direction indicated by arrow 28, the notches 15A become misaligned with the ink suction paths 11 so that the ink suction paths 11 are sealed. Similar effects may also be obtained with a mechanism in which the hollow shaft 15 pivots to seal the ink suction paths 11.
Although not shown in the figure, the air suction hollow shaft 26 is of the same configuration as that of the ink suction hollow shaft 15. More specifically, the air suction hollow shaft 26 has notches for communicating four air suction paths 25 with the negative pressure suction source, a contact member for engaging with the cam 13A of the lever 13, and a spring for urging the contact member against the cam 13A. When the lever 13 is moved downward, the respective air suction paths 25 communicate with the negative pressure suction source so as to draw air through the filters 23. At this time, a small amount of ink is also drawn through the filters 23. When the lever 13 is returned to the position shown in FIG. 2, each air suction path 25 is sealed and mixing of inks between the respective air suction paths 25 is prevented. When the lever 13 is moved downward, the ink suction paths 11 are first connected to the negative pressure suction source. However, it is apparent that the air suction paths 25 may be connected with the negative pressure suction source as the ink suction paths 11 are connected thereto, by suitably selecting the positions or sizes of the notches.
FIG. 5 shows the negative pressure suction source 17. The negative pressure suction source 17 comprises a piston 18 which is vertically movable therein; O-rings 30A, 30B and 30C for providing a hermetic seal; a valve 31 which is open during the suction period; a spring 32 having a biasing force for urging the piston 18 upward; and pump suction openings 34 formed at positions such that they can communicate with a negative pressure space 33 formed when the piston 18 is moved downward. One end of each of the ink suction tube 19 and of the air suction tube 20 is connected to the pump suction openings 34. With the negative pressure suction source 17 of this structure, when the lever 13 is moved in the downward direction indicated by arrow 14, the pin 12A formed integrally with the capping 12 moves forward in the cam 13B so as to urge the elastic cap 10 against the distal end surface of the recording head 9 on which the nozzles 21 and air suction holes 22 are formed. Thereafter, when the piston 18 of the negative pressure suction source 17 is urged by the lever 13 to expand the space 33 and to communicate it with the pump suction openings 34, a negative pressure is established in the hollow shafts 15 and 26. Thereafter, when the cam 13A returns to the position shown in FIG. 4A and the ink suction paths 11 and the air suction paths 25 are connected to the negative pressure suction source, the inks and air are drawn by suction to remove the excess air in the nozzles which is the cause of defective printing. When the amount of air in one of the subtanks is great, that is, when the ink level in the subtank in FIG. 3 is at the level 24A or the like, the filter 23 is not soaked with ink. Therefore, the air in the subtank can permeate through the filter 23 so that the ink level in the subtank can return to the normal ink level 24. In contrast to this, when the amount of air in the subtank is normal, the filter 23 is soaked with ink and does not substantially allow the air to permeate therethrough. Thus, the ink level is kept substantially at the normal ink level 24. More ink in an amount corresponding to the amount of drawn air is supplied to the subtank from the main tank (not shown).
When the lever 13 is moved to its lowermost position indicated by a dotted line 13D in FIG. 2 to as to draw the air and the inks and is then stopped, the piston 18 is returned to its original position by the spring 32 and the lever 13 is also returned to a position indicated by alternate-long-and-two-short dashed line 13C. Since the cam 13A moves upward, the ink suction hollow shaft 15 moves to the position 15C in FIG. 4B. Then, the ink suction paths 11 are sealed, and the air suction hollow shaft 26 also moves to a position to seal the air suction paths 25. On the other hand, when the lever 13 moves to the position 13C, the contact members of the shafts 15 and 26 contact the linear portions of the groove cam 13B. Since the capping 12 is in a state to seal the distal end surface of the head 9 and the biasing force of the spring 32 no longer acts on the lever 13, the lever 13 stops at this position. When the piston 18 is moved downward to draw the air and the piston 18 is thereafter released, the capping 12 seals the distal end of the head 9. Furthermore, since the ink suction hollow shaft 15 and the air suction hollow shaft 26 seal the ink suction paths 11 and the air suction paths 25, respectively, the inks may not mix with each other in this state.
The ink suction paths 11 and the air suction paths 25 are sealed in the state shown in FIG. 5, that is, in the state wherein the negative pressure established in the space 33 is maintained in the respective tubes. The respective ink and air suction paths 11 and 25 are also sealed in the state wherein pump suction openings 34 are located between the O-rings 30B and 30C. The inks in the ink suction tube 19 and the air suction tube 20 do not flow in the reverse direction, so that mixed inks may not contaminate the ink suction paths 11 and the air suction paths 25.
In order to open the capping 12, the lever 13 is pressed to the position shown in FIG. 2 by an appropriate means (not shown).
FIG. 6 shows the suction operation as described above. When the capping 12 seals the distal end of the head, the suction operation is not yet started. Thereafter, when the lever 13 is pressed, the ink is drawn by suction, and drawing of the air is started slightly after that of the ink. When the lever 13 is released after it has reached its lowermost position 13D, the lever 13 is moved upward by the spring 32. At this time, the negative pressure acting on the ink suction paths 11 and the air suction paths 25 is maintained. This is because the valve 31 of the negative pressure suction source 17 comprises a thin film and the resistance of this valve is smaller than the air flow resistance at the pump suction openings 34. Therefore, ink may not be returned during the return movement of the lever 13 but is held by suction so as to seal the suction paths 11 and 25 by means of the ink suction hollow shaft 15 and the air suction hollow shaft 26. Each subtank receives ink from the corresponding main tank (now shown) to balance the pressure therein.
The present invention is not limited to a sealed ink tank but may also be applied to an open ink tank.
According to the embodiment of the present invention as described above, mixing of different color inks by suction of air may be prevented.
Since a separate negative pressure suction source for air suction only need not be included and an air suction tube need not be mounted on the subtank, the apparatus of the present invention may be made compact in size. In an apparatus wherein a subtank is mounted on the carriage, the air suction tube is not required, and carriage travel may be fast and stable.
FIGS. 7 to 9 show the second embodiment of the present invention. Referring to FIG. 7, a cap 44 is connected to a negative pressure suction source 42 as a suction apparatus main body through flexible connecting tubes 43A to 43D for ink suction. A multinozzle head 45 as a recording head has four sealed subtanks 45-1 to 45-4 arranged next to each other. Inkjet nozzles for ink injection are arranged in the respective subtanks. An independent main tank (only 46 is shown) is connected to each subtank, which receives ink therefrom. Flexible air suction tubes 47A to 47D for air suction are connected to the subtanks 45-1 to 45-4 in order to draw the air therefrom. The respective tubes 47A to 47D are connected to the negative pressure suction source 42. When printing is not performed, the multinozzle head as described above has the cap 44 mounted on its distal end surface in a sealed state, thus preventing drying out of the nozzles of the head. The negative pressure suction source 42 mainly comprises a cylinder 48 and a piston 49. The piston 49 moves to produce a negative pressure so as to draw the inks from the respective nozzles through the tubes 43A to 43D and to draw the air from the subtanks through the air suction tubes 47A to 47D. A press button (not shown) is arranged above the piston 49. A cylinder sealing member 50 of an elastic material such as rubber is fitted in a portion of the piston 49. As shown in FIG. 8, the sealing member 50 has a ring shape with two annular ribs 50A and 50B which are in tight contact with the inner wall of the cylinder. The thickness of the rib 50B is greater than the diameters of suction openings 51 formed in an array around the circumference of the cylinder 48, so that the ink suction tubes 43A to 43D and the air suction tubes 47A to 47D may be sealed. A coil spring 52 serves to constantly urge the piston 49 upward. The apparatus further has an O-ring 39, an outlet port 37, and a check valve 38. When the piston 49 is moved upward from its lowermost position by the biasing force of a spring 52, the check valve 38 is opened. Ink which has been drawn into the cylinder 48 through the ink suction tubes 43A to 43D or the air suction tubes 47A to 47D is exhausted downward through the outlet port 37.
FIG. 7 shows a state wherein the distal ends of the nozzles of the head 45 are sealed by the cap 44 and the ink and air may be drawn by moving the piston 49 downward, and also a state wherein the piston 49 is returned to its original position by the spring 52 after drawing of the ink and air. When the piston 49 is at its lowermost position and the sealing member 50 is at the position indicated by the alternate-long-and-two-short-dashed line, a space 53 defined by the cylinder inner wall, the O-ring 39 and the piston 49 expands. The valve 38 is closed to produce a negative pressure. Then, inks of different colors flow from the subtanks 45-1 to 45-4 into the ink suction tubes 43A to 43D and the air suction tubes 47A to 47D. When the piston 49 is returned to its original position while the ink suction tubes 43A to 43D are kept at the negative pressure and before the space 53 is filled with the inks, the ink suction tubes 43A to 43D may be kept at the negative pressure when the upper rib 50A of the sealing member 50 passes by the suction openings 51. If grease is filled in a recess 50C of the sealing member 50B shown in FIG. 3, the piston 49 can maintain a negative pressure in the ink suction tubes 43A to 43D even when it is moved upward by one stroke to the position indicated by the solid line in FIG. 7, by means of the spring 52. The inks in the space 53 are exhausted through the outlet port 37 when the piston returns to its original position. At this time, the outer circumferential surface of the lower rib 50B of the sealing member 50 closes the suction openings 51. When the suction openings 51 are closed under the negative pressure, the ink continues to be drawn by suction from the subtanks and nozzles, which are kept substantially at atmospheric pressure. Thus, the meniscus at each nozzle is kept normal, and ink injection may be properly performed. When the apparatus is left in the state shown in FIG. 7, all the ink suction tubes 43A to 43D and all the air suction tubes 47A to 47D are kept isolated by the lower rib 50B of the sealing member 50, so that mixing of different color inks may be prevented.
The suction openings 51 may be formed at any position on the outer circumferential surface of the cylinder 48. Therefore, the ink suction tubes 43A to 43D and the air suction tubes 47A to 47D may be arranged close to each other as indicated by broken lines indicating the position of the latter in FIG. 9, so that the ink and air suction tubes may be arranged in a compact manner. Each suction opening 51 need only have a diameter of 0.5 mm, and the lower rib 50B of the sealing member 50 need only have a thickness of 1 mm. Accordingly, the sliding resistance of the piston may be reduced to the minimum.
In accordance with the embodiment of the present invention as described above, since the sealing member of the piston closes the suction opening of the cylinder, mixing of the different color inks may be prevented. Furthermore, since the arrangement of the suction openings may be freely selected, the ink and air suction tubes may be easily mounted and the sliding resistance of the piston may be reduced to the minimum. | An inkjet printer has a plurality of storing members for storing inks of different colors, a plurality of recording units for injecting the inks stored in the storing member, a plurality of air suction paths which are disposed in correspondence with the storing member for drawing the air in the storing member and which are independent from each other and do not communicate with each other, suction unit for drawing the air in the storing member through the air suction paths in the suction mode and for sealing the air suction paths and for sealing communication between the air suction paths in the non-suction mode. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] Pursuant to 35 U.S.C.§119(a), this application claims the benefit of earlier filing date and right of priority to Korean Patent Application No. 10-2006-0075134, filed on Aug. 9, 2006, the contents of which are hereby incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a mobile communication terminal, and more particularly, to a method for placing a call. Although the present invention is suitable for a wide scope of applications, it is particularly suitable for providing a recorded voice of a called party by using a speed dial feature.
DISCUSSION OF THE RELATED ART
[0003] Generally, a terminal includes a variety of functions to increase user convenience. The functions may include one or more of an MP3 player, a camera, Bluetooth™ data link, and infrared communication. The terminal may also include a speed dialing function whereby a user may select a stored phone number from a phonebook by entering one, two, or three digits.
[0004] The most advanced terminal technology is accompanied with complicated functions and difficulty in use, and speed dialing functions have been incorporated into terminals for some time to alleviate this problem. However, a user still has difficulty and inconvenience in confirming a called party.
SUMMARY OF THE INVENTION
[0005] Accordingly, the present invention is directed to a mobile communication terminal and a method for placing a call that substantially obviate one or more problems due to limitations and disadvantages of the related art.
[0006] An embodiment of the present invention provides a terminal and a method for placing a call, by which the terminal replays a stored message when a phonebook entry is selected using a speed dial number and the stored message is associated with the selected phonebook entry. Replaying the stored message provides an audio indication associated with the called number.
[0007] Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0008] To achieve these objects and other advantages and in accordance with a purpose of the invention, as embodied and broadly described herein, a method of making a call in a terminal according to one embodiment includes entering a speed dial number from a key input unit to select one of a plurality of phonebook entries wherein each phonebook entry includes a contact number, replaying an audio message if the audio message is associated with the selected phonebook entry, and dialing the contact number of the selected phonebook entry.
[0009] Entering the speed dial number comprises entering one, two, or three digits followed by a function key, or alternatively, pressing a number key on the key input unit for a specified duration of time. Completion of the specified duration of time may be indicated by an audible sound. If the audio message is associated with the selected phonebook entry, the audio message is replayed for a pre-selected duration of time. The audio message may be recorded using a microphone disposed on the terminal or may be recorded from a connected call, and stored in a memory of the terminal. Further, the audio message may be password protected.
[0010] In another embodiment of the invention, a method of placing a call using a mobile communications terminal, the method comprises entering a speed dial number from a key input unit to select one of a plurality of phonebook entries wherein each phonebook entry includes a contact number, converting a text message to a voice message if the text message is associated with the selected phonebook entry, and dialing the contact number of the selected phonebook entry.
[0011] The test message is converted to a voice message using a text-to-speech (TTS) function, wherein the TTS function includes at least one of a male voice, a female voice, and a child voice. The text message may be password protected and the voice message may be played for a pre-selected duration.
[0012] In yet another embodiment of the invention, a mobile communications terminal comprises a key input unit configured to provide a speed dial number, an audio output unit, a microphone configured to receive a voice input, a memory configured to store a plurality of phonebook entries and a plurality of messages wherein each phonebook entry comprises at least a contact number is associated with one of the plurality of phonebook entries, and a control unit configured to select one of the plurality of phonebook entries according to the speed dial number, to play the message if the message is associated with the selected phonebook entry, and to dial the contact number of the selected phonebook entry.
[0013] The terminal may further comprise a text-to-speech (TTS) configured to convert the message to a voice message if the voice message is a text message, wherein the TTS synthesizer includes at least one of a male voice, a female voice, and a child voice, and the control unit is further configured to play the voice message for a pre-selected duration.
[0014] It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiments of the invention and together with the description serve to explain the principle of the invention.
[0016] FIG. 1 is a block diagram of a terminal according to the present invention.
[0017] FIG. 2 is a flowchart of a process for recording a voice in a terminal according to the present invention.
[0018] FIG. 3 is a flowchart of a process for outputting a voice using an abbreviated number in a terminal according to an embodiment of the present invention.
[0019] FIGS. 4 to 8 are diagrams of a display depicting embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0021] The terminal described in this specification can include portable electronic devices such as a mobile phone, a digital broadcast terminal, an MP3 player, a personal digital assistant (PDA), and a portable multimedia player (PMP).
[0022] A speed dial function is characterized by accessing a terminal phonebook entry by entering one, two, or three digits, and when the particular phonebook entry is accessed, dialing the phone number associated with that particular phonebook entry. A phonebook entry may also be accessed by pressing a particular key for a specified duration rather than by entering a speed dial number and then pressing a separate function key to access the phonebook entry. In describing embodiments of this invention, either pressing a single key for a specified duration or entering one or more digits followed by a separate function key will enter a speed dial number.
[0023] FIG. 1 is a block diagram of a terminal according to the present invention. Referring to FIG. 1 , the terminal includes a key input unit 100 as a user interface. The key input unit 100 has a plurality of number and function keys for providing information to the control unit 150 .
[0024] Other elements of the terminal include a microphone 110 ; a memory 120 for storing programs and data to control the overall operation of the terminal; a display unit 130 for displaying data corresponding to signals from the key input unit 100 , received data, and operational status of the terminal according to the control unit 150 ; and an audio output unit 140 .
[0025] The control unit 150 controls providing a stored audio message to the audio output unit 140 when a speed dial number is provided. The memory 120 stores audio messages, contact numbers, and corresponding speed dial numbers. A speed dial number is entered to initiate a call. The speed dial number selects a phonebook entry, and if a stored audio message is associated with the selected phonebook entry, the stored audio message is replayed. After completion of replaying the stored audio message, the control unit 150 transmits a dual tone multi frequency (DTMF) tone signal to initiate a call to the contact number stored in the phonebook entry.
[0026] FIG. 2 is a flowchart of a process for recording a voice in a terminal according to the present invention. A command for a recording an audio message (S 200 ) is entered in a terminal menu, and a message is recorded (S 210 ). Any audio message may be recorded.
[0027] The recorded audio message is then stored in memory and associated with a phonebook entry (S 220 ).
[0028] FIG. 3 is a flowchart showing use of the stored audio message. A speed dial number is entered into the terminal to select a phonebook entry to initiate a call. When the phone call is initiated, the control unit 150 determines whether the stored audio message is associated with the phonebook entry (S 310 ). If a stored audio message is associated with the phonebook entry, then the stored audio message is provided to the audio output unit 140 (S 320 ). The contact number is dialed at the completion of replaying the stored audio message, or if no stored audio message is associated with the phonebook entry, the contact number is dialed directly (S 330 ).
[0029] The stored audio message may be a message recorded by the terminal user or it may be recorded from a correspondent party of an earlier communication.
[0030] FIGS. 4 to 8 depict displays which illustrate a method for replaying a stored message using a speed dial number according to one embodiment of the present invention.
[0031] Referring to FIG. 4 , a voice recording is made according to a menu item, and the duration of the recording is preset to a specific length, for example, 5, 10 or 20 seconds. The voice recording is associated with a phonebook entry and stored in memory as an audio message. Ring tones are currently offered as a downloadable file from a service and can also be stored as an audio message associated with a phonebook entry.
[0032] In one embodiment, the stored audio message is provided to the audio output unit when a phonebook entry is selected and a call initiated. For instance, if a user sets a play time to five seconds, a stored audio message is replayed for five seconds instead a dial tone. At the completion of the audio message, the call is initiated by dialing the contact number.
[0033] In particular, a phonebook entry will include at least a correspondent party's name, a speed dial number, a phone number of the correspondent party (contact number), and a stored audio message.
[0034] The speed dial number, the contact number, and the stored audio message are stored together. In general, a stored audio message requires about 30 KB for a 30 second message. In particular, assuming that a size of an MP3 file is about 5 MB, then about 5 MB is usable for storing about 100 audio messages by associating the audio messages with phonebook entries. Therefore it is possible to store more messages in a smaller amount of memory.
[0035] When a record command is provided during a connected call, the conversation of parties to the call is stored by associating the recorded conversation with a speed dial number. If the speed dial number is subsequently entered, the conversation recorded during the call is replayed when the phonebook entry associated with the speed dial number is selected. Namely, parties to conversations are able to be recorded. According to one embodiment of the present invention, the recorded conversation is stored by associating with a speed dial number. In case of making an outgoing call, the conversation can be replayed.
[0036] As an added measure of privacy protection, the stored audio message or conversation may be password protected.
[0037] In another embodiment, a text message may be stored by associating a phonebook entry having a speed dial number to the text message. Referring to FIG. 5 , a text message is associated and stored with a selected phonebook entry. A stored text message is shown in FIG. 6 .
[0038] Selecting the “Menu” function shown in the lower left portion of the display shown in FIG. 6 will display a further menu of subsequent actions shown in FIG. 7 . If “voice hearing” is selected, the stored audio message will be replayed. If the stored message is a text message, the text message will be vocalized using a text-to-speech (TTS) function thereby enabling a sight-impaired user to listen to the text message. The TTS function includes at least one of a female voice, a male voice, and a baby voice.
[0039] The present invention is further explained in detail. A name “Mongsil” and contact number “019-300-3000” are entered into the terminal phonebook, a recording of Mongsil's voice is associated with Mongsil's phonebook entry, and Mongsil's phonebook entry is assigned a speed dial number of “1”. When “1” is pressed for a specified duration to initiate a phone call, Mongsil's recorded message is replayed before the outgoing call is initiated ( FIG. 8 ). Therefore, the terminal user has an audio indication to whom the call has been placed.
[0040] Accordingly, the present invention provides the following advantage. When a terminal user places a call using a speed dial number, the user is able to hear the name of the called party in the party's own voice as soon as the phonebook entry is selected. Therefore, the terminal user is able to reconfirm to whom the outgoing call has been placed.
[0041] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A mobile communication terminal having a phonebook replays a stored message when an entry of the phonebook is selected using a speed dial number and the stored message is associated with the selected phonebook entry. The message may be the spoken name of the person associated with the selected phonebook entry thereby enabling the terminal user to have an audio confirmation of the party being called. The message may be recorded by the terminal microphone or may be captured from a connected call. Alternatively the message may be a text message that is synthesized to a voice message by a text-to-speech function. | 7 |
TECHNICAL FIELD OF THE INVENTION
[0001] The invention relates to fall detection and/or prevention systems, and in particular to a fall detection and/or prevention system having a fall detection algorithm that can be adapted to the characteristics of a particular user.
BACKGROUND TO THE INVENTION
[0002] Falling is a significant problem in the care of the elderly that can lead to morbidity and mortality. From a physical perspective, falls causes injuries, while from the mental perspective, falls causes fear-of-falling, which in turn leads to social isolation and depression.
[0003] In terms of intervention, there are two aspects where electronic devices can assist. One is to provide an automated and reliable fall detection system, and the other is to provide a fall prevention system that provides early feedback to the user or the user's care provider if the user engages in a (more) risky situation. The first assures adequate measures will be taken in case of a fall incident, which also provides a level of reassurance to the user, and the second assists the user in staying healthy, which provides a further level of reassurance. Fall detection systems are becoming widely available, and fall prevention systems are expected to appear shortly.
[0004] Commonly, automated fall detection systems are centered around an accelerometer which is to be attached to the user's body. The detector tracks the signals from the accelerometer and determines that a fall has taken place if a characteristic pattern is identified. A typical pattern is a combination of a high impact value in which the acceleration signal exceeds a preconfigured threshold, followed by a period of relatively constant acceleration, for example gravity only, since the user is lying motionless on the ground. The pattern may continue by revealing activity, deviating from the relatively constant period, when the user stands up again.
[0005] Several refinements and extensions exist to this simple system. For example, gyroscopes and/or magnetometers can be used to measure the body's orientation to check for a sustained non-vertical position in evaluating whether a fall has occurred.
[0006] Current automatic fall detection systems are typically equipped with an “alarm-reset” button that the user can press to suppress false alarms (false positives—FP) before they reach a care provider, so that further intervention by the care provider is aborted. Often, the alarm-reset button, or alternatively an “alarm” button, is used to enable the user to request assistance, which, in a way, indicates a missed alarm (i.e. a false negative—FN). These two functions can appear as two separate buttons for the user to press. They can also be integrated in one physical button, in which case the function switches with the current state of the detection algorithm (no-fall versus fall detected). It should be noted however that the buttons are not required to be part of the device attached to the user's body. They could also be part of a base station, located in the home of the user, to which the sensor communicates and which further transmits an alarm to the care provider's call centre. It makes most sense to mount the button for the reset function on the base station and to have the alarm function with the sensor.
[0007] One problem with automatic fall detection systems is the reliable classification of falls and non-falls, characterized through sensitivity and specificity. Clearly, for reliable classification, false positives and false negatives should be suppressed as much as possible. Full reliability (i.e. no FP or FN) is only achievable if the characteristics of the signal feature set can be distinguished completely in two separate sets, one characterizing a fall incident, the other a non-fall incident. Obviously, in fall prevention, the system cannot make use of the high acceleration events in the signal, since they will not (yet) be present, and the problem of correct identification of increased risk situations is even more difficult.
[0008] Many techniques to arrive at correct classifications are known. They are collectively referred to as machine learning [T. M. Mitchell, Machine Learning, McGraw-Hill, 1997]. In these methods, an algorithm is designed that classifies value combinations of features from the sensor signals as characterizing a fall or a non-fall. Using feature sets that are known to correspond to a fall or non-fall, the algorithm's parameters are adapted to provide a correct response to this training data. The amount of adaptation is usually derived from a statistical analysis of the algorithm, so that the update process converges to a situation that matches an optimality criterion. Of course, in order to be perfectly successful, it is required that the signals, i.e. their observed features, are distinguishable in the ideal, i.e. noise-free, situation. If this is not the case, errors (FP and FN) will fundamentally remain, and the task is to find an optimal setting trading these FP and FN. For an effective training of the algorithm, a sufficient amount of data samples are needed, so that the classification boundaries can be optimized for the variance in the feature set.
[0009] A problem that remains concerns the acquisition of the reference data so that it is of sufficient size and sufficiently represents the classes to be distinguished. Since people move in different ways, and hence will generate different signals and patterns, it is hard to provide a “one-size-fits-all” set of reference data.
[0010] Therefore, it is an object of the invention to provide a fall detection and/or prevention system that can be adapted to a particular user's fall or activity characteristics in order to improve the reliability of the fall detection algorithm, without requiring the user to spend a dedicated period of time training the detector. It is a further object of the invention to provide a fall detection and/or prevention system that can adapt to changes in the user's activity characteristics (for example, due to ageing).
SUMMARY OF THE INVENTION
[0011] In accordance with a first aspect of the invention, there is provided a fall detection and/or prevention system, comprising one or more sensors for detecting characteristics of movement of a user of the fall detection and/or prevention system and for generating corresponding signals; processing means for analyzing the signals from the one or more sensors using a fall detection algorithm to determine if a fall has taken place or is likely to take place; wherein the processing means is further adapted to update said fall detection algorithm based on the result of the analysis of the signals and an indication whether a fall has actually taken place from the user or a third party.
[0012] Therefore, as an indication of whether a fall has actually taken place is compared with the result of the fall detection algorithm, the fall detection algorithm can be updated in order to reduce the incidence of false positives and false negatives.
[0013] Preferably, the processing means is adapted to generate an alarm signal in the event that a fall has taken place or is likely to take place.
[0014] In a preferred embodiment, the system further comprises a memory for storing the signals, an indication from the fall detection algorithm of whether the fall detection algorithm has determined that a fall has taken place or is likely to take place and the indication whether a fall has actually taken place.
[0015] In a further embodiment, the system further comprises means for generating a trace for a plurality of signals from the one or more sensors, and the memory is adapted to store the trace of the signals.
[0016] Preferably, the indication whether a fall has actually taken place comprises a reset signal.
[0017] Preferably, the processing means determines that the fall detection algorithm has provided a false positive in the event that the fall detection algorithm detects that a fall has taken place and the reset signal is present, and the processing means is adapted to update the fall detection algorithm accordingly.
[0018] Preferably, the processing means determines that the fall detection algorithm has provided a true positive in the event that the fall detection algorithm detects that a fall has taken place and the reset signal is not present, and the processing means is adapted to update the fall detection algorithm accordingly.
[0019] In a further embodiment, the system further comprises means for receiving the reset signal from a third party.
[0020] In a further embodiment, the system further comprises a first user operable component for allowing a user to selectively generate the reset signal.
[0021] In a further preferred embodiment, the system further comprises a second user-operable component for generating an alarm signal.
[0022] Preferably, the processing means determines that the fall detection algorithm has provided a false negative in the event that the fall detection algorithm does not detect that a fall has taken place and the alarm signal is present, and the processing means is adapted to update the fall detection algorithm accordingly.
[0023] Preferably, the processing means determines that the fall detection algorithm has provided a true positive in the event that the fall detection algorithm detects that a fall has taken place and the alarm signal is present, and the processing means is adapted to update the fall detection algorithm accordingly.
[0024] Preferably, the fall detection algorithm comprises one or more feature sets representing signals from the one or more sensors.
[0025] Preferably, the processing means is adapted to monitor the frequency with which the fall detection algorithm is updated, and if the frequency exceeds a threshold, the processing means is adapted to remove one or more feature sets from the fall detection algorithm.
[0026] Preferably, the processing means determines if a fall has taken place or is likely to take place by comparing the one or more feature sets with the corresponding signals generated by the one or more sensors.
[0027] Preferably, the processing means is adapted to update the fall detection algorithm in order to selectively optimize false positives, where the algorithm incorrectly detects a fall, false negatives, where the algorithm incorrectly detects that no fall has taken place, or to obtain a stable ratio between false positives and false negatives.
[0028] A second aspect of the invention provides a method of training a fall detection and/or prevention algorithm for use in a fall detection and/or prevention system, the method comprising obtaining measurements of characteristics of movement of a user of the fall detection and/or prevention system; analyzing the measurements using a fall detection algorithm to determine if a fall has taken place or is likely to take place; and updating the fall detection algorithm based on the result of the step of analyzing and an indication whether a fall has actually taken place from the user or a third party.
[0029] A third aspect of the invention provides a computer program product comprising executable code that, when executed on a suitable computer or processor, performs the steps of receiving signals indicating characteristics of movement of a user of a fall detection and/or prevention system; analyzing the signals using a fall detection algorithm to determine if a fall has taken place or is likely to take place; and updating said fall detection algorithm based on the result of the analysis of the signals and an indication whether a fall has actually taken place received from the user or a third party.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The invention will now be described, by way of example only, with reference to the following drawings, in which:
[0031] FIG. 1 shows a fall detection system attached to a user;
[0032] FIG. 2 is a block diagram of the fall detection system;
[0033] FIG. 3 is a flow chart illustrating a first method in accordance with the invention;
[0034] FIG. 4 is a flow chart illustrating a second method in accordance with the invention; and
[0035] FIG. 5 is a flow chart illustrating a method of training a fall detection algorithm in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] FIG. 1 shows a fall detection system 2 attached to a user 4 via a band or other attachment means 6 . The fall detection system 2 is preferably attached at the upper part of the user's body 4 , such as around the waist, at the wrist, or as a pendant around the neck.
[0037] In this embodiment, the fall detection system 2 includes an alarm reset button 8 that the user 4 can operate to prevent or stop an alarm signal being sent to a call-centre or other assistance unit. Thus, if the fall detection system 2 detects a fall by the user 4 , an alarm signal will be sent to a call-centre or other assistance unit, unless the user 4 indicates that a fall has not taken place by pressing the alarm reset button 8 . This is considered to be a false positive (FP).
[0038] In this case, the fall detection algorithm executing in the system 2 is considered to have incorrectly identified a fall from the signals received from the sensors. It may be that the criteria or parameters used to identify falls from the received signals are not set at an appropriate level for the particular user 4 of the system 2 , so it is desirable to train or adapt the fall detection algorithm to the particular characteristics (for example gait and balance) of the user 4 . In addition, it is desirable for the fall detection algorithm to learn the types of situations or falls for which the user does or does not require assistance. Near falls for which the user 4 does not require call-centre intervention can be used to train the algorithm to classify them as non-falls.
[0039] In addition, if the user 4 does fall but stands up again, user 4 may want to decide him/herself whether assistance is needed and the fall detection system 2 should not alarm autonomously. For example, system 2 may observe the duration of the time period of relative constant acceleration when user 4 is lying down after a fall and before they stand up. If this period exceeds a threshold, the final decision on a fall is made and an alarm is sent to the call centre.
[0040] Suppressing this alarm, possibly even before the period reaches the threshold indicates that this time-out period should be extended for user 4 . Also, the other way around, calling for help, i.e. pressing the alarm button (if present) before the period reaches the threshold, indicates the threshold of the time-out period needs to be shortened.
[0041] FIG. 2 is a block diagram of a fall detection system 2 in accordance with the invention.
[0042] The system 2 comprises one or more sensors 10 that detect characteristics of movement of the user 4 and that generate corresponding signals. The one or more sensors 10 can comprise an accelerometer, magnetometer, gyroscope and/or other sensors.
[0043] The signals from the sensor(s) 10 form a feature set, possibly after some processing. Exemplary features include magnitude, spectral content, directional distribution, mean, variance, etc., but alternatively the signals themselves, i.e. the time series of sample values, can serve as feature set. The features are provided to decision logic 14 that executes the fall detection algorithm. In particular, the decision logic 14 determines whether a fall has taken place by comparing the feature set to a set of parameters that are used to classify whether a fall has taken place or not. These parameters can include, or be based on, feature sets from known falls, or risky situations.
[0044] At least a subset of the signals, or the extracted features, from the sensor(s) 10 are also provided to a FIFO buffer 16 that temporarily stores them for a predetermined time period. The duration of this time period can be different for different parts of the stored signals and features. For example, sub-sampling may be applied after passing a first time period. The stored signals and features are provided from the FIFO buffer 16 to a trace generating unit 18 that generates a trace for the signals that can be selectively stored in a memory 20 . A trace is generated in case a fall is detected by the decision logic 14 or in case the alarm reset button 8 has been pressed. The state of the decision logic 14 (fall/no-fall) as well as of the button 8 (pressed/not-pressed) is labeled with the trace.
[0045] If the decision logic 14 determines that a fall has taken place, an alarm signal is generated and sent to a time-out unit 22 . The time-out unit 22 is connected to the alarm reset button 8 , and, if the time-out unit 8 receives an alarm reset signal from the button 8 within a predetermined time-out period (which may be zero), the alarm signal is stopped. Otherwise, if no alarm reset signal is received within the time-out period, the alarm signal is transmitted to a call-centre or other assistance point. Alternatively, the alarm may be issued immediately to the call-centre, and a reset signal sends a revocation to the call-centre.
[0046] It should be noted that, in alternative embodiments, the fall detection system 2 can comprise a sensor unit for attachment to a user and a separate base station that receives the signals from the sensor unit and hosts the processing required to detect falls and generate alarm signals. In further alternative embodiments, the processing can be located at the call centre or at an intermediate location between the system 2 and call centre.
[0047] The complete trace, i.e. the signal and/or features from the FIFO 16 and states of decision logic 14 and button 8 , are provided to the memory 20 .
[0048] In some embodiments, as suggested above, the alarm reset button 8 can also be used by the user 4 to indicate that a fall has taken place, in the event that a fall is not detected by the system 2 . In this case, if the decision logic 14 does not detect a fall from the feature set, but the alarm reset button 8 is pressed, an alarm signal can be transmitted. In addition, the signal from the decision logic 14 indicating that no fall has been detected is provided to the memory 20 , along with the signal from the alarm reset button 8 , where they are stored with the relevant signal trace.
[0049] If no alert is generated by the decision logic 14 and the alarm-reset button 8 is not pressed, the relevant feature sets that led to this decision can be discarded from the FIFO buffer 16 . In these cases, the decision logic 14 has correctly identified from the features sets that no fall has taken place, or that no fall is likely to take place.
[0050] In alternative embodiments, an alarm button can be provided in addition to the alarm reset button 8 for allowing the user 4 to explicitly indicate that a fall has taken place (whether or not the algorithm has detected a fall), or that assistance is required. In this embodiment, if the decision logic 14 does not detect a fall from the feature set, but the alarm button is pressed, an alarm signal can be transmitted. The signal from the alarm button is provided to the memory 20 where it is stored with the trace of the signals from the sensor(s) 10 .
[0051] Thus, the fall detection system 2 , which can comprise a single accelerometer, is extended with a storage system 16 , 18 , 20 that is dedicated to store a feature set of the signals from the accelerometer. Raw sensor signals from the accelerometer can also be stored in cases where this is more efficient, for example when the decision logic 14 is based on direct signal characteristics, such as a threshold of the magnitude or frequency of the signal. In addition to the signal and/or its feature set, other data can be stored, such as time stamp data. It should be appreciated that, although not shown in the illustrated embodiment, the storage system can be physically remote from the accelerometer (i.e. remote from the device attached to the user 4 ). Timing data can be relative, indicating the progression within one trace of subsequent feature sets.
[0052] During operation, feature sets are stored in the memory 20 and are analyzed by the decision logic 14 for characterizing a fall, in case of fall detection, or an increased risk for falling, in case of fall prevention. Clearly, the algorithm can be used in both fall detection and fall prevention. The algorithm can use the stored data directly, i.e. compare current signal/features with those in memory 20 . It can also use the stored data indirectly, in which case the algorithm maintains internal settings and thresholds which are regularly adapted during an update process based on the (new) data stored in memory 20 . An update can be triggered upon each change in memory 20 (trace added or trace removed), or after a certain number of changes, possibly combined with a time out. An (additional) update can also be triggered if the rate at which memory 20 is updated changes.
[0053] As described above, if the alarm-reset button 8 is pressed, the trace of feature sets in the buffer is copied into the memory 20 , where it will be kept for a possibly indefinite length of time. Next to the trace data, the decision value is stored. Thus, in the case that the decision logic 14 has raised an alert, but the alarm reset button 8 is pressed, the trace data is labeled to represent a FP. In the case of no alert, but there is an indication from the user 4 that there was a fall, the trace data is labeled to represent a FN. Trace data raising an alert and for which no button press has been received can be stored as a TP (true positive). Optionally, signals and feature sets that do not raise a fall detection by the decision logic 14 and which are neither labeled with an (alarm) button press can be stored as well, labeled as TN (true negative). This may help the training of the adaptive algorithm.
[0054] In order to adapt to possible changes in the user's characteristics, e.g. related to ageing, traces in memory 20 may expire. Expiration can be triggered by similar mechanisms as the updating of the decision algorithm 14 . Expiration itself can trigger such an update.
[0055] At first use of the fall detection system 2 , the memory 20 and the algorithm 14 can be loaded with values that represent the characteristics of the population in general. These values, or part of them, can be labeled to expire in any case, or to expire in a shorter time period, e.g. as soon as a sufficient amount of user specific data has been collected.
[0056] In the alternative embodiment where separate buttons may be present for performing an alarm reset and for activating the alarm, traces representing TP can be selected based on the explicit alert presses (together with a generated alert).
[0057] In accordance with the invention, the stored information is used to adapt or train the algorithm used in the decision logic 14 to reduce the rates of false positives and false negatives. Thus, the decision logic 14 is trained using the trace data and the associated button press status (i.e. was a reset button 8 pressed?) or the trace data and associated status, FP, FN or TP.
[0058] The algorithm used in decision logic 14 can be updated each time that a button 8 is pressed, or can be updated every five button presses, say. Alternatively, the algorithm can be updated after a given period of time has passed, or any combination of the above.
[0059] In this way, the algorithm used in the decision logic 14 will become personalized to moving patterns of the user 4 . In addition, in the case of fall prevention, the algorithm will learn what situations the user 4 considers risky. In preferred embodiments, by obtaining data from multiple sensors 10 and sensor types, the measurable space of these risky situations will be expanded.
[0060] In particular, in the case of fall prevention, physiological data is of interest, such as characteristics indicating dizziness, and including quantities like blood pressure, oxygen level (SPO2), heart rate (ECG), muscle activity and fatigue (EMG and MMG), temperature, lung sounds, etc.
[0061] If the fall detection system 2 correctly classifies a non-risk situation (i.e. correctly in terms of the trained algorithm with its reference data and user feedback), but is succeeded closely by a fall, the system 2 can revisit its risk and non-risk categories and classify the traces therein with reference to earlier data (from other people, or from initial or factory settings). In this way, it is possible to identify those traces in the training set that are labelled as non-risky but are classified as risky in the earlier reference data. These traces can be refracted from the personalized training set, after which the decision algorithm can be trained again.
[0062] A refinement for the updating algorithm is to check the update rate, i.e. the time interval between subsequent button presses. If the intervals are small, this can indicate that the algorithm has a suboptimal adaptation state (i.e. the algorithm is frequently generating false positives or false negatives), whereas long intervals, or saturation in getting longer, indicates that optimality is reached. In particular, if the update rate increases (i.e. the intervals get shorter), this may indicate the algorithm is becoming “over fitted”, or too specific/narrow. To prevent this, samples (i.e. traces) can be removed from the training set. However, this process should also take into account that there may be changes in the user's moving patterns (gait & balance). For example, the user's ability to maintain balance can decline over time. This latter information can, for example, be entered on the basis of the regular examination by the user's general practitioner.
[0063] The computation for determining the time interval between updates can also be adapted to the user's activities. For example, if the user takes off or switches off the fall detection system 2 , this time should not be counted towards an update interval. Similarly, if the user tends to sit steadily or stay in bed for long time periods, the update time interval computation can take this into account. In some embodiments, the time intervals can be computed relative to the average duration between instants where, say, the measured acceleration exceeds a or some reference thresholds.
[0064] In some embodiments, another measure that can be used to estimate the optimality of the algorithm is a stable ratio between FP and FN rates, or between TP and FP rates. This indicates that further improvement of the algorithm (in terms of reducing FP and FN) is not possible without the addition of additional or other types of sensor signals. In some embodiments, the user 4 can be informed of the ratio. It is also possible for the user 4 to be provided with the ability to set the ratio is considered optimal. For example, “no FN” can be a setting, and the ratio can be used to train and tune the algorithm accordingly.
[0065] In further embodiments of the invention, instead of solely labeling the traces on the basis of the alarm-reset button 8 (or an alarm button) being pressed, other interventions can trigger the described storing and training process as well. For example, a care provider may observe a near-fall or a risky situation and trigger the system 2 to use the data for training. This trigger may comprise the care provider pressing the button 8 on the system 2 , or the care provider remotely sending a signal to the system 2 .
[0066] The stored patterns or traces can also be set apart for inspection by the care provider or general practitioner. In particular, if they have been labeled as false positive by the user 4 , the care provider can use the data as a report to form an expert opinion on the well-being (and the trend therein) of the user 4 . Possibly, the care provider can decide to override the user's label to consider the incident a false positive.
[0067] In addition to the user 4 initiating the training of the algorithm when an alarm reset/alarm button is pressed, a care provider or care centre can also initiate the training update. For example, if an alert reaches the call centre and the user does not issue an alert-reset, while the care centre finds out if it was a false alarm, the care centre can send a training command to the system 2 .
[0068] Referring now to FIG. 3 , the method of operating a fall detection system 2 that has an alarm reset button 8 is presented. In step 101 , a feature set is received from the sensor(s) 10 and is analyzed using the fall detection algorithm in the decision logic 14 . If a fall is not detected (step 103 ), the process returns to step 101 where a subsequent feature set is analyzed.
[0069] If a fall is detected (step 103 ), the process moves to step 105 where the fall detection system 2 waits for a predetermined period for the alarm reset button 8 to be pressed.
[0070] If the reset button 8 is pressed (step 107 ), the feature set or a trace of the feature set is stored in a memory 20 (step 109 ). This feature set or trace is stored along with the alarm reset indication, which means that it is stored as a false positive (step 111 ). The process then returns to step 101 .
[0071] If the reset button 8 is not pressed (step 107 ), an alarm signal is transmitted (step 113 ). In alternative embodiments, step 113 can also be triggered directly by a ‘yes’ at step 103 , in which case ‘yes’ by step 107 can raise a revocation.
[0072] Optionally (as indicated by the dashed arrows and boxes), the feature set or a trace of the feature set is stored in a memory 20 (step 115 ) along with an indication that the alarm reset button 8 was not pressed, which means that it is stored as a true positive (step 117 ). In either case, the process then returns to step 101 .
[0073] A method of operating a fall detection system 2 that has both an alarm reset button 8 and an alarm button is shown in FIG. 4 . In step 131 , a feature set is received from the sensor(s) 10 and is analyzed using the fall detection algorithm in the decision logic 14 .
[0074] If a fall is detected (step 133 ), the process moves to step 135 where the fall detection system 2 waits for a predetermined period for the alarm reset button 8 to be pressed.
[0075] If the reset button 8 is pressed (step 137 ), the feature set or a trace of the feature set is stored in a memory 20 (step 139 ). This feature set or trace is stored along with the alarm reset indication, which means that it is stored as a false positive (step 141 ). The process returns to step 131 where a subsequent feature set is analyzed.
[0076] If the reset button 8 is not pressed (step 137 ), an alarm signal is transmitted (step 143 ). Step 143 can also be triggered directly by a ‘yes’ at step 133 , in which case ‘yes’ by step 137 can raise a revocation.
[0077] Optionally (as indicated by the dashed arrows and boxes), the feature set or a trace of the feature set is stored in a memory 20 (step 145 ) along with an indication that the alarm reset button 8 was not pressed, which means that it is stored as a true positive (step 147 ). Alternatively, or in addition, if the alarm button was pressed, the feature set can be stored in the memory 20 along with an indication that this alarm button was pressed. The process can then return to step 101 .
[0078] If a fall is not detected at step 133 , it is determined whether the alarm button has been pressed (step 149 ). If the alarm button is not pressed, then no fall has occurred, and the process returns to step 131 .
[0079] If the alarm button is pressed, an alarm signal is transmitted (step 151 ), and the feature set or a trace of the feature set is stored in the memory 20 , along with an indication that the alarm button was pressed (step 153 ). Thus, this is stored as a false negative (step 155 ).
[0080] The process then returns to step 131 .
[0081] FIG. 5 is a flow chart illustrating the steps in the method of training or adapting the fall detection algorithm in accordance with the invention. In step 161 , suitable training data is acquired. This training data, which comprises feature sets or traces of feature sets, along with indications of whether the feature sets were false positives, false negatives and/or true positives, can be acquired as described above with reference to FIGS. 3 and 4 .
[0082] Then, in step 163 , this training data is used to update the fall detection algorithm. In particular, if the fall detection algorithm includes a category or categories of feature sets or traces that indicate falls or non-falls, the newly acquired training data can be used to further populate those categories and/or be used to remove existing feature sets or traces, if it has now been found that those existing feature sets or traces are not appropriate for that category.
[0083] Thus, there is provided a fall detection system that can be adapted to a particular user's fall or activity characteristics in order to improve the reliability of the fall detection algorithm. In particular, the training data for the algorithm is generated from sensor measurements and on whether an alarm reset button is pressed by a user or care provider. In this way, the algorithm used for detecting falls or near falls can be trained as the detection system 2 is in use, so realistic data can be obtained and used in the training, rather than being artificially created by a user mimicking a fall or non-fall in a specific training phase, as in conventional systems. In addition, by training the algorithm for a particular user, the algorithm will be adapted to the particular physical characteristics of that user, such as gait and posture, that user's movement patterns and that user's opinion on the severity of falls that require assistance from a call centre.
[0084] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments.
[0085] Variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. A single processor or other unit may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage. A computer program may be stored/distributed on a suitable medium, such as an optical storage medium or a solid-state medium supplied together with or as part of other hardware, but may also be distributed in other forms, such as via the Internet or other wired or wireless telecommunication systems. Any reference signs in the claims should not be construed as limiting the scope. | There is provided a fall detection and/or prevention system, comprising one or more sensors for detecting characteristics of movement of a user of the fall detection and/or prevention system and for generating corresponding signals; processing means for analyzing the signals from the one or more sensors using a fall detection algorithm to determine if a fall has taken place or is likely to take place; wherein the processing means is further adapted to update said fall detection algorithm based on the result of the analysis of the signals and an indication whether a fall has actually taken place from the user or a third party. | 6 |
BACKGROUND OF THE INVENTION
(1.) Field of the Invention
The present invention relates to a process for producing polyester fibers having excellent tensile properties.
The polyester fibers produced by the present invention are suitable for use as industrial materials, particularly as reinforcement materials for tire, belts, etc.
(2.) Description of the Prior Art
It is known from Kobunshi Ronbunshu (vol. 42, pp. 159-166, 1985) that highly oriented low specific gravity polyester fibers can be obtained by drawing at a temperature lower than the glass transition temperature of the polyester.
It is also known, according to Japanese Patent Kokai (Laid-open) No. 169513/83, that in the production of high-speed spun amorphous polyethylene terephthalate yarns for producing textured yarns, the extruded filaments are quenched in a liquid bath placed under the spinneret.
According to Japanese Patent Kokai (Laid-open) No. 210590/83, it is also known that highly oriented low specific gravity polyester filaments can be obtained by stretching, using laser beams, and that highly oriented low specific gravity polyester filaments can be improved in tensile properties by heat treatment of the filaments.
The above mentioned process, employing conventional techniques, has some disadvantages in terms of productivity, property and installing expense.
For example, in the case of the process mentioned in Kobunshi Ronbunshu, 42, 159, 1985, highly, oriented low specific gravity polyester fibers, drawn at lower temperatures than glass transition temperatures should be spun at lower speed than one in which orientation induce crystallization occurs, and required a huge drawing apparatus for industrial production. This means low productivity and high installing expense. Also the tensile property of yarn by this method is not sufficient for industrial use.
In the case of Japanese Patent Kokai (Laid-open) No. 169513/83, this method relates to a method of producing textured yarns which has high shrinkage properties. Inevitably, the tensile properties are not enough for industrial use, and also the winding speed is higher than 5000 m/min; this means very high facility expenses.
In the case of Japanese Patent Kokai (Laid-open) No. 210590/83, this process uses laser power for drawing to obtain highly oriented low specific gravity polyester filaments. The apparatus used in such process, however, requires high power and is huge, expensive and dangerous in operation. Also, according to such a process, further heat treatment is required to obtain low shrinkage properties for industrial use.
SUMMARY OF THE INVENTION
We have found that in the highly oriented low crystalline polyester filaments to be submitted for stretching in the present invention, when the filaments are once wound up, stress relaxation takes place on the winding bobbin, and there occurs a considerable difference in the yarn denier between the outer layers and inner layers of the winding bobbin. This results in that the filaments have a lower degree of orientation toward the outer layers and even after these yarns are drawn and heat-treated, the fibers obtained have lower physical properties toward the outer layers.
The object of the present invention is to solve all of the above mentioned problems and to provide a process for producing polyester fibers having improved tensile properties at high productivity by means of a compact apparatus, wherein highly oriented low specific gravity polyester filaments are produced by means of a compact apparatus at high productivity under good operation conditions, followed by drawing immediately without winding up.
Briefly, the present invention is a process for the production of polyester fibers which comprises melt-spinning a polyethylene terephthalate to form highly oriented low crystalline filaments which, at the stage of spun filament, have a birefringence (Δn) and specific gravity (SG) within the below indicated ranges (a) and (b), and then, without winding-up, subjecting the said filaments immediately to drawing and heat treatment between the first godet rolls and second godet rolls under a draw ratio (DR) defined by the following formulas:
Δn≧5SG-6.64 (a)
Δn≧0.100 (b)
2.0≧DRA>1.0 (c)
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail by referring partly to the accompanying drawings wherein
FIG. 1 is a wide angle X ray diffraction pattern of drawn polyester fibers which are oriented and crystallized.
FIG. 2 is a wide angle X ray diffraction pattern of polyester fibers which are highly oriented but have an amorphous structure.
FIG. 3 is a rough schema showing the production process of the present invention.
FIG. 4(A) is a schematic drawing showing interference fringes of spun filaments in the present invention as seen through an interference microscope.
FIG. 4(B) is a schematic drawing of a cross-section of the filament in FIG. 4(A).
FIG. 5 is the cross-section of a liquid cooling apparatus used in the practice of the present invention.
FIG. 6 shows the relationship between the birefringence and specific gravity of the as-spun filaments in the Examples, Reference Examples and Comparative Examples, and in the Figure, E, R and C respectively means Examples, Reference Example and Comparative Examples.
FIG. 7 is a schematic drawing of the spin-draw process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is characterized in that such novel polyester filaments, more particularly polyester filaments which are extremely highly oriented but have low crystalline structure, are immediately drawn after spinning, without being wound-up.
It has been known that polyester fibers have, for example, a high degree of crystallinity, a high melting point, and excellent properties in respect to heat resistance, chemical resistance, light resistance and strength. On the other hand, polyester fibers, which are highly oriented but have very low crystallinity are extremely rare.
The polyesters which form the polyester filaments of the present invention are composed mainly of ethylene terephthalate units, and they are usually polyesters containing 85 mol % or more of ethylene terephthalate units, or homopolyesters, or mixtures of these polyesters. Among copolymeric components other than terephthalic acid and ethylene glycol, there may be mentioned isophthalic acid, 2,6-naphthalene dicarboxylic acid, adipic acid, sebatic acid, oxalic acid, diethylene glycol, propylene glycol, cyclohexane dimethanol, p-oxybenzoic acid, metal salts of 3,5-di(carbomethoxy)benzenesulfonic acid, or derivatives of these compounds. However, they are not limited to the above mentioned specific examples.
The filaments to be submitted for drawing in the present invention satisfy the above mentioned formula (a) as to the relationship between the index of birefringence (Δn) (parameter of the degree of orientation) and specific gravity (SG) (parameter of the crystallinity) and at the same time, they satisfy the formula (b) as to the birefringence (Δn).
When the formula (a) is not satisfied, orientation-induced crystallization takes place, and therefore, highly oriented amorphous fibers cannot be obtained.
This orientation-induced crystallization can be evaluated by observing wide angle X-ray diffraction patterns of the filaments.
FIG. 1 is a wide angle X-ray diffraction pattern of drawn polyester fibers which are oriented and crystallized. FIG. 2 is a wide angle X-ray diffraction photograph of polyester fibers which are sufficiently oriented but have an amorphous structure.
When the formula (a) is satisfied, a pattern like FIG. 1 is not observed in the as-spun fibers, but a diffused diffraction pattern, caused by amorphous polyethylene terephthalate, like FIG. 2, is observed.
In order to produce filaments having improved tensile properties, fibers having a structure of that of the present invention must be drawn as described herein. The as-spun filaments can be easily improved as compared with conventional as-spun materials, since very small quantities of crystals in the as-spun filaments of this invention does not disturb the drawing thereof.
The birefringence (Δn) of the filaments to be submitted for drawing in the present invention satisfies the formula (b) and Δn is preferably in the range of from 100×10 -3 to 270×10 -3 .
When Δn is lower than 10×10 -3 , the drawn filaments will be inferior in mechanical properties. On the other hand, when Δn exceeds 0.27, the mechanical properties of drawn filaments fall extremely. We are not able to fully explain the reason for this, but we conjecture that the molecular chains might be pulled out during the drawing, because the chains are subjected to excessive elongation.
The lower limit of favorable specific gravity (SG) of the filaments to be submitted for drawing in the present invention is 1.335. Filaments having a specific gravity lower than 1.335, contain voids, and the mechanical properties of such drawn filaments are extremely deteriorated and hence such filaments are not desirable. Even if filaments have an SG within the suitable range, but contain voids, such filaments are not desirable.
The filaments to be submitted for drawing in the present invention not only have high orientation and amorphous structure viewed the such Δn and SG valves, but also are characterized in that they have little denier unevenness in the lengthwise direction of the yarn.
In the case of using a conventional method of attaining the same degree of high orientation and non-crystallinity, to attain obtaining non-oriented non-crystallized undrawn filaments, by spinning at a low speed, and the filaments are drawn without heat (cold drawing), a draw ratio far exceeding the natural draw ratio is necessary. Even if such fibers are obtained, the denier unevenness in the lengthwise direction of the yarn will be extremely large, and such fibers will be hardly worthy of practical use.
The method of cold-drawing non-oriented non-crystallized undrawn filament yarns at a natural draw ratio (NE) has been heretofore the only method of obtaining highly oriented amorphous yarns. However, the Δn of the highly oriented amorphous yarns obtained by such a method is from 0.070 to 0.080 at highest, and yarns having a Δn exceeding 100×10 -3 cannot be obtained.
In the filaments to be used for drawing in the present invention, the difference in orientation degree between the surface and center of a filament is remarkably larger in comparison with highly oriented amorphous filaments obtained by the ordinary drawing method. On the surface of the filaments, extremely highly oriented molecular chains exist, and this has an effect of facilitating the production of fibers of higher strength and higher modulus by drawing. To explain this in more detail, the difference in orientation between the yarn surface and yarn center is 5×10 -3 or more, preferably 10×10 -3 or more. On the other hand, by the ordinary method, it is difficult to obtain a birefringence difference of 5×10 -3 or more.
The process of the present invention will now be explained in more detail in the following paragraphs.
The filaments before drawing in the process of the present invention are obtained by melt-spinning a polyester having an intrinsic viscosity (IV) of 0.8 or more, of which the major chemical units are ethylene terephthalate units, quenching the spun filaments with a liquid cooling apparatus in tubular form, while satisfying special cooling specifications, controlling the relationship between the polymer extrusion velocity and the take-up velocity of the filaments, and then taking-up the filaments at a high speed.
In the case of using an ethylene terephthalate polyester having an intrinsic viscosity (IV) less than 0.8, it becomes impossible to stably produce highly oriented non-crystalline filaments at a take-up speed of less than 5000 m/min., while satisfying the formula (a) and formula (b), and therefore such a process is hardly worthy of practical use from an industrial viewpoint. There is used therefore a polyester having an IV higher than 0.8, preferably higher than 1.0.
The cooling apparatus used herein is indicated by 3 in FIG. 3 or FIG. 7, and the structure is, for example, that shown in FIG. 5. Incidentally, in FIG. 3 and FIG. 7, 1 is a spinneret, 2 is spun filaments, 3 is a liquid cooling apparatus (liquid quenching tube), 5 is the first godet rolls, 6 is an oil applying apparatus, 7 is a heating zone, and 8 is second godet rolls. In FIG. 5, 4 is an opening for flowing down the liquid, 9 is inlets for the cooling liquid, and 10 is a rectifying screen. The cooling liquid used is an ordinary water.
In the following paragraphs of the present invention, the liquid cooling apparatus is sometimes referred to as a liquid quenching tube.
The liquid quenching tube 3 is characterized in that the cooling liquid flows in the direction of passage of the filaments 2, and is so designed that the flow velocity will vary according to the distance from the liquid surface. To explain in detail, by permitting the liquid at the inlet of the quenching tube to flow extremely slowly, it is possible to prevent mutual fusion of the filaments at or near the air-liquid interface.
In the present invention, it is important to satisfy all of the following process requirements (1)-(5), upon taking-up of the melt-spun filaments.
(1) The distance L (cm) between the spinneret 1 and the liquid surface of the liquid cooling apparatus 3≦ filament solidification point -5, wherein the filament solidification point is a value determined by filament diameter measurement according to on-line measurement of filament diameter change of filaments spun under the air quenching conditions of 20° C., 65% RH, 0.3 m/sec.
(2) The liquid flow down velocity (m/min.) at the lower end of the liquid cooling apparatus 3≧V w /60, wherein V w is the take-up velocity (m/min.) of the filaments.
(3) The take-up velocity V w (m/min.) ≧V o ×200, wherein V o is the extrusion velocity (m/min.) of the polyester from the spinneret 1.
(4) The vertical distance H (cm) from the liquid surface of the liquid cooling apparatus to the bottom of the liquid ≧5 cm.
(5) The liquid temperature of the liquid cooling apparatus ≦50° C.
The reasons for the necessity of satisfying the requirements (1) to (5) are as follows:
(1): In order to suppress crystallization and to decrease the specific gravity, the distance L between the spinneret 1 and the quenching tube 3 must be brought close towards the spinneret at least 5 cm from the filament solidification point. As used herein the term "filament solidification point" means the point where the solidification of filaments occurs when the filaments are taken-up at a velocity of V w without providing a liquid quenching tube. If the quenching tube 3 is placed farther than the above mentioned position from the spinneret 1, orientation-induced crystallization will take place at parts of the filaments 2 higher than the quenching tube 3, and thus the object of the present invention can not be attained.
For decreasing denier unevenness in the lengthwise direction, it is desirable to slowly cool the space between the spinneret 1 and the liquid cooling apparatus 3 with a gas such as air.
(2): It is desirable to bring the liquid flow down velocity at the downstream end of the qluenching tube 3 to more than 1/60 of the take-up velocity V w . When the liquid flow down velocity is lower than this, the tension of the filaments 2 between the lower end of the quenching tube 3 and the rolls 5 becomes large, and excessive drawing stress is exerted. Thus, damage to the filament quality occurs, such as filamentation and yarn breakage.
(3): The take-up speed (V w ) must be V 0 ×200 or more, in order to increase the orientation, wherein V 0 is the polymer extrusion velocity from the spinneret 1. When the take-up speed is lower than V 0 ×200, it is difficult by the method of the present invention to obtain filaments whose Δn is higher than 100×10 -3 .
(4): In order to decrease the liquid flow at or near the liquid surface of the quenching tube 3 and to bring the liquid flow down velocity at the lower end of the quenching tube 3 to V w /60 or more, the length of the quenching tube 3, that is, the vertical distance H from the liquid surface to the liquid bottom of the liquid cooling apparatus 3, must be 5 cm or more. With an apparatus shorter than this, a spin-like whirl generated by the liquid flow down at the quenching tube 3 reaches the surface of the cooling bath. This is a cause of mutual fusion of the filaments and denier unevenness of the filaments.
(5): The temperature of the cooling liquid in the quenching tube 3 must be 50° C. or less. If the liquid temperature becomes higher than this, the cooling power will lowered, and although the orientation of the filaments becomes higher, crystallization will proceed. Thus the object of the present invention cannot be attained.
The crystallization of terephthalate polyester proceeds from its molten state to its cooled and solidified state. By the process of the present invention, the staying time of the polymer in the temperature range in which crystallization takes place, can be shortened to a large extent, by quenching with a quenching tube, during the time in which the filaments are cooled in the melt-spinning process of which the temperature is lower than the melting point T m and higher than glass transition temperature T g . We believe that, in the present invention, filament yarns of low crystallinity can be produced by thus shortening the staying time of the polymer in said temperature range.
The highly oriented low crystalline polyester filaments thus produced, without once being wound up, are drawn and heat-treated between the first godet rolls 5 and second godet rolls 8 at a draw ratio (DR) shown in the formula below and wound up, whereby the filaments are improved in tensile properties, that is, given improved strength and improved modulus.
2.0≧DR>1.0 (c)
If the highly oriented low crystalline polyester filaments used in the present invention are once wound up without being immediately subjected to draw-heat treatment, remarkable relaxation of orientation occurs, on the winding bobbin. Since a further draw-heat treatment will give impart sufficient improvements, it is necessary to immediately subject the filaments to draw-heat treatment, without once winding up the filaments.
At the time when the filaments are spun and immediately subjected to a draw-heat treatment without being once wound up, it is necessary that the draw ratio (DR) should be 2 or less and larger than 1.
When the draw ratio exceeds 2, even if such drawing is possible, much filamentation will occur, and thus the improving effect of the tensile properties will be lowered.
If the draw ratio is less than 1, relaxation of orientation occurs and the improvement of the tensile properties is be lowered, and the draw ratio must be therefore 2 or less and larger than 1.
The drawing temperature must be so determined that the practical drawing temperature is in the range of from 150° C. to 260° C., preferably from 210° C. to 250° C.
Furthermore, subsequent to the draw-heat treatment, the filaments are preferably subjected to a relaxation treatment at a relaxation ratio of 15% or less between the second godet rolls 8 and third godet rolls. When the relaxation treatment is not conducted, quality fluctuation is liable to occur, and in particular, when the winding amount per bobbin is large, it causes a serious problem in terms of package shape.
Although the heating method in the draw-heat treatment is not particularly limited, it is preferable to provide a heating zone 7, between the first godet rolls 5 and the second godet rolls, particularly a heating zone in which steam is used as the medium.
At this time, the temperature of the first godet rolls is preferably higher than 5° C. and lower than 60° C.
When the temperature of the first godet rolls is higher than 60° C., the highly oriented low crystalline polyester filaments obtained by spinning will crystallize easily, and thus the drawability will be remarkably impaired. Hence in the draw-heat treatment of the present invention, it is most desirable to provide a heating zone 7 between the first godet rolls 5 and the second godet rolls 8.
On the other hand, when the temperature of the first godet rolls 5 is less than 5° C., dew condensation will occur on the roll surface and thereabout, and therefore the operability will be seriously aggravated. When providing the heating zone 7 between the first godet rolls 5 and the second godet rolls 8, it is most desirable, from the viewpoint of cost maintenance, to use high temperature steam (super-heating steam) as the heating medium.
Thus, the important and novel feature of the present invention is to first produce polyester filaments having the particular birefringence and specific gravity as mentioned before by melt-spinning and, without winding-up, and to subject the resulting filaments immediately to drawing under the particular conditions to produce polyester fibers having excellent properties. Except for these features and conditions, the production of the polyester fibers can be conducted in a conventional manner and with a conventional apparatus known per se for the production of polyester fibers.
In the following paragraphs, Examples of the present invention will be shown, but the invention is by no means limited to these Examples.
Incidentally, the methods of measuring the physical properties used for the evaluation of the present invention are as follows:
Measurement of the birefringence (Δn):
Measurement was effected by the use of a Nikon polarization microscope (POH type) with a Berek compensator manufactured by Leitz. For the light source, there was used an apparatus for generating an Na D-line, manufactured by Toshiba (Toshiba SLS-3-B). A specimen, cut at an angle of Ca. 45° to the fiber axis, of 5 to 6 cm long was placed on a slide glass, with an upward cut surface. The slide glass was placed on a rotatable stand, and the stand was rotated so as to make an angle of 45° between the specimen and the polarizer. An analyzer was inserted to make a dark field, the compensator was adjusted to 30, and the number of fringe patterns (n) was counted. The compensator was rotated clockwise and the scale (a) at which the specimen first became darkest was read. Then, the compensator was rotated counterclockwise, and the scale (b) at which the specimen first became darkest was read. The compensator was returned to 30, the analyzer was taken off, and the diameter of the specimen (d) was measured. The index of birefringence (Δn) was calculated according to the following equation (average of 20 measured values):
Δn=Γ/d
wherein
Γ (retardation)=nλ o +E
λ o =589.3 mμ
ε is obtained from C/10000 and i in the Leitz's explanatory manual of the compensator,
i being a-b (i.e. the difference in the readings of the compensator).
Measurement of specific gravity:
A density gradient tube composed of n-heptane and carbon tetrachloride was prepared, and the tube was regulated to a temperature of 30° C.±0.1° C. A sufficiently defoamed specimen was placed in the tube. After allowing the tube to stand for 5 hours, the position of the specimen in the tube was read by the scale of the tube, and the value obtained was converted into specific gravity from the calibration graph of (density gradient tube scale)-(specific gravity), scaled according to a standard glass float. The measurement was repeated 4 times (n=4). As a rule, the specific gravity values were read to the fourth decimal place.
Measurement of the distribution of Δn in filament section:
From the refractive index at the center (n.sub.⊥,0 and n.sub.∥,0) and the refractive index at the outer layer (n.sub.⊥,0.9 and n.sub.∥,0.9) measured by the use of an interference the specific molecular orientation of the filaments of the present invention is made clear, and the relationship between the filament and its excellent strength can be shown. According to the interference fringe method using an interference microscope (for example an interference microscope "Interfaco" produced by Carl Zeiss Jena of East Germany), the distribution of the average refractive index observed from the side of the filament can be measured. This method is applicable to a filament having a circular section. The refractive index of the filament is characterized by the refractive index (n.sub.∥) to the polarization vibrating in parallel with the filament axis and the refractive index (n.sub.⊥) to the polarization vibration perpendicular to the filament axis. Measurements as hereinafter explained are all carried out with the refractive indexes (n.sub.∥ and n.sub.⊥) obtained by the use of a xenon lamp as the light source and a green color beam (λ=544 nm) through an interference filter under polarization.
In the following, n.sub.∥,0 and n.sub.⊥,0.9 obtainable from the measurement of n.sub.∥ and n.sub.⊥ will be explained in detail. The filament to be tested for n.sub.⊥ (n.sub.⊥,0 and n.sub.⊥,0.9) is immersed in a immersion liquid having a refractive index (n E ) which will produce a retardation of the interference fringe within a dn/Dn of 0.2 to 1 (in FIG. 4). The refractive index of the immersion liquid (n E ) indicates the value measured by the use of an Abbe refractometer at 20§C. The immersion liquid may be, for instance, a mixture of liquid paraffin and α-bromonaphthalene, having a refractive index of 1.48 to 1.65. A single filament of the filaments is immersed in the immersion liquid, and the pattern of the interference fringe is photographed. The resulting photograph is enlarged to 1,000 to 2,000 magnification and is subjected to analysis. As schematically shown in FIG. 4, the light path difference L can be represented by the following equation:
L=dn/Dnλ=(n.sub.f -n.sub.E)t
wherein n E is the refractive index of the immersion liquid, n f is the average refractive index between S' and S" of the filament, t is the thickness between S' and S", λ is the wave length of the light used, Dn is the interval between the parallel interference fringes of the background (corresponding to 1λ), and dn is the retardation in the interference fringe caused by the filament.
The pattern of interference fringe is evaluated using two different immersion liquids having the following refractive indexes (n 1 , n 2 ).
n.sub.f <n.sub.1
n.sub.f >n.sub.2
wherein n f is the refractive index of the specimen.
Thus, the light path differences (L 1 , L 2 ) in the case using the different immersion liquids having the refractive indexes n 1 and n 2 are represented by the following equations: ##EQU1##
Therefore, the distribution of the average refraction index (n f ) of the filament in various positions from the center to outer layer of the filament can be obtained from the light path difference at those positions according to the equation (5). Due to any variation of the conditions on the manufacture or any accident after the manufacture, the filament may have any non-circular section. In order to avoid the inconvenience caused by such section, measurement should be made for the parts where the interference fringe is symmetric to the filament axis. Measurement is effected with intervals of 0.1 R between 0 and 0.9 R being the radius of the filament, and the average refractive index at such position is obtained. Therefore, the distribution of n.sub.∥ and n.sub.⊥ can be obtained, and therefore the distribution of birefringence can be obtained according to the following equation:
Δn.sub.(r/R) =n.sub.∥,r/R -n.sub.⊥,r/R (6)
The value Δn.sub.(r/R) indicates an average on at least three filaments, preferably 5 to 10 filaments.
Measurement of intrinsic viscosity (IV):
The intrinsic viscosity (IV) of an ethylene terephthalate polyester in the present invention is obtained by converting the intrinsic viscosity (η) measured with a mixed solvent of p-chlorophenol/tetrachloroethane in the ratio of 3/1 at 30° C. into the intrinsic viscosity (IV) measured with a mixed solvent of phenol/tetrachloroethane in the ratio of 60/40, according to the following equation:
IV=0.8325×(η)+0.005
Measurement of the solidification point of the filaments:
The solidification point is the position where the thinning of the filaments is terminated due to their solidification.
The thinning behavior of running filaments was measured by a Diameter Monitor by irradiating a beam of infrared ray to the filaments, and the quantity of the shadow of the filaments is measured by a light receiving sensor. The quantity is then converted to the diameter.
By passing a single filament selected from the running filaments through a detector of the Diameter Monitor, the filament diameter at this position can be easily obtained. The solidification point can be clearly determined by plotting the relationship between the distance of the filament from the spinneret and the filament diameter.
Measurement of filament denier:
The single filament denier (d) was measured in a test room of a standard condition (20° C.±2° C.; RH 65±2%) by using a denier measuring apparatus DENIER COMPUTER DC-11, B-TYPE, produced by Search Co. The length of the filament length for testing was 50 mm.
Measurement of the strength of the filaments:
The tensile strength (tenacity) of the filaments was measured for a tensile strength of a single filament, according to JIS-L-1013 (1981) 7.5.1, in a test room of standard condition, by using an INSTRON-type tensile testing machine TENSILON UTM-III produced by Toyo Baldwin Co.
The specimen was drawn under measuring conditions of a load cell of 5 kg f, with the distance between jaws being 3 cm, a elongation velocity of 3 cm/min (a strain rate per minute is 100%), and a delivery velocity of recording paper of 100 cm/min. The load (gf) at which the specimen was broken was measured, and the tenacity (g/d) was calculated according to the following equation. ##EQU2##
Measurement of the initial tensile modulus of the filaments:
The measurement of the initial tensile modulus of the filaments was made in the same way as the above-mentioned measurement of the strength of the filaments, according to JIS-L-1013 (1981) 7.5.1. A load-elongation curve (stress-strain curve) was drawn on recording paper, and from this curve and according to the initial tensile modulus calculating formula mentioned in JIS-L-1013 (1981) 7.10, the initial tensile modulus (g/d) was calculated.
EXAMPLE 1
A polyethylene terephthalate having an intrinsic viscosity (IV) of 1.0 was extruded at a spinning temperature of 310° C. through a spinneret having 24 spinning orifices and an orifice diameter of 0.4 mm, at a through-put of 1.5 g/min per orifice, and an extrusion velocity (V 0 ) of 11.4 m/min. The solidification point of the filaments was 48 cm from the spinneret. The extruded filaments were introduced into the quenching tube shown in FIG. 5. In the figure, 4 is the flow down opening for the quenching liquid, 6 is inlets for the cooling liquid, and 7 is a rectifying screen. The flow of the liquid from the surface of the quenching tube to 5 cm downward therefrom was kept in a gentle state by another rectifying screen 10. The height (H) of the liquid in the quenching tube was fixed at 25 cm. At the lower end of the quenching tube, i.e. 25 cm downstream from the surface, the liquid flow velocity in the flow down direction was regulated so as to be 2,000 m/min. The length (L) from the orifice surface of the spinneret to the liquid surface of the quenching tube was set at 36 cm. The cooling liquid used was water of room temperature (25° C.).
The Δn and the specific gravity of the thus obtained yarn was 150×10 -3 and 1.3528, respectively. As regards the distribution of the birefringence in the cross section of the yarn, the Δn on the surface was found to be by 15×10 -3 larger than that of the center of the yarn.
EXAMPLE 2
The filaments were produced in the same spinning and quenching conditions as in Example 1 except that the take-up speed (V w ) was 3300 m/min. The solidification point of the filaments was 62 cm from the spinneret. The Δn and the specific gravity of the thus-obtained yarn was 129×10 -3 and 1.3492, respectively.
EXAMPLE 3
The filaments obtained in Example 1, without being wound, were subjected to a drawing treatment of 1.31 times by means of the apparatus shown in FIG. 7, between the first godet rolls 5 and second godet rolls 8, using a steam heater of 245° C., and the filament were wound. Thus, there was obtained a drawn yarn having the characteristics shown in the column of Example 3 of Table 1.
COMPARATIVE EXAMPLES 1-5
On the other hand, the filaments obtained in Example 1 were once wound (winding time: 20 minutes), and were allowed to stand for 24 hours in an atmosphere of 22° C. and 65% RH. Thereafter, from the undermost layer of the bobbin toward the lengthwise direction of the filaments, the filaments were divided into 5 parts (layers), i.e. the 1st 1/5 (outermost) layer, 2nd 1/5 layer, 3rd 1/5 layer, 4th 1/5 layer, and 5th (innermost) layer, and these were respectively drawn 1.26 times, at a feed roller velocity of 100 m/min, using a slit heater of 245° C. The fiber properties thus-obtained are shown in the column of Comparative Examples 1-5 of Table 1.
As shown in Table 1, the physical properties dropped according as the position in the bobbin of the fibers proceeds toward the outer layers.
COMPARATIVE EXAMPLE 6
Filaments were obtained under the same spinning conditions as in Example 1 except that the filaments were cooled with an ordinary air quench, without using the quenching tube, and were then wound up. The filaments were drawn 1.5 times at 150° C., at a feed roller speed of 50 m/min, followed by drawing to 1.5 times at 240° C. The properties of the thus-obtained fibers are shown in the column of Comparative Example 6 of Table 1.
Incidentally, the Δn and the SG of the filaments used in Comparative Example 6, before the drawing treatment were 88.2×10 -3 and 1.3722, respectively. These data do not satisfy the formulas (a) and (b).
EXAMPLE 4 AND COMPARATIVE EXAMPLE 7
After draw-heat treatment under the same conditions as in Example 3, the filaments, without being wound, were subjected to relaxation treatment at a relaxation ratio of 3% on third godet rolls arranged subsequent to the second godet rolls, and were then wound up. In this way, there were obtained drawn fibers having the properties shown in the column of Example 4 of Table 1. In comparison with the drawn fibers obtained in Example 3, the fibers had a nice winding shape. There was no irregular wound edge of the bobbin, even after winding as much as 3 kg. On the other hand, when the relaxation ratio was 17%, there occurred a considerable slack between the second godet rolls and the third godet rolls and winding was therefore impossible.
EXAMPLE 5
The filaments obtained in Example 1, without being wound-up, were subjected to a drawing treatment of 1.29 times, in an apparatus as shown in FIG. 7, using a plate heater at a temperature of 245° C., and were then wound up to obtain drawn fibers having the properties shown in the column of Example 5 in Table 5.
EXAMPLE 6
The filaments obtained in Example 1, without being wound up, were subjected to a drawing treatment of 1.27 times, in an apparatus as shown in FIG. 7, using an electric oven at a temperature of 700° C., and were then wound up to obtain drawn fibers having the properties as shown in the column of Example 6 of Table 1.
Incidentally, the draw ratio in Example 5 or Example 6 is lower, to a certain extent, in comparison with that of Example 3. These are, however, the highest winding ratios that can be wound in a stable operation for a long time under respective conditions.
EXAMPLES 7-9
The polymer extrusion velocity V 0 (m/min), the distance L (cm) between the spinneret and the liquid surface of the liquid cooling apparatus, the liquid flow down velocity (m/min) at the bottom of the liquid cooling apparatus, the take-up velocity V w , vertical distance H (cm) from the orifice surface of the spinneret to the liquid surface of the liquid cooling apparatus, and the temperature of the cooling liquid are shown in Table 2. Except that the conditions were changed, the spun filaments were otherwise taken up under the same spinning conditions as in Example 1. The physical properties of the thus-obtained fibers are shown in Table 2.
The filaments were subjected to a further draw-heat treatment (one-stage drawing using a slit heater of 245° C.) and were evaluated for the strength and tensile modulus. The fibers having a tenacity higher than 9 g/d and those having a tensile modulus higher than 150 g/d were marked with ○ marks and those that did not reach these values were marked with x marks. The draw ratios were 1.31, 1.25 and 1.57, respectively, in Examples 7, 8 and 9.
COMPARATIVE EXAMPLES 8-10
A polyethylene terephthalate having an intrinsic viscosity IV of 1.0 was extruded at a spinning temperature of 310° C. through a spinneret (24 spinning orifices, with an orifice diameter of 0.4) at an extrusion velocity (V 0 ) at the orifice of 10.7 m/min. The resulting filaments were air-quenched at 20° C. and were taken up under the respective conditions shown in Table 2, and were drawn at a natural draw ratio. The physical properties of the thus-obtained fibers are shown in Table 2.
Incidentally, the fibers thus obtained were subjected to a further draw-heat treatment (one-stage drawing using a slit heater of 245° C.) and were evaluated for the strength and tensile modulus. The fibers having a strength higher than 9 g/d and those having a tensile modulus higher than 150 g/d were marked with ○ marks and those that did not reach these values were marked with x marks. The draw ratios were 2.97, 3.08 and 2.85, respectively, in Comparative Examples 8, 9 and 10.
COMPARATIVE EXAMPLE 11
A polyethylene terephthalate having an intrinsic viscosity IV of 1.0 was extruded at 310° C. through a spinneret (24 spinning orifices, with an orifice diameter of 0.4 mm) at an extrusion velocity V 0 at the orifice of 10.7 m/min. The resulting filaments were cooled with an air-quench at 20° C., and without being heat-drawn, were taken-up at a take-up velocity of 3300 m/min. The physical properties of the thus-obtained fibers are shown in Table 2.
Incidentally, the resulting fibers were subjected to a further draw-heat treatment (two-stage draw at 150° C. and 240° C. respectively using two slit heaters with the first draw ratio of 2.01 and second draw ratio of 1.09). The resulting fibers were evaluated for the strength and tensile modulus. The fibers having a tenacity higher than 9 g/d and those having a tensile modulus higher than 150 g/d were marked with ○ marks and those that did not reach these values were marked with x marks.
COMPARATIVE EXAMPLES 12-13
A polyethylene terephthalate having an intrinsic viscosity IV of 1.0 was extruded through a spinneret (24 spinning orifices, with an orifice diameter of 0.4 mm) at a spinning temperature of 310° C. and at an extrusion velocity V 0 at the orifice of 10.7 m/min. The resulting filaments were cooled with an air-quench at 20° C. and taken-up under the conditions shown in Table 2, and hot-drawn at 80° C. under a natural draw ratio. The physical properties of the thus-obtained fibers are shown in Table 2.
Incidentally, the resulting fibers were subjected to a further drawing treatment. The resulting fibers were evaluated for the strength and tensile modulus. The fibers having a tenacity higher than 9 g/d and those having a tensile modulus higher than 150 g/d were marked with ○ marks and those which did not reach these values were marked with x marks.
COMPARATIVE EXAMPLE 14
The filaments were spun and taken up under the same spinning conditions as in Example 1 except that the polymer extrusion velocity V 0 was 14.3 m/min, the distance L between the spinneret and the liquid surface of the liquid cooling apparatus was 30 cm, the liquid flow down velocity at the bottom of the liquid cooling apparatus was 2000 m/min, the take-up velocity was 5500 m/min, the vertical distance H from the liquid surface of the liquid cooling apparatus to the bottom of the liquid was 10 cm, and the temperature of the cooling liquid was 25° C. Although a specimen for the determination of the physical properties could be collected somehow, it was impossible to stably spin and wind. The properties of the thus obtained fibers are shown in Table 2.
Incidentally, the thus-obtained fibers are subjected to a further draw-heat treatment (one-stage draw with a ratio of 1.22 and by the use of a slit heater of 245° C.), and the drawn fibers were evaluated for the strength and tensile modulus. The fibers which had a tenacity higher than 9 g/d and those having a tensile modulus higher than 150 g/d were marked with marks ○ , and those that did not attain these values were marked with marks x.
TABLE 1__________________________________________________________________________ Elongation Tensile Total denier Tenacity at break modulus D (d) DT (g/d) DE (%) IS (g/d) Remarks__________________________________________________________________________Example 3 42.9 11.31 7.4 171.3Comparative 47.1 10.41 7.9 150.3 1st (outermost) 1/5Example 1 layer*Comparative 46.3 10.61 7.8 155.3 2nd 1/5 layer*Example 2Comparative 45.7 10.66 7.8 160.2 3rd 1/5 layer*Example 3Comparative 46.2 10.72 7.6 159.3 4th 1/5 layer*Example 4Comparative 45.5 10.99 7.6 160.7 5th (innermost) 1/5Example 5 layer*Comparative 38.7 8.24 6.9 148.1Example 6Example 4 43.8 11.10 7.6 170.5 Wound package shape: goodComparative -- -- -- -- Impossible toExample 7 wind-upExample 5 43.4 11.16 7.6 160.4Example 6 44.3 11.02 7.5 161.5 Some filamentation__________________________________________________________________________ *Refer to page 21.
TABLE 2__________________________________________________________________________ Intrinsic Polymer Height H Length L (cm) from viscosity IV extrusion Take-up (cm) of the spinneret ori- liquid flow of the velocity velocity the cooling fices to the cool- down speed polymer V.sub.0 (m/min) V.sub.w (m/min) liquid ing liquid surface (m/min)__________________________________________________________________________Example 7 1.00 10.7 3900 10 30 1800Example 8 1.00 14.3 4500 10 30 2000Example 9 1.00 10.7 3000 10 30 1600Comparative 1.00 10.7 2000 / / /Example 8Comparative 1.00 10.7 2500 / / /Example 9Comparative 1.00 10.7 1500 / / /Example 10Comparative 1.00 10.7 3300 / / /Example 11Comparative 1.00 10.7 2500 / / /Example 12Comparative 1.00 10.7 3000 / / /Example 13Comparative 1.00 14.3 5500 10 30 2000Example 14Reference 0.65Example 1Reference 0.65Example 2__________________________________________________________________________ Properties of as-spun filaments Cooling Specific liquid Birefringence gravity δΔn Evaluation of drawn filaments temp. (°C.) Δn SG (× 10.sup.-3) Strength Initial modulus__________________________________________________________________________Example 7 25 0.164 1.352 14.0 O OExample 8 25 0.162 1.354 11.7 O OExample 9 25 0.117 1.343 7.0 O OComparative (20: air) 0.077 1.342 2.1 x xExample 8Comparative (20: air) 0.072 1.348 2.0 x OExample 9Comparative (20: air) 0.121 1.353 4.0 x xExample 10Comparative (20: air) 0.076 1.362 4.0 x xExample 11Comparative (20: air) 0.097 1.348 3.5 x xExample 12Comparative (20: air) 0.083 1.358 4.1 x xExample 13Comparative 25 0.153 1.361 Measurement x xExample 14 impossibleReference 0.169 1.368 x xExample 1Reference 0.158 1.368 x OExample 2__________________________________________________________________________ Reference Examples 1-2 are described in Kobunshi Ronbunshu vol. 42, No. 3 pp 159-166 (Mar. 1985) and quoted for comparison.
Since the present invention is composed as mentioned above, the invention provides, as apparent from the above mentioned Examples, a process which makes it possible to stably spin filaments of high orientation, never seen before, but of low crystallinity. Furthermore, the invention provides a high productivity process for stably improving physical properties of polyester fibers from said filaments, using a production apparatus for improving such filaments. | A process for producing polyester fibers having excellent tensile properties, particularly suitable as reinforcement material for tires, belts, etc., involves melt-spinning an ethylene terephthalate polyester to form highly oriented low crystalline polyester filaments which, at the state of being taken-up and prior to being drawn, having birefringence (Δn) and specific gravity (SG) within the below indicated ranges (a) and (b), and then, without winding-up, subjecting the said filaments immediately to drawing and heat treatment between the first godet rolls and second godet rolls under a draw ratio (DR) defined by the following formulas:
Δn≧5SG-6.64 (a)
Δn≧0.100 (b)
2.0≧DR>1.0 (c) | 3 |
SCOPE OF THE INVENTION
This invention relates to certain amine salts of leukotriene antagonists and the use of certain amines to form these salts as a means for crystallizing selectively optical isomers of the leukotriene antagonists recited herein.
BACKGROUND OF THE INVENTION
"Slow Reacting Substance of Anaphylaxis" (SRS-A) has been shown to be a highly potent bronchoconstricting substance which is released primarily from mast cells and basophils on antigenic challenge. SRS-A has been proposed as a primary mediator in human asthma. SRS-A, in addition to its pronounced effects on lung tissue, also produces permeability changes in skin and may be involved in acute cutaneous allergic reactions. Further, SRS-A has been shown to effect depression of ventricular contraction and potentiation of the cardiovascular effects of histamine.
Antagonists to SRS substances have been developed in an attempt to provide relief from the disease conditions giving rise to or resulting from these compounds. A number of the compounds developed are normally prepared as a racemic mixture, though activity lies primarily or completely in just one of the optical isomers. Resolving these mixtures is a useful, if not necessary step in preparing a useful formulation for treating these diseases. It has now been found that for certain compounds, the ones set out below, this can be accomplished most readily and inexpensively by means of (R)-4-nitro-α-methylbenzenemethanamine. This amine is uniquely suited to resolving certain enantiomers of the compounds given below so that the most active isomer can be obtained for use in treating SRS-related diseases.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this invention are (R)-4-nitro-α-methylbenzenemethanamine salts of formula I ##STR1## where: A is 1 and X is 1 or 2;
R 1 is C 8 to C 13 alkyl, C 7 to C 12 alkoxy, C 7 to C 12 alkylthio, C 10 to C 12 1-alkynyl, 10-undecynyloxy, 11-dodecynyl, phenyl-C 4 to C 10 alkyl, phenyl-C 3 to C 9 alkoxy, phenylthio-C 3 to C 9 alkyl with the phenyl optionally mono substituted with bromo, chloro, trifluoromethyl, C 1 to C 4 alkoxy, methylthio or trifluoromethylthio, furyl-C 4 to C 10 alkyl, trifluoromethyl-C 7 to C 12 alkyl or cyclohexyl-C 4 to C 10 alkyl;
q is 0, 1 or 2, with the proviso that R 1 is not alkylthio or phenylthioalkyl when q is 1 or 2;
Y is COR 3 , C(R 4 )H(CH 2 ) m COR 3 , or (CH 2 ) 0-1 -C-tetrazolyl;
R 3 is O - , amino, or C 1 to C 6 alkoxy,
R 4 is hydrogen, methyl, C 1 to C 4 -alkoxy, fluoro or hydroxy;
m is 0, 1, or 2;
R is (CH 2 ) n COR 6 ;
n is 0 to 6;
R 6 is O - , amino, or C 1 to C 6 -alkoxy;
with the proviso that at least one of Y or R must have an R 3 or R 6 group respectively which is O - .
This invention also relates to a process for separating a single isomer, either the R or S form, from a racemic mixture of a compound of formula II ##STR2## where R, R 1 , q and Y are defined above with the proviso that R 3 and R 6 are R 3' and R 6' where R 3' and R 6' are independently --OH, amino, or C 1 to C 6 alkoxy, with the further proviso that at least one of R 3' or R 6' must be --OH or a salt thereof, which process comprises treating a racemic mixture of formula II with about 0.5 to 2.5 equivalents, relative to the number of carboxylic acid groups in the formula, of either (R)-4-nitro-α-methylbenzenemethanamine or (S)-4-nitro-α-methylbenzenemethanamine, recovering a crystalline salt, and converting the salt to an acid or a pharmaceutically acceptable salt. It is preferred to use 0.5 to 1.5 equivalents of the nitro compound per carboxylic acid group in formula II. This process yields a substantially pure single enantiomer from a racemic mixture.
A preferred class of salts are those of formula (IA) ##STR3## wherein A is 1, X is 1 or 2, and R 1 and R are described above.
Another preferred group of these salts are 3-aryl-propionates of formula (IB) ##STR4## wherein R 1 is defined above, particularly where R 1 is phenylalkyl. Most preferred among the salts of this group are:
the bis-(R)-4-nitro-α-methylbenzenemethanamine salt of (S)-β-[(2-carboxyethyl)thio]-2-(1-dodecyl)benzenepropanoic acid; and the
bis-(R)-4-nitro-α-methylbenzenemethanamine salt of (S)-β-[(2-carboxyethyl)thio]-2-(8-phenyloctyl)benzenepropanoic acid.
Another preferred group of salts are the aryl-acetates of formula (IC). ##STR5## where R 1 is described above, particularly where R 1 is phenylalkyl.
The salts of the formula (IC) are exemplified by the following compounds:
the bis-(R)-4-nitro-α-methylbenzenemethanamine salt of (R)-α-[(2-carboxyethyl)thio]-2-(1-dodecyl)benzeneacetic acid; and the
bis-(R)-4-nitro-α-methylbenzenemethanamine salt of (R)-α-[(2-carboxyethyl)thio]-2-(8-phenyloctyl)benzeneacetic acid.
Another preferred group of salts are 3-aryl-2-hydroxypropionates of formula (ID) ##STR6## where R 1 is defined above, particularly where R 1 is phenylalkyl.
The compounds of formula (ID) are exemplified by the following compounds:
the bis-(R)-4-nitro-α-methylbenzenemethanamine salt of [R-(R*,S*)]-β-[(2-carboxyethyl)thio]-α-hydroxy-2-(8-phenyloctyl)benzenepropanoic acid; and the
bis-(R)-4-nitro-α-methylbenzenemethanamine salt of [R-(R*,S*)]-β-[(2-carboxyethyl)thio]-α-hydroxy-2-(1-dodecyl)benzenepropanoic acid.
In a process for resolving racemates of formula II, the following sets of general and specific compounds are preferred.
A set of preferred racemates are those of formula (IIB), ##STR7## more particularly those where R 1 is a phenyl-C 4 to C 4 to C 10 -alkyl. Most particularly racemates of formula (IIB) can be treated with the (R)-4-nitro-α-methylbenzenemethanamine to obtain, after further manipulation, the isomers (S)-β-[(2-carboxyethyl)thio]-2-(1-dodecyl)benzenepropanoic acid and (S)-β-[(2-carboxyethyl)thio]-2-(8-phenyloctyl)benzenepropanoic acid.
Another set of preferred racemates are those of formula IIC ##STR8## particularly those where R 1 is a phenyl-C 4 to C 10 alkyl. Most particularly racemates of formula (IIC) can be treated with (R)-4-nitro-α-methylbenzenemethanamine to obtain, after further manipulation, the isomers (R)-α-[(2-carboxyethyl)thio]-2-(1-dodecyl)benzeneacetic acid and (R)-α-[(2-carboxyethyl)thio]-2-(8-phenyloctyl)benzeneacetic acid.
Yet another preferred set of racemates are the 2S*,3R*-isomers represented by formula (IID), ##STR9## particularly those where R 1 is a phenyl-C 4 to C 10 -alkyl. Most particularly the racemate of formula (IID) can be treated with (R)-4-nitro-α-methylbenzenemethanamine to obtain, after further manipulation, the isomer [R-(R*,S*)]-β-[(2-carboxyethyl)thio]-β-hydroxy-2-(8-phenyloctyl)benzenepropanoic acid.
The racemates of this invention can be prepared according to the disclosure set out in U.S. Pat. No. 4,820,719 issued Apr. 11, 1989. That disclosure, in full, is incorporated herein by reference as if set out herein.
The amine, (R)-4-nitro-α-methylbenzenemethanamine, can be purchased as a hydrochloride salt from a commercial source such as Chiron, a Norwegian company. Or the hydrochloride salt may be made by the process of Baker, J. W. & Ingold, C. K., J. Chem. Soc., 261-264, 1927, and the R and S isomers fractionally crystallized by the method of Nerdel, F. and Liebeg, H., Ann 621:42-50, 1959. A more recent process for making the hydrochloride salt of this amine is given in Perry, C. W. et al, Synthesis 492-494, 1977. The amine can be prepared by treating the hydrochloride salt with a strong base and extracting the amine into an organic solvent, for example methylene chloride or toluene. Amine prepared in this manner may be stored prior to use. Alternatively, the amine can be liberated in-situ by treating the hydrochloride salt with a strong base in an aqueous alcoholic solvent, and then used immediately.
This amine is a particularly effective resolving agent for separating out a particular isomer from a racemic mixture of compounds denoted by formula II. A salt is formed between the amine and the carboxylate function. This salt can be fractionally crystallized, giving a salt comprising the amine and just one isomer of the acid. An alcohol is the preferred solvent for crystallization. This method provides excellent selectivity for the desired isomer.
These salts may be converted to the corresponding acid by means of a dilute acid. Or they may be converted to another salt, such as an alkali metal salt, by treating a solution of the isolated salt with a base. For example, the salt can be converted to the free acid by treating a solution of that salt with dilute mineral acid, for example 0.5N HCl at room temperature or thereabouts. The mixture is then extracted with an appropriate organic solvent, or subjected to other convenient separatory means, and the pure isomer obtained as the free acid after removing the solvent.
The following examples illustrate the process for making and preparing the compounds of this invention. Being examples they are not to be considered as limiting the invention set forth in the claims appended hereto.
EXAMPLE 1
Preparation of (S)-β-[(2-Carboxyethyl)thio]-2-(8-phenyloctyl)benzenepropanoic acid, compound with (R)-4-Nitro-α-methylbenzenemethanamine (1:2)
Racemic β-[(2-carboxyethyl)thio]-2-(8-phenyloctyl)benzenepropanoic acid [6.05 g (60.7% assay, 8.3 mmol)] was dissolved in 80 mL of 2-propanol and treated with a solution of 1.48 g (8.9 mmol) of (R)-4-nitro-α-methylbenzenemethanamine in 2-propanol. The mixture was heated to reflux, then allowed to cool to 0° C. The resulting solids were isolated by filtration to afford, after drying, 2.33 g of crude product. Chiral HPLC analysis indicated 97.7% of the desired S-enantiomer. After recrystallizing from 2-propanol, the content of S-enantiomer was enhanced to >99.5%. The salt contained 2 moles of amine per mole of diacid: Mp 239°-240° C.; [α] D 25 =-8.9° (c=1.0, methanol); Chiral HPLC (Bakerbond Chiralcel OD, 4.6 mm×250 mm, 3.5/96.5/0.1 isopropanol/n-hexane/trifluoroacetic acid, 2.0 mL/min, ambient temperature, UV detection at 215 nm): Retention Time=15.9 min (minor peak; R-enantiomer), Retention Time=19.4 min (major peak; S-enantiomer); Anal. Calcd for C 42 H 54 N 4 O 8 S: C, 65.09; H, 7.02; N, 7.23; S, 4.14. Found: C, 65.11; H, 7.00; N, 7.39; S, 4.09; 1 H NMR (CDCl 3 /CD 3 OD, 270 MHz) δ 8.21-8.24 (m, 4H), 7.57-7.60 (m, 4H), 7.14-7.39 (m, 9H), 4.47-4.53 (t, 1H), 4.30-4.38 (q, 2H, J=6.6 Hz), 2.32-2.91 (m, 10H), 1.32-1.60 (br, 18H).
EXAMPLE 2
Preparation of [R-(R*,S*)]-β-[(2-Carboxyethyl)thio]-α-hydroxy-2-(8-phenyloctyl)benzenepropanoic acid, compound with (R)-4-Nitro-α-methylbenzenemethanamine,(1:2)
A solution of racemic (R*,S*)-β-[(2-carboxyethyl)thio]-α-hydroxy-2-(8-phenyloctyl)benzenepropanoic acid (2.32 g, 6.6 mmol) was prepared by warming the acid in 40 mL of 2-propanol. The resulting solution was treated with 2.32 g (13.9 mmol) of (R)-4-nitro-α-methylbenzenemethanamine in 50 mL of absolute ethanol. The solution was heated to reflux, then cooled to room temperature. The resulting solids were isolated by filtration to afford, after drying, 1.95 g of crude product. Chiral HPLC analysis indicated 95.2% of the desired 2S,3R-enantiomer. After recrystallizing from absolute ethanol, the content of 2S,3R-enantiomer was enhanced to >99.5%. The salt contained 2 moles of amine per mole of diacid: Mp 141.5°- 142.5° C.; [α] D 25 =-20.0° (c=1.0, methanol); Chiral HPLC (Bakerbond Chiralcel OD, 4.6 mm×250 mm, 10.0/90.0/0.1 isopropanol/n-hexane/trifluoroacetic acid, 2.0 mL/min, ambient temperature, UV detection at 215 nm): Retention Time=6.1 min (minor peak; 2R,3S-enantiomer), Retention Time=9.5 min (major peak; 2S,3R-enantiomer); Anal. Calcd for C 42 H 54 N 4 O 9 S: C, 63.78; H, 6.88; N, 7.08; S, 4.05. Found: C, 63.80; H, 6.93; N, 7.12; S, 3.94 ; 1 H NMR (DMSO-d 6 , 270 MHz) δ 8.22-8.16 (m, 4H), 7.70-7.65 (m, 4H), 7.28-7.01 (m, 9H), 4.53 (d, 1H, J=3.4 Hz), 4.33-4.26 (q, 2H, J=6.7 Hz), 4.05 (d, 1H, 3.4 Hz), 2.90-2.84 (m, 1H), 2.66-2.34 (m, 7H), 1.53 (m, 4H), 1.37 (d, 6H, J=6.8 Hz), 1.29 (s, 8H).
EXAMPLE 3
Determination and Confirmation of Absolute Configuration
Both (S)-β-[(2-carboxyethyl)thio]-2-(8-phenyloctyl)benzenepropanoic acid and [R-(R*,S*)]-β-[(2-carboxyethyl)thio]-α-hydroxy-2-(8-phenyloctyl)benzenepropanoic acid react with two molar equivalents of (R)-4-iodo-α-methylbenzenemethanamine to produce highly crystalline salts. In each of these salts, the absolute configuration of the diacid portion was determined unambiguously by single crystal x-ray analysis.
In order to correlate this information to the salts obtained in Examples 1 and 2, each salt was treated with aqueous acid and extracted with ethyl acetate. By analyzing the extracts on an HPLC column (cellulose tris-3,5-dimethylphenylcarbamate chiral stationary phase, coated on silica gel) and comparing retention times to authentic samples of the racemates, it was determined that the diacid portion of the salt from Example 1 possessed the S-configuration, and the diacid portion of the salt from Example 2 possessed the 2S,3R-configuration. | This invention relates to certain salts of leukotriene antagonists and the use of certain amines to form these salts as a means for selectively crystallizing optical isomers of the leukotriene antagonists recited herein. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a building module and a building-module system for erecting flat structures, in particular walls.
2. Description of the Prior Art
A building module of this type constitutes the subject matter of European Patent Application No. 95105246.3. This patent application proposes a manageable building module which, in relation to the known building elements known, for example, from EP Patent 0 214 088, permits structures to be erected in a more straightforward manner and allows straightforward conversion with a wide range of possible configurations.
The object of the present invention is further to improve a building module of this type, and a building-module system, in order to increase further, by straight-forward design means, the wide range of possible configurations.
Pursuant to this object, and others which will become apparent hereafter, one aspect of the present invention resides in a building module for erecting flat structures, which building module comprises two parallel, plane-like wall parts which have outer surfaces that are directed away from one another, and a module-core made up of a plurality of individually produced and interconnected parts arranged between the two wall parts and fixedly connected thereto so that a space is formed between the wall parts, the mold core including at least one mold core part which runs in a longitudinal direction of the building module so as to project from the wall parts and be insertable between wall parts of a further building module so as to form, with these further wall parts, an innerlocking connection which absorbs forces in a transverse direction. The building module further includes means provided at the module-core for forming, with a module-core of a further building module, an interlocking connection which absorbs forces in the longitudinal direction.
Another aspect of the invention resides in a building-module system for erecting flat structures, which is comprised of a plurality of the building modules.
The advantages achieved by the invention can be seen, in particular, in that, with modules of the same dimensions, it is possible to cut back on the amount of material used and to gain more space for installations or insulation material without impairing the stability of the building module to any great extent.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained in more detail with reference to the drawing, in which:
FIG. 1 shows a first exemplary embodiment of a building module in a perspective illustration as seen from above;
FIG. 2 shows the building module according to FIG. 1 in a perspective illustration as seen from below;
FIG. 3 shows a plan view of the building module according to FIG. 1;
FIG. 4 shows a section along line IV--IV in FIG. 3;
FIG. 5 shows a section along line V--V in FIG. 4;
FIG. 6 shows a plan view of a second exemplary embodiment of a building module;
FIG. 7 shows a section along line VII--VII in FIG. 6;
FIG. 8 shows a section along line VIII--VIII in FIG. 7;
FIG. 9 shows an illustration, corresponding to FIG. 8, of a reduced-height building module;
FIG. 10 shows a further illustration, corresponding to FIG. 8, of a reduced-height building module;
FIG. 11 shows an illustration, corresponding to FIG. 8, of a further building module;
FIG. 12 shows a plan view of a building module with an end-side covering;
FIG. 13 shows a section along line XIII--XIII in FIG. 12;
FIG. 14 shows a plan view of a further building module, which is similar to the building module shown in FIGS. 1 to 5 and has wall openings;
FIG. 15 shows a section along line XV--XV in FIG. 14;
FIG. 16 shows a plan view of a building module with a wood-filled core;
FIG. 17 shows a section along line XVII--XVII in FIG. 16;
FIG. 18 shows a plan view of a further exemplary embodiment of a building module;
FIG. 19 shows a section along line XIX--XIX in FIG. 18;
FIG. 20 shows a plan view of a further building module, which is of a width which is increased with respect to the building module according to FIGS. 3 to 5;
FIG. 21 shows a section along line XXI--XXI in FIG. 20;
FIG. 22 shows a further variant of a building module which is of a width which is increased with respect to the building module according to FIGS. 3 to 5, and is compatible with one of the building modules according to FIGS. 1 to 19;
FIG. 23 shows a section along line XXIII--XXIII in FIG. 22;
FIG. 24 shows a plan view of a building module which is of a width which is double that of the building module according to FIGS. 3 to 5;
FIG. 25 shows a section along line XXV--XXV in FIG. 24;
FIG. 26 shows a further exemplary embodiment of a building module in a perspective illustration as seen from above;
FIG. 27 shows the building module according to FIG. 26 in a perspective illustration as seen from below;
FIG. 28 shows a plan view of the building module according to FIG. 26;
FIG. 29 shows a section along line XXIX--XXIX in FIG. 28; and
FIG. 30 shows a section along line XXX--XXX in FIG. 29.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to FIGS. 1 to 5, a building module 1 has two parallel, rectangular wall parts 2, 3 which each form part of one of the two surfaces of a wall which is to be erected. These wall parts may be wood panels, board sections, or panels made of derived timber products or other types of materials. It is also possible for one of the wall parts 2, 3, or both wall parts, to be designed as a gypsum board or to consist of other generally known materials, e.g. clay, fibrated concrete, etc. The longitudinal direction of the building module 1 is designated by X, the transverse direction is designated by Y and the vertical direction is designated by Z.
On its inside, which is directed toward the interior of the building module 1, each wall part 2, 3 is provided with a bottom strip 4, arranged in the longitudinal direction X of the building module 1, and with a top strip 5, which is oriented in the same direction. Whereas the bottom strips 4 are offset into the interior of the building module 1 in the vertical direction Z with respect to the wall parts 2, 3 (i.e. bottom surfaces 6 of the strips 4 are arranged at a higher level than bottom surfaces 7 of the wall parts 2, 3, see FIGS. 1, 2, 4 and 5), the top strips 5 project beyond the wall parts 2, 3 in the vertical direction Z (i.e. top surfaces 8 of the strips 5 are located at a higher level than top surfaces 9 of the wall parts 2, 3). In this region, the outside of the top strips 5 is provided with oblique surfaces 10, although that part of the outer surfaces of the top strips 5 which projects beyond the wall parts 2, 3 and is designated by 11 is provided for absorbing forces in the transverse direction Y, which will be described hereinbelow. However, the strips 5 could also be profiled differently and have, for example, rounded surfaces instead of the oblique surfaces 10.
The wall parts 2, 3 may either be in one piece or be made up of a plurality of sections, for example board sections, as is illustrated in FIG. 3. The connection of the wall parts 2, 3 to the wood strips 4, 5 is preferably produced by adhesive bonding, but could also take place by means of mechanical connecting means which are known in general.
In the same way, a plurality of, possibly four, vertically arranged intermediate webs 15, which are spaced apart from one another at regular intervals and are of rectangular cross section, are connected to the bottom and top strips 4, 5 of the two walls 2, 3. The intermediate webs 15 are also produced from wood and form, together with the two pairs of strips 4, 5, a module core designated by 14.
As can be seen from FIGS. 4 and 5, bottom end surfaces 16 of the intermediate webs 15 are located in the same plane as the bottom surfaces 6 of the strips 4. These end surfaces 16 are provided with downwardly directed protrusions in the form of stubs 19 which are produced by milling, or are inserted into the intermediate webs 15, do not project beyond a plane defined by the bottom surfaces 7 of the wall parts 2, 3 and are protected by the wall parts 2, 3 against any damage, for example being broken off, by virtue of being set back into the interior of the building module 1 in this way. Top end surfaces 17 of the intermediate webs 15 are flush with top surfaces 8 of the strips 5 and have depressions 20 which mate with the stubs 19. In this embodiment, the stubs 19 (as well as the depressions 20) are located at the same distance a from the two wall parts 2, 3.
Vertical through-cavities 22 are provided between the individual intermediate webs 15.
When a further building module 1 is attached, the wall parts 2, 3 of the further building module 1 engage, by way of their bottom region, which projects beyond the actual module core 14, around the module core 14 of the bottom building module 1, said module core projecting upward beyond the wall parts 2, 3. The top surfaces 8 of the strips 5 and the top end surfaces 17 of the intermediate webs 15 of the bottom building module 1 come to rest against the bottom surfaces 6 of the strips 4 and the bottom end surfaces 16 of the attached building module, the stubs 19 passing into the depressions 20. The bottom surfaces 7 of the wall parts 2, 3 of the attached building module 1 come into contact with the top surfaces 9 of the bottom building module 1. This vertical joining achieves an interlocking connection, of the building modules 1 positioned in layers one above the other, which absorbs not just vertical forces but also forces in the two horizontal directions, i.e. both in the longitudinal direction X of the building module 1 and in the transverse direction Y thereof. It is preferable for the wall parts 2, 3 in each case to absorb most of the vertical forces. In the longitudinal direction X, the stubs 19 and the depressions 20 form the force-absorbing means; in the transverse direction Y, the forces are absorbed not just by the stubs 19 and the depressions 20 but also via the wall parts 2, 3 of the attached building module 1 and via the parts 11 of the top strips 5 which project out of the bottom building module 1. The oblique surfaces 10 of the top strips 5 make it easier to join the two building modules 1 together.
In the abovedescribed vertical joining of two building modules 1, it is also possible, if required, for the wall parts 2, 3 of the top building module 1 to be nailed from the side, in their bottom region, to the upwardly projecting module core 14 of the bottom building module 1.
The building module 1 according to the invention is a building element which can be managed by hand. It preferably has a length of from 20 to 100 cm, a width of from 6 to 36 cm and a height of from 10 to 50 cm. In the embodiment illustrated in FIGS. 1 to 5, the building modules 1 can be positioned in a row with their end sides directly one beside the other and can be interconnected vertically one above the other, it also being possible, by virtue of the symmetrical construction, for the building modules to be turned through 180° about a vertical axis. However, for positioning one above the other, the building modules are also advantageously arranged, as seen in the longitudinal direction X, so as to be offset with respect to one another by one, two or three web spacings in each case, this ensuring a form-fit connection of the building modules 1 which are adjacent in the longitudinal direction X. The cavities 22 of the building modules positioned in layers one above the other are each arranged to be in alignment with one another. The lowermost row of building modules is fastened (in a manner which is not illustrated specifically) on a base beam, which is preferably provided with a plug-in profile suitable for the underside of the building modules.
Of course, it would also be possible to achieve the vertical joining with building modules 1 which are turned through 180° about a horizontal axis.
That embodiment of a building module 1 which is illustrated in FIGS. 1 to 5 constitutes a standard module which, for specific purposes, can be modified in various ways, as is described hereinbelow.
A further embodiment of a building module 1a is illustrated in FIGS. 6 to 8. The similar parts with the same functions continue to be designated by the same designations as in FIGS. 1 to 5. Unlike the first variant, the top strips 5 have a plurality of cutouts 25 which run in the transverse direction Y and--as seen in the longitudinal direction X of the building module 1a--are each located in the center between two intermediate webs 15. In each case two cutouts 25 form a plug-in segment 26, of which the length s corresponds to the distance 2a between the inner walls 27, 28 of the wall elements 2, 3. There are four plug-in segments 26 in this embodiment. The plug-in segments 26 allow a further building module 1a to be attached to the bottom building module 1a at right angles. In this case, the wall parts 2, 3 of the attached building module 1a are inserted into the cutouts 25 assigned to one of the web segments 26. When longitudinally directed building modules 1a are positioned in layers one above the other, the cutouts 25 cannot be seen from the outside. Instead of providing the entire building module 1a, or the top strips 5 thereof, with the cutouts 25, it is, of course, also possible to provide the cutouts 25 just at the desired location.
The building modules 1, 1a illustrated in FIGS. 1 to 8 may also be combined with building modules 1b and 1c according to FIGS. 9 and 10, these respectively having a reduced height h' and h" in relation to a height h of the building modules 1, 1a (FIG. 4) and allowing the wall to be of a freely configured height.
According to FIG. 11, further strips 30, 31 may be provided between the two strips 4, 5 of the two wall parts 2, 3. This solid-surface-area design of the inner strip layer makes it possible to bridge relatively large spans, e.g. doors, windows, etc.
As can be seen from FIGS. 12 and 13, it is possible for the building modules to be fully closed off on the end sides, with the result that, in the case of corners and transverse-wall connections, there are no openings in the cover layer. An end-wall-covering end panel is designated by 32.
In order for it to be possible to install insulating materials, installations, etc. in the wall, the wall parts 2, 3, or even just one of the two, may be provided with openings 33 at certain locations; in FIG. 14, as an example, the two wall parts 2, 3 are subdivided into four vertical wall segments 2', 3' in each case by these openings 33. However, it is also quite possible for a building module just to have a single opening 33. Of course, it is also possible for the openings 33 to be provided just in individual building modules provided for a wall. Openings of this type may also serve for the fitting of installations, for example electric sockets and switches.
In the embodiment of a building element 1d which is illustrated in FIGS. 16 and 17, the space between the wall parts 2, 3 is filled entirely with wood. According to FIG. 17, a module core 14d has a plurality of, possibly five, wood layers 35 to 39 which are arranged one above the other and of which the lowermost wood layer 35 is offset in the vertical direction Z with respect to the wall parts 2, 3, in the same way as the bottom strips 4 and intermediate webs 15 of the preceding exemplary embodiments, and has the stubs 19. The uppermost wood layer 39 projects beyond the wall parts 2, 3 at the top and has the oblique surfaces 10, the outer-surface parts 11, which absorb the forces in the transverse direction Y, and the depressions 20. Of course, it would also be possible for the number of wood layers used to differ from that illustrated in FIG. 17. Building elements 1d of this type can be used in the case of large openings, for example in the case of windows, as lintel elements, as a suspender beam or as a bearing for large single loads.
The building module 1e according to FIGS. 18 and 19 is provided for receiving a cover element (not illustrated in the drawing) which closes off the wall at the top. In this embodiment, the top strips 42 are also set back into the interior of the building module 1e. The intermediate webs 41 are stepped in the top region, their horizontal step surfaces 44 being flush with the top surfaces 43 of the strips 42. A gap 46 for receiving the cover element, or its wall parts, is formed in each case by the respective wall part 2 or 3, the horizontal surfaces 43, 44 and vertical step surfaces 45 of the intermediate webs 41. The depressions 20 are provided for corresponding stubs of the cover element.
In all the building modules described above, it is advantageous if the ratio of building-module length to building-module width is a whole number, for example between 2 and 8, preferably 4.
FIGS. 20 and 21 show a building module 1f which is of a width b' which is increased with respect to the standard building module (building module 1) or the width b thereof (FIG. 3). The increase in the size of the cavities 22' provided for the heat and/or sound insulation can increase the resistance of the wall to heat and/or sound transmission. The wider intermediate webs are designated by 50. The stubs 19 and depressions 20 provided as interlocking-connection means with a form fit in the transverse direction are located at the same distance a from the wall part 2, which forms the outer surface of the wall which is to be erected, as in the case of a standard module (building module 1). This means that it is also possible for the building module 1f to be attached to a standard module. Should, on the other hand, a standard module be attached to the building module 1f, then that part of the standard-building-module wall part 3 which projects downward beyond the module core 14 would have to be removed.
In the case of the variant of a building module 1g, which is illustrated in FIGS. 22 and 23, the top end surfaces 53 of the intermediate webs 52, which correspond in width to the intermediate webs 50 from FIGS. 20 and 21, are each additionally provided with a longitudinal groove 54, which runs in the longitudinal direction X and of which the base 55 is located in the same plane as the top surfaces 8 of the wall parts 2, 3. The bottom end surfaces 57 of the intermediate webs 52 each have longitudinal ridges 58, which are located vertically opposite the longitudinal grooves 54. The width of the longitudinal grooves 54 and of the longitudinal ridges 58 corresponds to the thickness of the wall parts 2, 3. The distance 2a of the wall part 2 from the side surfaces 59 and 60 of the longitudinal grooves 54 and of the longitudinal ridges 58, respectively, corresponds to the distance 2a between the wall parts 2, 3 of the standard module (building module 1). In the case of this variant, it is possible for the wider building module 1g to be joined together on both sides, as seen in the vertical direction Z, with in each case one standard module. Of course, it is also possible for two or more building modules 1g to be positioned in layers one above the other, the longitudinal-groove/longitudinal-ridge connection additionally reinforcing the interlocking connection which absorbs the forces in the transverse direction Y. Together with the oblique surfaces 10 of the top strips 5, the oblique surfaces 56 of the recesses 54 make it easier to attach the building module 1g. The interlocking connection which absorbs the forces in the longitudinal direction X (stubs 19, depressions 20) is configured in the same way as in the case of the above-described building module 1f. In both cases, the wall formed by wall parts 2 remains stepless.
According to FIGS. 24 and 25, building modules 1h, for increasing the resistance to heat and/or sound transmission, may also be of a width 2b which is double that of the standard module, in each case two stubs 19 and in each case two depressions 20 expediently being assigned to each intermediate web 65 in this embodiment. The stubs 19 and the depressions 20 are located at the same distance a from the respective wall part 2 or 3 as in the case of a standard module.
In all the abovedescribed embodiments of the module cores, the stubs 19 (as well as the longitudinal ridges 58 of the building module 1g according to FIGS. 22 and 23) are protected, by the projecting part of the walls 2, 3, against any damage, for example being broken off.
FIGS. 26 to 30 illustrate a further embodiment of a building module 1k. Fastened, once again, on the inside of the wall parts 2, 3 are in each case two laths or strips 71, 72, which are arranged in a manner corresponding to the strips 4, 5, are connected to one another via intermediate webs 75 in the manner described above and, together with these webs, form a module core 14k. The top strips 71 have cutouts 76 which are spaced apart at regular intervals at the top, run in the transverse direction Y and form a plurality of, possibly four, plug-in segments 77, which project beyond the wall parts 2, 3. The bottom strips 72 are provided on the underside with mating plug-in grooves 78, which are arranged opposite the plug-in segments 77. The intermediate webs 75 are vertically flush with the plug-in segments 77 and the plug-in grooves 78 and--as seen in the longitudinal direction X of the building module 1k--are each arranged in the center thereof. Whereas the base 79 of the cutouts 76 is advantageously located at a somewhat higher level than the top surfaces 9 of the wall parts 2, 3, the bottom surfaces 80, which are interrupted by the plug-in grooves 78, are offset upward by the same extent with respect to the bottom surfaces 7 of the wall parts 2, 3. However, it would also be possible for both the base 79 of the cutouts 76 and the surfaces 80 to be in alignment with the wall parts 2, 3. In this embodiment too, it is advantageous for the length s of the plug-in segments 77 to correspond to the distance c between the inner walls 27, 28 of the wall elements 2, 3 (FIGS. 29 and 30), with the result that it is also possible for the building modules 1k to be positioned one above the other at right angles. Once again, in the longitudinal direction X, it is possible for the building modules 1k to be positioned in layers one above the other in a state in which they are offset with respect to one another by one, two or three cutout spacings. In this variant, the plug-in segments 77 and the plug-in grooves 78 form, for the modules 1k which are positioned in layers one above the other, the interlocking connection which absorbs the forces in the longitudinal direction X. An interlocking connection which absorbs the forces in the transverse direction Y is formed by the outer surfaces 81 of the top strips 71, said outer surfaces projecting beyond the wall parts 2, 3, and the inner surfaces 27, 28 of the wall parts 2, 3 of the attached building module 1k. It is also the case in this variant of an interlocking connection for the vertical joining of building modules 1k which are positioned in layers one above the other that the wall parts 2, 3 absorb at least most, if not all, of the vertical forces.
It would also be possible for this embodiment to serve as a standard building module and to be modified for specific purposes similarly to the building module 1 (for example further strips arranged so as to fill the surface area between the strips 71, 72, wall parts 2, 3 provided with openings, building modules of various heights is combined, etc.). It is advantageous in the case of this variant too, if the ratio of building-module length to building-module width is a whole number, for example between 2 and 8, preferably 4.
All of the abovedescribed building-module variants are stable, warp-resistant building modules which make it possible, in a straightforward manner, to build load-bearing structures, in particular walls, by hand without additional transverse connecting means and in the "dry" state--i.e. without additional bonding and sealing agents. In this case, the building modules and/or module cores according to the invention--with the exception of the building module 1d according to FIGS. 16 and 17, which is provided for special purposes--constitute a solution which cuts back on a large amount of material but does not impair the stability of the building modules. In the case of these building-module variants, the cavities provided in building modules which are positioned in layers one above the other, said cavities being in alignment with one another in the vertical direction, have a large capacity and provide a large amount of space for installation lines or insulation material. Subsequent conversion or additions to the installation network can also easily be carried out. A fundamental advantage is that it is possible to combine different types of building module with one another as desired, as has been described above. Since a standard building module is compatible with a multiplicity of specially designed building modules--as has been described above--this makes available a building-module system which, in a straightforward manner, permits a wide range of possible configurations for the purpose of erecting walls.
Although the module cores are preferably produced from wood, it would also be possible to produce at least individual module-core parts from other materials, for example metal.
The grain direction in the wood preferably runs in the vertical direction in the wall elements 2, 3 and in the intermediate webs 15, 41, 50, 52, 65, whereas a horizontal grain direction is preferred in the strips 4, 5, 71, 72 or in the wood layers 35 to 39.
Using wood as the building material makes it possible to erect cost-effective, comfortable and ecologically sound structures. | This invention concerns a building module for producing flat construction, especially walls, which has two parallel, panel-shaped wall parts (2, 3) the exterior surfaces of which form the wall to be constructed. A module core (14) of wood connects the two wall parts (2, 3). The module core (14) has at least one module core part (5, 39, 47, 71) which runs in the longitudinal direction (X) of the building module. When an additional building module is put in plate between the wall parts (2, 3), this core (14) protrudes into this additional building module in the vertical direction (Z) and forms with these wall parts (2, 3) an interlocking connection which takes up forces in the transverse direction (Y). Means (19, 20; 77, 78) are provided for the purpose of forming an interlocking connection which takes up forces in the longitudinal direction (X) when an additional building module is put into place. Building modules with modified module cores can be stacked one on the other, making varied wall construction possible. Extensive space is created for installations or insulating materials while saving on material, without detracting from the stability of the building module. | 4 |
This is a National Phase Application filed under 35 U.S.C. §371 as a national stage of PCT/ES2008/000138, with the filing date of Mar. 13, 2008, which claims priority to Spanish application P 2007 00758, with the filing date of Mar. 22, 2007, both of which are hereby incorporated by reference in their entirety.
FIELD OF THE ART
The present invention relates to the stationary anchoring arrangement of chairs positioned at work desks, proposing a supporting foot for supporting the chairs in said arrangement, which allows a movement of the corresponding chair in order to be able to enter and exit between the chair and the desk in relation to the sitting position, as well as to comfortably get up from said position to remain standing between the chair and the desk.
STATE OF THE ART
The embodiment of chairs with a rotating support so that the user can orient his position in any direction remaining seated is known; and the embodiment of supporting elements which support the chairs provided with rolling supports, to allow movements to different working positions while sitting on the corresponding chair, is also known.
These embodiments are suitable for applications in which the chairs are arranged in a space allowing movements, but there are applications in which, due to limitation of the space or due to the type of installation, the chairs must remain in a stationary anchoring arrangement, which is a problem when dealing with the arrangement of the chairs positioned at a work desk, since the necessary proximity of the chair in relation to the desk, in order for there to be a suitable position for working on the desk while sitting, makes it very difficult and uncomfortable to stand up, as well as to enter and exit in relation to the sitting position.
OBJECT OF THE INVENTION
According to the invention, a supporting foot for chairs is proposed, which is provided with constructive and functional features allowing the movement of the body of the chair on a stationary anchoring arrangement, overcoming the drawbacks of access and standing of the users in the installation of the chair positioned at a corresponding work desk.
This foot object of the invention consists of a column provided with an anchor for securing same to the ground, including, according to a conventional rotating assembly arrangement, an upper supporting element for securing the body of the chair, in which supporting element there is included a carriage which can move in a longitudinal movement, on which carriage the body of the chair is secured.
An assembly is thus obtained which allows the rotation of the chair on the supporting column secured to the ground, and which furthermore, by means of the arrangement of the assembly on the supporting element for securing the body of the chair, also allows a backward movement of the body of the chair in relation to the supporting column.
With said rotation and movement arrangement, the body of the chair can move such that in a stationary anchoring installation of the chair in front of a work desk, the user can access and exit comfortably and without difficulty in relation to the sitting position at the desk. And likewise, the movement of the body of the chair allows the user to get up from the sitting position, in order to stand vertically between the chair and the desk.
The proposed foot therefore provides a satisfactory solution so that the users can move about easily and comfortably between a chair and a desk facing one another and in a stationary anchoring arrangement.
The arrangement of the mobile assembly of the body of the chair on the supporting foot is nevertheless provided with springs for the return, both in rotation and in movement, to the facing and proximity position in relation to the desk of application; such that the body of the chair thus returns automatically to the “zero” or use position, thus facilitating the positioning for the use functions.
Said foot object of the invention therefore has truly advantageous features, acquiring its own identity and a preferred character for the arrangement of the installation of chairs positioned at desks for which it is intended.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exploded perspective view of the proposed supporting foot for chairs.
FIG. 2 is an exploded perspective view of the assembly between the supporting foot and the securing structure for securing the body of the corresponding chair, according to an embodiment.
FIG. 3 is a side view of the previous assembly assembled, with the securing structure for securing the body of the chair in a forced movement position, a cut having been made to see the spring recovering the movement.
FIG. 4 is an enlarged plan view of the foot, with the carriage for securing the body of the chair in the normal position.
FIG. 5 is a plan view of the foot, with the carriage for securing the body of the chair in the forced movement position.
FIG. 6 is a diagram in plan view of the movements of the body of a chair in relation to a desk arranged facing it, according to the invention.
FIG. 7 is a schematic example of an installation of chairs facing desks, indicating the sitting and standing user positions.
FIGS. 8 , 9 and 10 depict an exploded perspective view of the securing of different types of chairs on the proposed foot.
FIG. 11 depicts an exploded perspective view of the column of the proposed foot seen from above, with a solution for the automatic recovery of the rotation.
FIG. 12 is an exploded perspective view similar to the previous one but seen from below.
FIG. 13 is a diametric section view of the column of the foot provided with the solution for the automatic recovery of the rotation, in the stable position of the recovering mechanism.
FIG. 14 is a section like that of the previous figure in a forced position of the recovering mechanism.
DETAILED DESCRIPTION OF THE INVENTION
The object of the invention relates to a foot intended for supporting chairs in a stationary anchoring arrangement positioned at corresponding work desks, with features allowing the mobility of the body of the chair in relation to the supporting foot, to make it easier for the user to move about between the chair and the respective desk.
The proposed foot consists of a column ( 1 ) provided with a lower anchor ( 2 ) for securing same on the ground, while it includes in a conventional rotating assembly an upper supporting element ( 3 ) intended for securing the body of the chair ( 13 ) of application.
The rotating assembly of the supporting element ( 3 ) is established by means of a plate ( 4 ) which is included coupled with bearings at the upper end of the column ( 1 ), and on which the supporting element ( 3 ) is secured by means of fastening with screws ( 5 ) and washers ( 6 ), as observed in FIG. 1 .
In the supporting element ( 3 ) there is arranged a carriage ( 7 ), included in an assembly capable of movement on a guide ( 8 ), which is secured with screws ( 9 ) in said supporting element ( 3 ).
A structure ( 12 ) intended for securing the body of the corresponding chair ( 13 ) is secured on the carriage ( 7 ) by means of fastening with screws ( 10 ) and washers ( 11 ), which chair can be a chair of any type, as shown in FIGS. 8 , 9 and 10 , which depict different types of bodies of chairs ( 13 ), according to non-limiting examples. The securing structure ( 12 ) can likewise vary according to the type of body of the chair ( 13 ), as observed in the same FIGS. 8 , 9 and 10 .
Between the casing of the supporting element ( 3 ) and the securing structure ( 12 ) for securing the body of the chair ( 13 ), there is included parallel to the guide ( 8 ) for the movement of the carriage ( 7 ), a pushing spring ( 14 ) assembled between sheets ( 15 ) which are secured by means of corresponding screws ( 16 ).
With such arrangement, the supporting element ( 3 ) can rotate in relation to the column ( 1 ) by means of the plate ( 4 ), whereas the carriage ( 7 ) can move along the guide ( 8 ) of the supporting element ( 3 ) between respective end positions, as shown in FIGS. 4 and 5 ; which involves a mobility of the body of the chair ( 13 ) in rotation and movement on the column ( 1 ).
This allows the installation of the supporting foot in a stationary anchoring arrangement on the ground in order to arrange a chair ( 13 ) positioned at a corresponding work desk ( 17 ), such that with the supporting foot remaining static on the stationary anchor in that arrangement, the body of the chair ( 13 ) can rotate and move backwards, as observed in FIG. 6 , which allows the user to be able to enter and exit easily in relation to the sitting position at the desk ( 17 ).
The spring ( 14 ) which is arranged in the supporting element ( 3 ) tends to move the securing structure ( 12 ) for securing the body of the chair ( 13 ) in the direction of approach of said body of the chair ( 13 ) towards the facing desk ( 17 ), whereby in the normal conditions the body of the chair ( 13 ) is close to the desk ( 17 ) in the suitable position for working on it from the sitting position, being able to force the movement of the mentioned body of the chair ( 13 ) backwards by means of a simple push overcoming the action of the spring ( 14 ).
To prevent abrupt blows of the carriage ( 7 ) against the casing of the supporting element ( 3 ), elastic stops ( 18 ) are arranged in the end walls of said casing of the supporting element ( 3 ), against which stops ( 18 ) the carriage ( 7 ) collides such that its blows are cushioned.
Likewise, in a preferred embodiment, the rotating assembly of the supporting element ( 3 ) on the column ( 1 ) of the supporting foot is provided in turn with elastic recovery towards a position, which in the assembly of application of the supporting foot is made to coincide with the orientation of the body of the chair ( 13 ) towards the respective desk ( 17 ), said rotating assembly being established with limitation of the rotation in an angle (β) of 60°, for example, towards each of the sides.
In that sense, the column ( 1 ) of the supporting foot is provided, as observed in FIGS. 11 to 14 , with a mechanism associated to the plate ( 4 ) of the upper part which is arranged in a rotating assembly by means of bearings ( 21 ), said mechanism comprising a cam ( 22 ) which is associated in rotation with the mentioned plate ( 4 ) by means of a transverse pin ( 23 ), and which determines at the lower part a helical track ( 24 ), whereas supported in that lower part of said cam ( 22 ) there is arranged another cam ( 25 ) provided with a reciprocal helical track ( 26 ) and which is pushed upwards by a spring ( 27 ), this lower connecting rod ( 25 ) being assembled with axial freedom but with blocked rotation in relation to a rod ( 28 ) integral with a plate ( 29 ) which is secured by means of screws ( 30 ) at the lower part of the column ( 1 ).
Thus, in normal conditions, as a result of the push of the spring ( 27 ) the cam ( 25 ) forces the cam ( 22 ) and with it, by means of the plate ( 4 ), the entire assembly supporting the chair of application, to a stable position such as the one depicted in FIG. 13 , which can be established corresponding with the chair of application arranged facing the respective desk.
If from said position the supported chair is forced to rotate towards a side, the relation between the cams ( 22 ) and ( 25 ), by means of their helical tracks ( 24 ) and ( 26 ), forces the lower cam ( 25 ) to move downwards against the spring ( 27 ), as observed in FIG. 14 , whereby there is a load tending to return the assembly to the initial position by the push of the spring ( 27 ), said initial position being automatically recovered when the force which obliges the rotation of the supported chair ceases.
Thus, due to the action of the spring ( 14 ) and due to the elastic recovery of the rotating assembly, there is established an automatic return of the body of the chair ( 13 ) to the position referred to as “zero” or starting position, in which the body of the chair ( 13 ) is in the suitable position in relation to the desks ( 17 ) to work on the latter.
The support of the body of the chair ( 13 ) in these conditions allows the application in distributions of successive rows of chairs with facing desks ( 17 ), for example for halls for conferences or similar activities, as observed in FIG. 7 , such that in normal conditions the bodies of the chairs ( 13 ) are in the suitable position at the corresponding desks ( 17 ) to work on the latter, leaving a free space ( 19 ) behind them which serves as a passage to be able to walk, said space ( 19 ) allowing the movement of the bodies of the chair ( 13 ) so that users ( 20 ) can access and exit in relation to the sitting position, as explained above.
The backward movement of the bodies of the chair ( 13 ), in those conditions, also allows, as observed in this same FIG. 7 , any user ( 20 ) to be able to get up from the sitting position and remain standing in a vertical position between the body of the chair ( 13 ) and the respective desk ( 17 ), since as a result of the backward movement of the body of the chair ( 13 ) when pushed by the legs of the user ( 20 ), the space necessary for the user ( 20 ) to be able to stand is vertically clear. | The invention relates to an anchoring foot for chairs positioned at desks, comprising a column ( 1 ) having a lower anchor ( 2 ) for securing same to the ground and an upper supporting element ( 3 ), rotatably coupled thereto, for securing the body of the chair ( 13 ). The supporting element ( 3 ) includes a carriage ( 7 ) which can move longitudinally along a guide ( 8 ) forwards and backwards in relation to the desk ( 17 ) and which can rotate in relation to the column ( 1 ). In addition, the supporting element ( 3 ) can include a lower cam ( 25 ) positioned facing another complementary upper cam ( 22 ) that is inserted therein by means of helical tracks ( 24 ). The lower cam ( 25 ) is pushed upwards by the return force of a spring ( 27 ), thereby rotating the upper cam ( 22 ) and rotating the seat to the initial position thereof. | 0 |
FIELD OF TECHNOLOGY
[0001] This invention relates to the field of chemistry, in particular to the application of a type of compound clonidine hydrochloride as an information intervention agent and an information intervention product and the method of making the same.
BACKGROUND
[0002] The compound clonidine hydrochloride, also known as 2-(2,6-Dichloroanilino)-2-imidazoline hydrochloride, has a chemical formula C 9 H 9 Cl 2 N 3 .HCl, and a molecular weight of about 266.56. It is a white crystalline powder, odorless, soluble in water or ethanol, very slightly soluble in chloroform, and practically insoluble in ether. A known use of clonidine hydrochloride is as a chemical drug that enters the human body by oral administration or by transdermal absorption, and is excreted from the human body by metabolic decomposition. Clonidine hydrochloride is a central α2 receptor agonist, clinically used to treat high blood pressure, migraine, menopausal hot flashes, dysmenorrhea, and rapid detoxification during the opiate withdrawal. Pharmaceutical formulations of clonidine hydrochloride include tablets, injection, eye drops, transdermal patches and gel formulation agents. The known clonidine hydrochloride medications are used as a chemical treatment; the compound clonidine hydrochloride molecules enter the human body (by direct injection into the blood, oral absorption into the bloodstream, or through the skin and mucous membrane absorption into the blood), and distribute to distinctive organs, and produce pharmacological effects through chemical reactions of molecules in the human body. The use of clonidine hydrochloride as the chemical treatment has its insurmountable disadvantages. First, its side effects on the human body include dry mouth, drowsiness, dizziness, constipation, sedation, general weakness, fatigue, headache, orthostatic symptoms of the cardiovascular system, palpitations, tachycardia or bradycardia, congestive heart failure, abnormal electrocardiogram, nervousness and agitation, depression, insomnia, behavioral changes, nausea, vomiting, stomach intestinal discomfort, abnormal liver function, regression of libido, impotence and loss of libido, etc. Second, the therapeutic window is small. The effective dose that is approved for use is very small due to the side effects on the human body, which limits the effect of the treatment results. The approved maximal oral administration dose is 0.6 mg each time and 2.4 mg each day. Any dose beyond the approved maximal oral administration does can lead to intoxication. Third, the only known use is as a chemical treatment. After entering the human body, Clonidine hydrochloride is metabolically broken down or excreted from the human body, which prevents prolonged effects.
SUMMARY
[0003] The goal of this invention is to overcome the disadvantages of the compounds clonidine hydrochloride as a chemical treatment, and to find its new use and new methods to overcome the disadvantages, thereby creating an unprecedented new product as an information intervention agent. This invention is also to present the method of making an information intervention agent from clonidine hydrochloride and the resultant product.
[0004] In order to realize the goal, the invention adopts the following technical solutions.
[0005] A method of making a clonidine information intervention product, according to an embodiment, comprises selectively adding paraffin and supplement carrier materials to clonidine hydrochloride powder based on a specific mass fraction; sealing the resultant mixture in a porous carrier material; packing the mixture in a container (with pores; and assembling a piece of hanger hardware onto the container with pores. The clonidine information intervention product can be used by hanging it near a surface of the human body, at a distance of 1-10 mm (preferably about 2 mm) to the surface of the human body (e.g., skin), preferably at the umbilicus, with the pores facing the surface of the human body (e.g., skin). According to treatment needs, the clonidine information intervention product may be used once a day for 1-3 hours, or twice a day for 1-2 hours. The intervention is achieved through a physical interaction of the clonidine information with information receptors in the human body, instead of through clonidine hydrochloride entering the human body and reacting with clonidine receptors to achieve the therapeutic treatment. In this invention, clonidine is used as an information intervention agent, not as a chemical treatment drug. After a period of time in use as the information intervention agent, the clonidine material may be used again as a chemical treatment drug after the wax is removed. When the clonidine material is prepared as a conventional agent in chemical treatment, it has the same therapeutic effect as the clonidine hydrochloride. In addition, it can be used as a synergist for the conventional preparation.
[0006] In this invention, said newly synthesized clonidine raw material powder refers to clonidine raw materials within three months of its synthesis and containing no less than 99.0 wt % of dry C 9 H 9 Cl 2 N 3 .HCl.
[0007] In this invention, said paraffin is a mixture of solid hydrocarbons from either petroleum or shale oil, suitable for use as medical wax matrix material.
[0008] In this invention, said supplement carrier material is fine particles, with diameters of 100 nm-10 micron, of crushed natural mineral tourmaline functional crystal material selected from the group consisting of lithium-, iron-, and magnesium-rich tourmaline, sodium- and manganese-rich tourmaline, calcium- and magnesium-rich tourmaline, and Bouguer tourmaline.
[0009] In this invention, said porous carrier material is selected from the group consisting of porous nonwoven fabric, porous fabric, porous paper and porous plastics. The size and density of the pores are such that the carrier material is both air permeable and leak-proof of the powder in the clonidine information intervention product.
[0010] In this invention, said container with pores can be a round box, an oval box, a box of any other shape, a bag or any other suitable container. The container has pores on one or more of its sides, wherein the pores have diameters between 0.3-3 mm.
[0011] In this invention, said hanger hardware is a support fixture that is configured to support the clonidine information intervention product. The hanger hardware can be a rope, belt, bag, rack, hook or sticker, etc.
[0012] In this invention, said clonidine information intervention product has a formulation of the clonidine raw material ( 1 ), packed and hung at a distance of 1-10 mm, preferably 2 mm, to the human skin, to prevent the direct contact of the drug substance with the skin. There is no absorption of the drug substance, and the intervention to human body is only through its information intervention.
[0013] In this invention, according to an embodiment, the method of making the clonidine information intervention product includes: based on mass fraction, weighing clonidine hydrochloride raw material 1-90%; paraffin 1-90%; supplement carrier material 1-30%, said supplement carrier material being the ultrafine particle in a diameter range of 100 nm-10 micron of the natural mineral tourmaline functional crystal materials; putting the clonidine hydrochloride raw material, supplement carrier material and paraffin into a mixer and mixing mechanically and thoroughly at room temperature and atmosphere pressure, to form the clonidine information agent packing material, at the mixing temperature of 10-25° C., preferably 20° C., and with a mixing time of 30-60 minutes, preferably 45 minutes; putting the fully mixed packing material into a powder dispensing machine, and dispensing the clonidine information agent packing material into bags made of the porous carrier material at 1-500 grams per bag, and sealing the bag by heating or other methods, to form clonidine information agent package fillers; putting the clonidine information agent packet filler into the container with pores, one packet filler per container; attaching the hanger hardware to the container. The clonidine information intervention product can be heated using a microwave oven at medium power level for 3-5 minutes prior to use for better results.
[0014] In this invention, according an embodiment, the method of making the clonidine information intervention product further include: weighing 1-200 g of paraffin particles; placing the paraffin particles in the container and then inside an oven, and heating the container to a temperature of 70° C. until the paraffin particles melts completely; weighing 1-500 g of the clonidine raw material; weighing 1-50 grams of the supplement carrier material; putting the clonidine raw material and the supplement carrier material into the melted paraffin, mixing thoroughly to embed the clonidine raw material and the supplement carrier material into the melted paraffin; putting the mixture in the oven and heating at a temperature of 70° C. for another 10-30 minutes; wrapping the mixture with the porous carrier material and compressing the wrapped mixture in a mold press; after cooling down and solidification, placing the molded product in a container with pores for packaging.
[0015] To facilitate understanding of this invention, the terms used in this invention are further explained.
[0016] The term “information intervention agent” as used herein means a non-chemical treatment drug. A chemical treatment drug is a substance which enters the human body by conventional means, such as by direct injection into the blood, oral absorption through the skin into the blood, or transdermal and mucosal absorption into the blood, wherein the substance distributes in various human organs, produces its pharmacological effects by chemical reaction with the human body, is broken down or metabolized in the human body, and is excreted. In contrast, the information intervention agent does not contact the human body nor does it enter the human body; it only uses its molecular information to regulate the body functions, and to realize intervention. Thus, treatment using an information intervention agent is novel and is based on a physical method of drug information intervention.
[0017] The term “secondary application of drugs” or “secondary use” as used herein means that the compound clonidine can be used twice or at a second time. This invention discloses the application of the information intervention of clonidine and its enhancing effect beyond common knowledge, because clonidine is not absorbed by the human body during the use in information intervention, and only the information of clonidine is used, which allows the use of the compound at a second time as a chemical treatment after the information intervention use, and does not affect the conventional chemical treatment effect of clonidine in a chemical treatment.
[0018] The term “therapeutic window” as used herein is the ratio of the effect to the side effects. The size of the therapeutic window can be understood as follows. If the affinity of a drug to its target and its side effect sites differs greatly, and the affinity to the target sites is stronger than the affinity to the side effect sites, then the drug has a large “therapeutic window”. When the therapeutic window is large enough, the dose can be increased by 5 times, 10 times, or even 50 times without serious side effects. Ideally, a developer of new drugs, doctors or patients desire that the drugs taken have the therapeutic window greater than 100 or greater than 500. One point to note is that when determining the dose of a drug for a large group of people, the differences in drug metabolism among individuals may be as high as 10 times. For some patients, a therapeutic window of only 10 times effectively equals no effective window. In fact, the conventional chemical treatment using clonidine drug has a very small therapeutic window. However, when the clonidine hydrochloride is used as an information intervention agent, the therapeutic window increases by more than 1000 folds from the therapeutic window of using clonidine in a chemical treatment.
[0019] It is contemplated that the use of clonidine hydrochloride as an information intervention agent is applicable to treatment of high blood pressure and sedation, analgesia, menopausal syndrome, withdrawal syndrome of addiction disorders, ulcerative colitis, children with short stature, children with attention deficit hyperactivity disorder, depression and others.
[0020] This invention can replace the chemical treatments, and can be used as the synergist to expand the therapeutic window of its chemical drug, enhancing the treatment effects of the chemical treatment without increasing the side effects of the drug.
[0021] This invention discloses the new use of the compound clonidine hydrochloride as an information intervention agent, discloses a new type of clonidine product and the method of making the same, and shows significant effectiveness as presented below.
[0022] First, this invention greatly expands the original clonidine hydrochloride therapeutic window in a chemical treatment. In the use of clonidine hydrochloride as the information intervention agent, no clonidine substance enters the human body, which avoids the side effects of clonidine, expands the therapeutic window from only 10 to more than 1000. The effects of clonidine treatment are enhanced while the side effects of clonidine are avoided. Meanwhile, when the conventional formulations of clonidine hydrochloride as a chemical treatment is not satisfactory, clonidine hydrochloride used as the information intervention agent can function as synergist and enhance the effect of clonidine hydrochloride as a chemical treatment without increasing its side effects.
[0023] Second, this invention can achieve secondary application of the clonidine hydrochloride. Clonidine hydrochloride, after use for one to two months as an information intervention agent, does not have diminished effect as a chemical treatment and may be used as a chemical treatment drug after wax removal, which significantly reduces the cost of treatment and increases the application value of clonidine hydrochloride. At the same time, the repeated use of clonidine reduces waste of drug, saves medical resources, and reduces environmental pollution caused by the pharmaceutical industry.
[0024] Third, this invention does not require use of a lot of accessory materials, additives, stabilizers, excipients and other non-drug ingredients used in the existing conventional pharmaceutical preparations in order to ensure the stability of the drug ingredients into the human body, and also avoids the adverse effects of these non-drug ingredients entering the human body.
[0025] Fourth, the usage of this invention is simple, convenient, safe, reliable and easy to accept. It is especially appropriate for use by senior people, unhealthy people, children, or people with disturbance of consciousness, mental retardation and behavioral disorders.
[0026] Fifth, this invention can reduce the trouble of administration of clonidine hydrochloride, reduce their labor intensity, and save human resources.
BRIEF DESCRIPTION OF FIGURES
[0027] FIG. 1 is a schematic diagram of the package filler.
[0028] FIG. 2 is a schematic diagram of the container.
[0029] FIG. 3 is a schematic diagram of the interior of the top of the container.
[0030] FIG. 4 is a schematic diagram of the exterior of the top of the container.
[0031] FIG. 5 is a schematic diagram of the information intervention agent.
[0032] In the figures: 1 , raw material, 2 , porous carrier material, 3 , package filler, 4 , container, 5 , pores, 6 , plastic cover, 7 , lid, 8 , hanging piece, 9 , information intervention agent.
DETAILED DESCRIPTION
[0033] The following embodiments are described to assist the understanding of this invention, but the scope of this invention is not limited to the embodiments.
[0034] An embodiment for the clinical use of clonidine hydrochloride to treat high blood pressure is described below.
[0035] With reference to FIGS. 1 and 2 , a method of making 10 clonidine information intervention products comprising weighing 20 grams of clonidine hydrochloride raw material 1 that is within three months from synthesis and meets the quality standards in the Chinese Pharmacopoeia; weighing 10 grams of paraffin (grain); weighing 1 gram of ultrafine powder of natural mineral tourmaline crystal material with particle diameter of less than 10 micron; mixing the clonidine hydrochloride raw material 1 thoroughly using a micro-mixer at a temperature of 20-25° C.; then putting the mixture in a small-dose powder dispensing machine, and dispensing the mixture into 10 bags made of the porous carrier material and sealing the bags by heating to form clonidine information package fillers 3 of 3.1 grams each; putting the clonidine information agent packet fillers 3 into 10 containers 4 with pores 5 , filler 3 per container 4 , wherein the container 4 is oval in shape and has a diameter of 6 cm, a height of 1 cm, a lid 7 and a number of pores 5 of 1 mm diameter on one side of the container 4 ; opening the lid 7 , and putting the clonidine information package filler 3 into the container 4 ; closing the lid 7 , and sealing the container 4 with an adhesive; installing the hanger hardware 8 , such as a rope (belt), onto the container 4 . Ten clonidine information intervention agents 9 are ready for clinical use. At the same time, another ten identical containers 4 of the same size, shape and color without the clonidine information package filler 3 are prepared and used as a placebo control.
[0036] Observation of clinical effects of the clonidine information intervention agents 9 on ten cases of clinical hypertension patients in the antihypertensive aspects are summarized as follows.
[0037] 1. The Method.
[0038] This study was a single-blind, self, placebo-controlled study. The subjects observed were with mild to moderate essential hypertension (DBP: 95-114 mmHg). There were a total of 10 cases, including 8 males and 2 females, with the mean age of 50.2±9.67 years (39-62 years). The hypertension patients with the following diseases were excluded: secondary hypertension, severe respiratory disease, liver and renal insufficiency, pregnancy, depression and skin allergies. The study required that all the selected patients stop taking all anti-hypertensive drugs, and use the placebo for two weeks; at the end of the placebo phase, blood pressure measurement was made followed by 24-hour ambulatory blood pressure monitors (ABPM) (such as Spaulabs 90207 made by Spacelabs Healthcare). In a following observation phase each patient wore a clonidine information intervention agent 9 hung at his or her umbilicus, with the pore 5 of the container 4 facing the skin for 4-5 hours each time every day. On day 7, a 24-hour ambulatory blood pressure monitoring was done. If the blood pressure was not reduced to the target blood pressure range (clinic blood pressure, DBP 90 mmHg) by using once a day, the use then was changed to twice daily for three hours each time from the second week. Again, the ABPM was done at the end of the third week. If by using twice daily for three hours each time, the patient blood pressure control was still not effective, then the monitor was stopped. After the monitoring of all patients using the clonidine information agent was completed, the observation continued for two more days. On the second day, ABPM was done to observe any lasting effect of clonidine. While the ABPM was done, the clinic blood pressure (the mean value of the sitting blood pressure taken as measured three times with an interval of 2 minutes) and heart rate were measured, other responses from the user were observed, and any adverse reaction was recorded.
[0039] Results to determination: before and after comparison of the blood pressure values, according to the clinical research guidelines points of the Chinese Ministry of Health.
[0040] “Significantly effective” means: DBP≧10 mmHg and dropped to normal; DBP not yet dropped to normal, but dropped by more than 20 mmHg.
[0041] “Effective” means: DBP dropped to normal although not by more than 10 mmHg; or DBP not yet dropped to normal, but dropped by 10-19 mmHg. n the case of systolic hypertension, systolic blood pressure dropped by ≧30 mmHg.
[0042] “Ineffective”: although a decline in blood pressure is observed, the decline is below the above standards.
[0043] The total effective rate (significantly effective+effective) is statistically analyzed using paired paired t test of the blood pressures before and after using clonidine information intervention agent 9 .
[0044] 2. The Results.
[0045] Among the selected cases of 10 patients with primary hypertension six had their blood pressures dropped to the target range by using the clonidine information intervention agent 9 once a day. The remaining four cases had their blood pressures dropped to the target range by using the clonidine information intervention agent 9 twice a day.
[0046] After the use of the clonidine information intervention agent 9 , the clinic blood pressure dropped significantly compared with before (p<0.01). The 24-hour average diastolic blood pressure (DBP), the average DBP during daytime (6 am-22 pm) and the average DBP during nighttime (22 pm-6 am) were all significantly reduced (p<0.05). The 24-hour average systolic pressure, the average daytime and nighttime systolic blood pressure were all significantly reduced (p<0.05). The heart rate did not change significantly before and after use. The day after the end of treatment, the clinic blood pressure increased slightly; the 24-hour systolic pressure increased slightly, while the diastolic pressure remained essentially unchanged. Before and after the use of the clonidine information intervention agent ( 9 ), the 24-hour ambulatory blood pressure circadian rhythm had no significant changes.
[0047] No side effects were observed.
[0048] According to an embodiment, the clinical use of the clonidine information intervention agent 9 for the treatment of heroin addiction is described below.
[0049] The clonidine information intervention agent ( 9 ) was prepared according to the following recipe:
[0050] Clonidine hydrochloride (content≧99%) 3 grams;
[0051] Paraffin wax (particle) 1 gram;
[0052] Ultrafine Tourmaline (diameter≦5 micron) 0.2 gram;
[0053] Mixing the above materials thoroughly at room temperature and atmosphere pressure; placing the mixture in a small-dose powder dispensing machine; packing the mixture in microporous air-permeable non-woven fabric bags at a net weight of 4.2 grams of mixture per bag; sealing the bags by heating; putting the bags in oval-shaped containers 4 with pores 5 on one side of the container 4 , the pores 5 having a diameter of 1 mm; packing and installing hanger hardware. Before each use, the clonidine information intervention agent 9 is heated in a microwave oven at medium power for 1-2 minutes.
[0054] The comparison between the clonidine information intervention agent 9 and methadone in the treatment of heroin addiction is summarized below:
[0055] 1. Materials and Methods.
[0056] 1.1. Subject selection criteria: 60 participants, in the range of 18-50 years of age, male or female, and opioid dependent as diagnosed according to the DSM-IV diagnostic criteria for opioid dependence. Prior to this study, the participants had been using opioids, had significant symptoms from attempted withdrawal, tested positive for morphinein urine; and exhibited cutis anserina, sweating, dilated pupils and other positive reactions during opioids addiction tests with naloxone. The route of heroin-containing narcotics ingestion was not limited (over 60% ingested heroin-containing narcotics by insufflation and intravenous injection).
[0057] 1.2. Subject exclusion criteria: candidates with serious heart disease, liver or kidney dysfunction, mental illness, serious bodily weakness, or pregnant or lactating women were excluded.
[0058] 1.3. Grouping: 60 cases of participants were randomly divided into two groups according to the order of admission: the test group and the methadone control group. The test group had 30 participants, and the methadone control group had 30 participants. The difference between the general characteristics of the two groups was not statistically significant, as shown in Table 1.
[0000]
TABLE 1
Comparison of general characteristics of the two groups (x ± s)
Clonidine
information
intervention
Methadone
agent test
control
Description
group
group
T
p
Age (years)
27.00 ± 6.01
27.27 ± 6.39
0.1676
>0.05
Weight (kg)
53.38 ± 4.67
54.97 ± 5.75
0.15
>0.05
Time of
2.47 ± 0.56
2.55 ± 0.71
0.50
>0.05
addiction (years)
Dose of
1.04 ± 0.22
0.86 ± 0.13
2.11
>0.05
addiction (g/d)
[0059] 1.4. Test methods: the test group used the clonidine information intervention agent 9 . The control group used methadone hydrochloride oral medication of 10 mg/10 ml each. Comparison method: according to the heroin-dependent self-restraining degree of 7-10 days, the treatment was designed to be 10 days long for both groups. The test group used the clonidine information intervention agent 9 once daily for six hours each time. The clonidine information intervention agent 9 was hung at the participants' umbilicus with the pores 5 facing the skin. The treatment concluded on day 10. Methadone control group was admitted 50-60 mg methadone on the first day; starting on day 2, the methadone dose was reduced by 10 mg per day each day; starting on day 6, the methadone dose was reduced by 2 mg per day each day. The treatment concluded on day 10. Supplementary drugs used in the two groups included normal doses of clonazepam tablets (clonazopam), alprazolam tablets (Alprazoli) once a day at night.
[0060] 1.5. Method of Observation and Evaluation.
[0061] 1.5.1. Clinical rating used indicators of withdrawal, which has 20 indicators including craving, anxiety, agitation, nausea, vomiting, hot face, chills, or alternating chills and fever, yawning, runny nose, tears, sweating, drowsiness, cutis anserina, tremors, bone and muscle pain, anorexia, abdominal pain, diarrhea, insomnia, and curled position. The rating was done daily on the day before the treatment and on each day during the treatment. The severity of withdrawal symptoms was scored as level 0-4 (five levels in total). Scoring for each participant was done at 9:00 am every day. During the process of the treatment, all participants were cooperative.
[0062] 1.5.2. Recordation of adverse reactions: adverse reactions were evaluated in the withdrawal symptom measurement table, using a total of 10 indicators that include: dizziness, syncope, malaise, nausea, vomiting, sweating, dry mouth, drowsiness, blurred vision, disturbance of consciousness. The recordation was done each morning at 9:00.
[0063] 1.5.3. The degree of anxiety symptoms: The Hamilton Anxiety Scale (HAMA) was used to assess in the degree of anxiety in the participants during the treatment.
[0064] 1.6. Statistical analysis of the two groups: the general characteristics, withdrawal symptoms, and anxiety symptoms of the two groups, were statistically analyzed using the t test, chi-square test and Fisher's Exact Test, using suitable software such as SPSS 7.0. The t test was applied to the symptom data of the two groups, and chi-square test or Fisher's Exact Test was applied to the count data.
[0065] 2. Results
[0066] 2.1. Comparison in the degree of withdrawal: the difference between the test group and the methadone control group in withdrawal symptoms was not statistically significant (p>0.05). During day 1 through day 5, the test group had more severe withdrawal symptoms than the methadone control group (p<0.01). During day 6 through day 10, the test group had less severe withdrawal symptoms than the methadone control group (p<0.01). Daily changes in the withdrawal symptoms of the two groups during the 10-day treatment are shown in Table 2.
[0000]
TABLE 2
Comparison of the withdrawal symptoms between
the two groups (x ± s)
Clonidine
information
intervention
Methadone
Days of
agent test
control
treatment
group
group
t
p
Before
55.43 ± 1.91
56.03 ± 1.80
1.25
>0.05
treatment
Day 1
50.54 ± 1.33
5.01 ± 0.83
159.07
<0.01
Day 2
42.07 ± 1.90
27.78 ± 1.40
32.16
<0.01
Day 3
32.48 ± 2.00
19.71 ± 1.13
30.45
<0.01
Day 4
22.93 ± 1.67
13.54 ± 1.01
26.35
<0.01
Day 5
14.20 ± 1.58
8.27 ± 0.28
20.75
<0.01
Day 6
3.39 ± 0.38
3.84 ± 0.06
6.40
<0.01
Day 7
2.51 ± 0.30
3.26 ± 0.27
10.42
<0.01
Day 8
2.50 ± 0.13
3.84 ± 0.07
49.07
<0.01
Day 9
2.45 ± 0.15
3.82 ± 0.18
32.45
<0.01
Day 10
2.20 ± 0.38
4.80 ± 0.11
35.99
<0.01
[0067] 2.2. Comparison of the adverse reactions: in the withdrawal symptoms. The difference between the two groups in the adverse reactions, including the abdominal pain, diarrhea, runny nose and tears, was not statistically significant (χ 2 =0.97, p>0.05), as shown in the Table 3.
[0000]
TABLE 3
Comparison of the adverse reactions (x ± s)
Adverse Reactions
Abdominal
Runny
Diarrhea
pain
Chills
nose
Tears
The test group
4
7
8
8
10
The Methadone
3
6
7
8
8
control group
[0068] 2.3 Emotional changes: measured by HAMA, the anxiety symptoms between the test group and the methadone control group on day 1 had no significant statistical difference (p>0.05). On day 5 and day 10, the differences between the two groups were both statistically significant. The anxiety symptom of the test group was significantly lower than that of the methadone control group, as shown in Table 4.
[0000]
TABLE 4
The emotional changes between the two groups during the
treatment measured by HAMA (x ± s)
Clonidine
information
intervention
Methadone
agent test
control
Treatment time
group
group
t
P
Day 1
18.48 ± 0.86
19.24 ± 0.56
3.13
>0.05
Day 5
5.03 ± 0.66
8.83 ± 0.45
24.51
<0.01
Day 10
1.13 ± 0.39
3.22 ± 0.36
20.32
<0.01
[0069] 2.4 Side effects: the methadone control group had side effects of dizziness, malaise, nausea, sweating and heart palpitations. The test group had none.
[0070] According to an embodiment, the clinical use of the clonidine information intervention agent 9 for smoking cessation is described below.
[0071] Referring to FIGS. 3-5 , the clonidine information intervention agent 9 was prepared according to the following recipe. Putting 60 grams of clonidine hydrochloride raw materials (content 99%), paraffin and 30 grams of wax (particle) into a dispensing machine; packing the mixture of clonidine hydrochloride raw materials and paraffin in 30 air-permeable non-woven fabric bags at a net weight of 3 grams of mixture per bag; sealing the bags by heating to form clonidine information package filler 3 . Preparing 30 magnetic suspension containers 4 . Magnetic suspension containers are prepared by a method comprising: making a flat circular container 4 box with a diameter of 4.5 cm and a height of 1 cm by plastic injection molding, a lower wall of the container 4 having pores 5 with diameters of 0.1 cm, the flat circular container 4 having an interior void space; inserting a disk-shaped magnet with a magnetic field of 500-1500 Gauss into the void space; covering the void space with a plastic cover 6 ; the plastic cover having a space to fit another disk-shaped magnet having a magnetic field of 500-1500 Gauss therein; wherein the magnet in the void space and the magnet in the plastic cover 6 are configured to secure the plastic cover 6 on the container 4 by magnetic attraction force. A set of teeth may be arranged to secure the plastic cover 6 to the container 4 . The clonidine information package filler 3 may be packed into the magnetic suspension container by opening the plastic cover 6 ; placing a clonidine information package filler 3 into the void space; closing the plastic cover 6 ; then sealing the plastic cover 6 with an adhesive to form the clonidine information intervention agent 9 .
[0072] Clinical use of the clonidine information intervention agent 9 for smoking cessation is compared with the nicotine replacement method.
[0073] 1. Materials and Methods.
[0074] 1.1. Clinical Data.
[0075] Participants Inclusion Criteria:
[0076] A history of smoking of more than 1 year; smoking 15 or more cigarettes per day; age between 18-65 years; no serious liver or kidney dysfunction; and Fagstram score greater than 5 points.
[0077] Participants exclusion criteria: a smoking history of less than 1 year; smoke less than 15 cigarettes per day; older than 65 years of age; having serious liver and kidney dysfunction, Fagstram score less than 5 points, having serious skin allergies, alcohol dependence, not being able to accommodate follow-up visits. Further exclusion criteria: first week of treatment adherence is less than 70% (the amount was calculated using the NRT patch), refusing to continue in smoking cessation.
[0078] 1.2 Research Methods
[0079] 60 participants who met the participants inclusion criteria were randomly selected. Routine physical examinations were performed before the treatment to record the blood pressure, heart rate, weight, etc. A Fagstram score was given to each participant and confidence in smoking cessation was assessed. The 60 participants were divided into Group A and Group B, 30 in each. Group A was treated with NRT (Nicotine Replacement Therapy) alone. Group B was treated with the clonidine information intervention agent 9 , once daily for 6-8 hours each time during the day, by hanging the container 4 on underwear at the umbilicus with the pore 5 side facing the skin. The NRT treatment used nicotine patches (that meet standards for drugs). The initial dose was estimated based on past amount of daily cigarette use, starting with one nicotine patch for each one pack of cigarette used per day. The dose was increased until the participant ceased to have desire for cigarettes. The dose was then maintained for the next 10-14 days. For each next 10-14 days, the dose was reduced by half from the dose for the previous 10-14 days. The treatment stopped when the dose reaches ¼ or ⅛ of the initial dose. Both groups were surveyed in the first, second, fourth, sixth, eighth and twelfth weeks by telephone and in-person visit. The abstinence rate, amount of cigarette use, and body weight were recorded for the first, second, third, fourth, fifth, sixth, seventh, eighth weeks. The abstinence rate and relapse rate of the seventh and twelfth weeks were used in the analysis below. Abstinence rate is calculated based on the standard that no cigarette was smoked in absence of both the clonidine information intervention agent 9 and the NRT treatment. Relapse rate was calculated as restarting smoking after achieving smoking cessation.
[0080] 1.3. Statistical Analysis
[0081] The number of smoking cessation and the abstinence rate of the seventh and twelfth weeks in each group were analyzed statistically. The statistical analysis can be done with using any suitable software such as SPSS. T test was used for continuous data; Chi-square test was used for discrete data. The statistical significance of the difference between the two groups was determined at α=0.05. Non-parametric method-Wilcoxon rank sum test was used for ranking data.
[0082] 2. Result.
[0083] 2.1. General characteristics of the participants: 2 females and 58 males. A total of 7 participants in Group A and 5 in Group B dropped out of the study for various reasons. 23 participants in Group A and 25 in Group B finished the smoking cessation study. There were no significant differences between the two groups in terms of age, length of smoking history, number of cigarettes smoked per day, Fagstram score, weight and heart rate before smoking cessation, as shown in Table 5.
[0084] 2.2 Comparison of the abstinence rate and relapse rate between the two groups: the abstinence rates of Group A participants at week 7 and week 12 were 52.17% ( 12/23) and 34.78% ( 8/23), respectively; the abstinence rates of group B participants at week 7 and week 12 were 64.00% ( 16/25) and 52.00% ( 13/25), respectively. The abstinence rates of Group B is significantly higher than that of Group A, with the statistically significant differences (p<0.05). The relapse rates at week 12 were 33.33% ( 4/12) in Group A, and 25.00% ( 3/16) in Group B, respectively. The relapse rate of Group A was significantly higher than that of Group B (p<0.05), as shown in Table 6.
[0085] 2.3. Comparison of abstinence symptoms and body weight during the abstinence process: major abstinence symptoms of the two groups include: irritability (35.4%), discomfort with placement of hands and feet (20.83%), muscle or joint pain (18.75%), full body discomfort (18.7%), and gum discomfort (80%). Most of these symptoms occurred during the first three days of the abstinence process. About 80% of the participants experienced weight gain, with an increase in the range of 0.5-3 kg.
[0000]
TABLE 5
General cessation of smoking cessation participants
Number of
Number of
cigarettes
Description
participants
Age
Fagstram
per day
Body weight
Heart rate
Group A
23
43.56 ± 13.45
7.00 ± 1.90
23.03 ± 9.42
62.34 ± 16.21
75.46 ± 6.23
Group B
25
43.23 ± 13.21
7.10 ± 1.81
22.46 ± 9.10
63.00 ± 15.94
75.63 ± 6.53
P
>0.05
>0.05
>0.05
>0.05
>0.05
[0000]
TABLE 6
Comparison of the abstinence rate and relapse rate of
the participants
Abstinence
Abstinence
Relapse
rate at week 7
rate at week 12
rate at week 12
(%)
(%)
(%)
Group A
52.17 (12/23)
34.78 (8/23)
33.33 (4/12)
Group B
64.00 (16/25)
52.00 (13/25)
25.00 (3/16)
P
<0.05
<0.05
<0.05
[0000]
TABLE 7
Abstinence effects during the treatment and comparison of body weights
Discomfort
with placement
Full body
of hands and
Muscle or joint
Palpitation
discomfort
feet
pain
Light sleep
Early wakeup
Irritation
Weight gain
Group A
(3)
1.30 ± 0.76
1.24 ± 0.65(6)
4
0
0
1.02 ± 0.75(8)
1.77 ± 1.37(20)
Group B
(4)
1.26 ± 0.63(4)
1.34 ± 0.55(4)
5
0
0
1.01 ± 0.72(9)
1.65 ± 1.34(18)
14.6%
18.7%
20.83
18.75%
0
0
35.4%
80%
P
>0.05
>0.05
>0.05 | This invention relates to a new application of compound Clonidine Hydrochloride in a use of preparation of information intervention agent, a new preparation method of information intervention agent, and a product. The Clonidine Hydrochloride interacts with the human information receptor, therefore realizing the intervention through the Clonidine Hydrochloride information physical method, and treatment was not a chemical treatment. This invention comprises: putting the compound Clonidine Hydrochloride information package filler ( 3 ) into a container ( 4 ), closing the lid ( 7 ), sealing by a glue, attaching a hanging piece to the container ( 4 ) to form the Clonidine Hydrochloride information intervention agent ( 9 ) for clinical use. The usage of this invention is simple, convenient, safe, reliable and easy to accept. It is especially appropriate for use by senior people, unhealthy people, children, or people with disturbance of consciousness, mental retardation, and behavioral disorders. This invention can reduce the trouble of administration of the drug by the nurses, reduce their labor intensity, and save human resources. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention concerns a yttria-based refractory composition for use in producing slurries needed for producing ceramic molds for use in casting reactive metals.
[0003] 2. Description of Prior Art
[0004] Aqueous suspensions of ceramic particles, such as yttrium oxide, zirconium oxide, yttria-alumina-zirconia, alumina, and zircon are used industrially to form ceramic articles due to their suitability for use as structural materials at high temperatures. These refractory materials often are also used for casting super alloys and reactive metals.
[0005] An example of such a reactive metal is titanium. Titanium normally reacts with materials used to form the mould, such as oxides, thereby releasing oxygen and forming oxygen-enriched titanium. A suspension is a system in which typically solid particles are uniformly dispersed in a liquid such as water. Particles in the order of less than about 1 μm can be classified as colloidal particles and a suspension of such particles is referred to as a colloidal suspension. Such suspensions are used as ceramic slurries for different purposes, as mentioned above. Ceramics normally are at least partially soluble in water. Furthermore ceramics tend to hydrate, forming a bond with water. To what extent and how quickly ceramics dissolve or hydrate, varies. Moreover, colloidal particles of ceramics may agglomerate in water. The extent to which ceramics dissolve, hydrate or agglomerate in water based systems depends on many factors, including the nature of the ceramic powder, the oxidation state of the ceramic, the pH; the temperature of the system and the dispersants which are used.
[0006] A lot of methods are known in the art to stabilize colloidal suspensions i.e. preventing the suspensions from agglomerating, while simultaneously reducing the dissolution and hydration rates. For instance, three known mechanisms include electrostatic, steric and electrosteric mechanisms. These mechanisms are reviewed in detail by Cesarano and Aksay “Stability of Aqueous Alpha-Al 2 O 3 Suspensions with Poly-(methacrylic acid) Polyelectrolyte”, J. Am. Ceram. Soc. 71 p 250-255 (1988).
[0007] In the U.S. Pat. No. 5,624,604 to Yasrebi et al. it is told that besides colloidal dispersion, reducing the attack of water (i.e. hydration and/or solvation) on the ceramic particle also is an important consideration for making commercially suitable ceramic slurries. Ceramic materials normally react with water and either partially dissolve (referred to as dissolution or solvation) or form hydrates. The extent of dissolution or hydration varies among different ceramic materials. As ceramic materials dissolve, the dissolved species may substantially change the ionic strength of the solution and consequently agglomerate the particles. In the case of particle hydration, some ceramics form a hydroxide surface layer. However, attack by water also may proceed farther than the surface layer and may advance into the body of the particle. As a result, size, morphology and the crystal phase of the particles may change.
[0008] In many commercially important ceramics, such as alumina (Al 2 O 3 ), zirconia (ZrO 2 ), and zircon (ZrSiO 4 ) to name a few, the dissolution rate and the extent to which dissolution proceeds is low enough so that it does not seem to interfere with their aqueous commercial use; at least under mild acidic or basic conditions such as from about pH 3 to about pH 11. Furthermore, hydration does not seem to form more than a thin surface layer, at least when the particle size is equal to or larger than one micrometer. However, other commercially important ceramics, such as magnesia (MgO), yttria-alumina-zirconia, and Y 2 O 3 (yttria), dissolve in an aqueous media to much larger extent and at faster rates than the ceramic materials discussed above. As a result, aqueous processing of these materials such as magnesia, calcia, yttria, yttria-alumina-zirconia is either difficult or even not practicable. Many attempts have been made by persons skilled in the art of ceramic processing to reduce the dissolution and hydration of ceramic particles, while simultaneously keeping the ceramic particles dispersed (unagglomerated) in suspensions. For example, Horton's U.S. Pat. No. 4,947,927 teaches that by adjusting the pH of a yttria slurry to high pH values in excess of pH 11 one can make yttria intrinsically less soluble in water, thereby decreasing its sensitivity to water attack.
[0009] Compared to electrostatic stabilization, electrosteric stabilization provides a better method for simultaneously dispersing colloidal particles in suspension and reducing water attack on the ceramic surface.
[0010] The limitations of this method were presented by Nakagawa, M. Yasrebi, J. Liu and I. A. Aksay (“Stability and Aging of Aqueous MgO Suspensions”) at the annual meeting of the Am. Ceram. Soc. (1989). Also monomers have been used to prevent the agglomeration of alumina suspensions. Graule et al. “Stabilization of Alumina Dispersions with Carboxyclic Acids”. Proceedings of the Second European Ceramic Society Conference (1991).
[0011] U.S. Pat. No. 5,624,604 Yasrebi et al. teaches a method for dispersing and reducing the rate of dissolution and/or hydration of colloidal ceramic suspensions by adding a non polymeric hydroxylated organic compound to a ceramic suspension. The ceramic suspension typically comprises a colloidal suspension of a metal oxide wherein the metal of the metal oxide is an alkali metal, alkaline-earth metal or rare-earth metal but preferably is magnesium, calcium or a rare-earth metal.
[0012] Other methods for increasing the lifetime of a casting slurry are described in U.S. Pat. No. 6,390,179 by Yasrebi et al., thus one feature of the invention is processing refractory powders at a first hydration level to produce powders having a second, lower hydration level before the processed materials are used to form casting slurries. Processing according to the disclosed methods results in a substantial increase in the lifetime of a slurry made using such processed materials compared to slurries made using materials not processed as described herein.
[0013] U.S. Pat. No. 5,464,797 describes an aqueous ceramic slurry having from about 70-weight percent to about 85 weight percent of a fused yttria-zirconia material. The weight-percent of zirconia in the fused yttria-zirconia preferably varies from about 1, 0 weight percent to about 10 weight percent. The slurries of the present invention are used to form ceramic mold facecoatings for casting reactive materials. These slurries are less sensitive to pH-fluctuations than slurries made from 100 percent yttria (yttria slurries).
[0014] Thus, it is understood that persons skilled in the art of ceramic processing have long searched for, and developed methods to increase the lifetime of casting slurries. Despite the prior inventions directed to this objective, there still is a need for convenient and practical methods for increasing the useful lifetimes of investment casting slurries in particular when using other (amongst others Ammonium Zirconium Carbonate, Zirconium Acetate), not colloidal silica based new binder systems to process such slurries.
[0015] In the U.S. Pat. No. 5,827,791 Pauliny et al focused yttria-based slurries for use in producing ceramic molds for use in the investment casting of reactive metals, particularly titanium and titanium, alloys, where the specific preferred binders amongst colloidal silica are ammonium zirconium carbonate and zirconium acetate.
[0016] Remet Corporation, a leading company in providing binders for the Precision Investment Casting Industry, offers Ammonium Zirconium Carbonate (Ticoat®-N) and cites that it is an effective binder system specifically for titanium castings. Remet Corporation also offers Colloidal Zirconia, that is defined as an acetate stabilized binder for high temperature applications.
[0017] In the U.S. Pat. No. 4,740,246 Feagin focused relatively unreactive mold coatings with titanium and titanium alloys that are prepared from zirconia or yttria sols, or mixtures thereof as a binder for refractory such as zirconium oxide, yttrium oxide and mixtures thereof. Feagin cites an example, where a cast-sample was made of a slurry containing yttrium oxide and zirconium acetate as essential parts. This sample is very low in alpha case being less than 0.001 inch.
[0018] From U.S. Pat. No. 4,057,433 a mold for casting molten reactive metals is known, which has a facing portion comprising finely divided particles of the oxyfluorides of the metals of Group IIIa and a back-up portion comprising finely divided particles of shell mold back-up material.
[0019] The Institution of Electrical Engineers, Stevenage, GB; September 1979 (1970-09), Udalova L. V. at AL describe the compaction kinetics of Y2O3 doped with 0.4-3.0 wt % LiF at 20-1250° C. and a specific pressure of 1000 kg/cm 2 .
[0020] Takashima M. published in the Journal of Fluorine Chemistry; Elsevier Sequoia, Lausanne, CH, vol. 105, no. 2, September 2000, pages 249-256 an article about the “Preparation and properties of binary rare-earth oxide fluorides” which are obtained by the solid-solid reaction between rare-earth oxide and fluoride at a temperature higher than 1000° C.
[0021] The Institution of Electrical Engineers, Stevenage, GB; November 1980 (1980-11), Udalova L. V. et al; describe in the published article “General features of compaction of powders of certain Lithiumfluoride doped powders” the reaction of pure yttrium oxide powder with lithium fluoride powder upon compaction at high pressure at room temperature.
SUMMARY OF THE INVENTION
[0022] In accordance with the invention and to achieve the objects thereof, the present invention is directed to a method for producing a mold for use in casting reactive metals comprising preparing a slurry of a yttria-based refractory composition and a binder, and using said slurry as a mold facecoat by applying said slurry onto a surface of a mold pattern, wherein said yttria-based refractory composition is obtainable by
(a) mixing particles of a yttria-based ceramic material and a fluorine containing dopant, and (b) heating the resulting mixture to effect fluorine-doping of said yttria-based ceramic material.
[0025] A preferred embodiment of said method is, wherein said yttria-based ceramic material comprises 50-100 wt.-% Y 2 O 3 , 0-50 wt.-% Al 2 O 3 and 0-50 wt.-% ZrO 2 .
[0026] A more preferred embodiment of said method is, wherein said yttria-based ceramic material is Y 2 O 3 , a Y/Al/Zr-oxide, a Y/Al-oxide or a Y/Zr-Oxide or combinations thereof.
[0027] Another embodiment of said method is, wherein said fluorine containing dopant is one of the group consisting of YF 3 , AlF 3 , ZrF 4 , a lanthanide fluoride and a zirconiumoxyfluoride.
[0028] Another more preferred embodiment of said method is, wherein said yttria-based refractory composition contains 0.10-7.5; preferably 1.0-7.5 mass-% fluorine.
[0029] In addition to that, the present invention is directed to a method for casting reactive metals comprising preparing a mold according to the method described above and casting said reactive metals using said mold.
[0030] The present invention is also directed to a Yttria-based refractory composition obtainable by
(a) mechanically mixing particles of a yttria-based ceramic material and a fluorine containing dopant other than an alkaline fluoride, and (b) heating the resulting mixture to a temperature within the range of 300-800° C. to effect fluorine-doping of said yttria-based ceramic material.
[0033] A preferred embodiment of said Yttria-based refractory composition can be obtained from a yttria-based ceramic material comprising 50-100 wt.-% Y 2 O 3 , 0-50 wt.-% Al 2 O 3 and 0-50 wt.-% ZrO 2 .
[0034] Said Yttria-based refractory ceramic material preferably is Y 2 O 3 , a Y/Al/Zr-oxide, a Y/Al-oxide or a Y/Zr-Oxide or combinations thereof.
[0035] Preferred embodiments for said fluorine containing dopant are YF 3 , AlF 3 , ZrF 4 , a lanthanide fluoride and a zirconiumoxyfluoride.
[0036] Another preferred embodiment of said Yttria-based refractory composition contains 0.1-7.5, preferably 1.0-7.5 mass-% fluorine.
[0037] The present invention is also directed to a method for producing a mold for use in casting reactive metals comprising preparing a slurry of a yttria-based refractory composition according to present invention and a binder, and using said slurry as a mold facecoat by applying said slurry onto a surface of a mold pattern.
[0038] In addition to that, the present invention is directed to a method for casting reactive metals comprising preparing a mold according to the method described above and casting said reactive metals using said mold.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The present invention provides new yttria-based materials for increasing the lifetime of casting slurries. One feature of the invention is processing such refractory powders which exhibit a significantly reduced rate of dissolution and/or hydration, when used in colloidal ceramic suspensions. This can be accomplished at any pH according to the present invention, thereby making it possible to reduce the aging of rare earth based slurries considerably.
[0040] The present invention also encompasses the use of compositions comprising an aqueous slurry of yttria-based particles doped with an amount of fluor effective to reduce the dissolution rate of the particles mentioned above. One skilled in the art will realize that an “effective amount” may vary from composition to composition. However, an effective amount typically means an amount of at least about 0.1 weight percent. Yttria-based refractory composition according to the present invention contain at least 0.1 wt.-% fluorine.
[0041] The dopant material is a fluoride or oxyfluoride or compounds that form such dopants as mentioned above upon further processing, wherein these fluorides or oxyfluorides are of metals especially selected from the group consisting of aluminium, zirconium, yttrium and lanthanides.
[0042] Doped yttria (Y 2 O 3 ), yttria alumina (Y/Al-oxide), yttria alumina zirconia (Y/Al/Zr-oxide) or yttria zirconia (Y/Zr-oxide) particles according to the present invention are not simply a binary mixture of the dopant and yttria or yttria-alumina-zirconia or yttria-zirconia. Instead, the phrase “doped particles” or similar phrases used herein, refers to an intimate mixture of yttria or yttria-alumina-zirconia or yttria-zirconia or yttria-alumina. “Intimately mixed” or “intimate mixture” is used to differentiate binary mixtures that result simply from the physical combination of two components. Typically, an “intimate mixture” means that the dopant material is atomically dispersed in yttria or yttria-alumina-zirconia or yttria-zirconia such as with a solid solution or as small precipitates in the crystal matrix of the solid yttria or yttria-alumina-zirconia or yttria-zirconia or yttria-alumina.
[0043] Alternatively, an intimate mixture may refer to compounds that are fused, such as, yttria or yttria-alumina-zirconia or yttria-zirconia or yttria-alumina. By way of example and without limitation, the dopants may be intimately mixed with yttria or yttria-alumina-zirconia or yttria-zirconia or yttria-alumina in the following ways: 1. finely dispersed in the yttria or yttria-alumina-zirconia or yttria-zirconia or yttria-alumina matrix or 2. provided as a coating on the surface of such particles or provided as a diffused surface layer of dopant on the outer surface of yttria or yttria-alumina-zirconia or yttria-zirconia or yttria-alumina particles. The dopant may be in solid solution with the matrix, or it may be in the form of small precipitates in the crystal matrix, or it may be a coating on the surface of the particle or portions thereof.
[0044] Without limiting the scope of this invention to one theory of operation, it is currently believed that the dopant shields dissolution sites on the surface of the yttria or yttria-alumina-zirconia or yttria-zirconia or yttria-alumina from attack by solvent molecules, such as water. In other words, the dissolution and/or hydration of these particles primarily is a surface reaction, and the dopant interferes with this surface reaction. Consequently, the dissolution rate of yttria or yttria-alumina-zirconia or yttria-zirconia or yttria-alumina is decreased due to the formation of yttrium oxyfluorides, on the surface of the above mentioned refractory powders.
[0045] For this reason and in the absence of any particle breakage, only a minor portion of the outer surface regions of the refractory powders related to this invention actually need to be doped. This means that the core of the particle may remain substantially pure yttria, yttria alumina, yttria alumina zirconia or yttria zirconia.
[0046] In the following, a general description of the production process of the preferred F doped yttria-based ceramic materials is given.
[0047] The dopant (a fluorine-containing substance, for instance YF 3 , zirconium oxyfluoride, AlF 3 ) is added to the raw material flour (preferred: yttria, yttria-alumina-zirconia, yttria-zirconia, yttria-alumina). In order to distribute the two flours homogenously, they are accurately blended respectively ground together and afterwards sieved. Subsequently the flour-mixture is heated, e.g. calcined to form a YOF-surface layer on the outer surface of the ceramic particles.
[0048] In the present invention F-doped Yttria-based refractories are produced at a preferred temperature range from 300 to 800 degrees. Treating the F-doped materials at a temperature higher than 800 degrees (Takashima M. describes in “Preparation and properties of binary rare-earth oxide fluorides” by Takashima M. temperatures higher than 1000° C.) causes a decrease of slurry stability of the F-doped Yttria based refractory in water based binder systems.
[0049] Contrary to the publication “General features of compaction of powders of certain Lithium fluoride doped powders”, where the powder and the dopant (Lithium fluoride) are mixed chemically; the fluorine containing dopant and the Yttria-based flour are mixed mechanically in the present invention. Furthermore no specific pressure is used for the production of the preferred Yttria-based refractories as described in the publication mentioned above and as described in “Compaction kinetics of Lithium fluoride-doped Yttrium oxide” written by Udalova et al.
[0050] Lithium fluoride and alkali metals are not used as dopants according to the present invention, due to their negative effect on the slurry stability in water-based binder systems.
EXAMPLES
[0051] To further illustrate the production of F-doped Y 2 O 3 , Y/Al/Zr-Oxide, Y/Zr-Oxide, Y/Al-Oxide and their effect on increasing the slurry lifetime following examples and the results of their slurry lifetime-tests are provided. The fluorine-contents that are indicated in the examples accord to the results of the chemical analysis of the materials used. The analysis was made by realising soda respectively soda potash pulping and by using an ion selective electrode.
[0052] First the two methods that were used for detecting the slurry lifetime, are described.
1. Measurement of the Torque—Method A
[0053] The experimental setup consists of
double jacket assay container made of stainless steel (inner diameter=5 cm, external diameter=7 cm), a Plexiglas cap and sealing member (stainless steel) therefore. In the middle of the cap there is a hole (bore=0.9 cm) for the mixer (shaft diameter=0.8 cm). The cap is sealed up with a grommet. agitator (IKA EUROSTAR power control-visc P4) and a horseshoe mixer (width=4.5 cm, altitude=5.5 cm) measuring instrument for detecting the dynamic torque, which acts on the agitating element (IKA VISKOKLICK® VK 600 control). The measuring unit transforms the dynamic into a static torque. thermostat (LAUDA ecoline RE 106) software labworldsoft 4.01
[0059] First the slurry is formulated (exact composition of the slurry see description of the examples) and then filled into the double jacket assay container, which is temperature controlled at 25° C. by a thermostat. The agitator with a horseshoe mixer works with a constant rotation speed of 30 revolutions per minute. The horseshoe mixer is positioned just 1-2 mm above the bottom of the assay container. At the beginning of the test the torque is reset and then recorded over time. Therewith the developing of the relative viscosity can be observed. For analysis the point of the first significant increase in slope is defined as the slurry-lifetime.
2. Measurement of the Cinematic Viscosity Using Zahn Cup Respectively Measurement of the Dynamic Viscosity Using Rheometer—Method B
[0060] The experimental setup consists of
a roller Polyethylen-bottle (2 L) (Bartelt) with cap Zahncup Nr. 4 (ERICHSEN GMBH & CO KG) respectively Rheometer Physica MCR 301 (Anton Paar GmbH)—Plate-Plate-System (PP50; measuring gap=0.5 mm unless otherwise noted; measuring temperature=25° C., viscosity value at a shear rate of 100/s).
[0064] Powder and binder (exact composition of the slurry see description of the examples) are mixed in the PE-bottle with an agitator and then put on the roller that has a constant rotation speed. The rotation speed of the bottle is 16.5 rpm. The slurry is stirred uniformly at room temperature and after one hour of stirring the start-viscosity is measured with Zahncup Nr. 4-unless otherwise noted (determining the efflux time and convert it to the cinematic viscosity according to the adequate formula of ASTM D 4212) or/and with the Rheometer. In certain time intervals (˜every 3-5 hours) and when the viscosity starts to increase, viscosity-measurements are done every two respectively every hour. For analysis the doubling of the start viscosity [cSt] is defined as the slurry lifetime. If the doubling of the viscosity takes place between two measurements, a straight line is built between these two measuring points, and the value of the doubling of the viscosity is calculated from the linear equation.
Slurry Composition
[0065] In the present invention the slurry is formed by mixing an aqueous based binder with e.g. yttria, yttria-alumina-zirconia, yttria-alumina or yttria-zirconia. The preferred binders are
Ammonium Zirconium Carbonate solution which finds use as a binder for titanium alloy casting (Ticoat®-N) Zirconium Acetate, an acetate stabilized Zirconia sol (binder).
Production of Yttria-Alumina-Zirconia
[0068] Appropriate quantities of Y 2 O 3 , ZrO 2 and Al 2 O 3 are mixed, put into an electric furnace and fused at the melting temperatures of the materials. After this operation the melt is cooled to get an ingot. The ingot obtained is crushed into particles of below 3 mm using a jaw crusher. Afterwards the particles are annealed.
COMPARATIVE EXAMPLES
Results of Slurry-Lifetime-Tests with Standard Materials
Measurement of the Torque—Method A
Comparative Example 1
[0069] 250 g of fused Y/Al/Zr (95.88/0.12/4.0) flour (TIAG) were mixed with 44.8 g of Ammonium Zirconium Carbonate and 22.11 g de-ionised water. The start viscosity of the slurry didn't change for 0.9 hour, but then the torque and therewith the viscosity increased dramatically. After 1.4 hours the torque rose up to 25 Ncm ( FIG. 1 ).
Comparative Example 2
[0070] 250 g of fused Y/Al/Zr (95.88/0.12/4.0) flour (TIAG) were mixed with 44.8 g of Zirconium Acetate and 22.11 g de-ionised water. The start viscosity of the slurry didn't change for 0.7 hours, but then the torque and therewith the viscosity increased dramatically ( FIG. 2 ).
Measurement of the Viscosity Using Zahncup Respectively Using Rheometer—Method B
Comparative Example 3
[0071] 1200 g of fused Y/Al/Zr-Oxide (95.88/0.12/4.0) flour (TIAG) were mixed with 360 g of Ammonium Zirconium Carbonate.
[0072] Because of the low start viscosity of the slurry, Zahncup measurements with Zahncup Nr. 3 and 4 were done. Accessorily viscosity measurements with the Rheometer were realised. You can see the results in FIG. 3 . After three hours the start-viscosity increased by 112 percent (Zahncup 4). At this point no reproducible measurements could be realised with Zahncup Nr. 3 because of the high slurry viscosity. After 4 hours the efflux time of the slurry couldn't be determined likewise with Zahncup Nr. 4 anymore (efflux time>2 minutes).
Comparative Example 4
[0073] 1200 g of fused Y/Al/Zr-Oxide (95.88/0.12/4.0) flour (TIAG) were mixed with 300 g of Zirconium Acetate. Viscosity measurements were made with Zahncup Nr. 4 and Rheometer. You can see the results in FIG. 4 . Because of the rapid increase of the viscosity, the start viscosity was measured after 5 minutes of stirring using the roller. After 35 minutes the start viscosity increased by 128 percent, after 60 minutes the slurry could not be measured with Zahncup Nr. 4 anymore, the viscosity increased dramatically.
Comparative Example 5
[0074] 1200 g of fused Yttria flour (TIAG) were mixed with 360 g of Ammonium Zirconium Carbonate. Viscosity Measurements were made with Zahncup Nr. 4 and Rheometer. After 125 minutes the start viscosity increased by 39.2%, after 185 minutes the slurry could not be measured with Zahncup Nr. 4 anymore (efflux time>2 min), the viscosity increased dramatically. ( FIG. 5 )
[0075] With the following examples the invention is described in more detail:
Example 1
[0076] 6.85 kg fused block material of Y/Al/Zr (95.88/0.12/4.0) were milled for 90 minutes in a ZrO 2 -lined ball mill (ZOZ GmbH TYP COMB 03-A03). Therefore 25 kg 1.25″ grinding-balls (Yttria stabilized Zirconium Oxide) were used. After the addition of 150.5 g (=2.15 wt %) Yttriumfluoride the powder mixture was milled for another 60 minutes. The milled product was sieved <45 μm and then calcined (Nabertherm C250) in Al 2 O 3 (0.9)-mullite(0.1)-crucibles (1.5 kg per crucible). The heating rate was 5° C./min up to a temperature of 550° C. that was maintained for 6 hours 50 min.
Life Time Test (Method A)
[0077] 250 g of the 0.8 wt % F-doped material were mixed with 44.8 g of Zirconium Acetate and 22.11 g de-ionised water. The slurry lifetime was 41 hours. ( FIG. 6 ). From this time on the viscosity increased sharply. After 50 hours a torque of 25 Ncm was achieved.
Example 2
[0078] Powder-production was performed according to Example 1.
Life Time Test (Method A)
[0079] 250 g of 0.8 wt % F-doped material were mixed with 44.8 g of Ammonium Zirconium Carbonate and 22.11 g de-ionised water. The slurry lifetime accounted for 56 hours (see FIG. 7 : Example 2 in comparison to the untreated Y/Al/Zr-Oxide).
Example 3
Powder-Production
[0080] Fused Y/Al/Zr-Oxide-flour (95.88/0.12/4.0) was milled with 3.3 wt % Zirkonylfluoride with a planetary mill (ZrO 2 grinding jars and balls) for 10 minutes. The weighted sample was 96.7 g Y/Al/Zr-flour and 3.3 g Zirkonylfluoride per grinding jar-four jars were used. (production of Zirkonylfluoride by fractionally converting Zirconium Carbonate with HF and following calcination at 450° C. for 4 hours). The powder mixture was calcined in a ZrO 2 -crucible at 550° C. for 3 hours using a muffle kiln (Heraeus Holding GmbH MR 170 E).
Life Time Test (Method A)
[0081] 250 g of the 1.0 wt % F-doped material were mixed with 44.8 g of Ammonium Zirconium Carbonate and 22.11 g de-ionised water. The slurry lifetime added up to 124 hours. (see FIG. 8 )
Example 4
Powder-Production
[0082] Raw materials and milling parameters according to Example 1. The milled product was sieved <45 μm and then calcined (High temperature kiln) in Al 2 O 3 (0.9)-mullite(0.1)-crucibles (1.5 kg per crucible). The heating rate was 5° C./min up to a temperature of 540° C. that was maintained for 8 hours.
Life Time Test (Method A)
[0083] 250 g of 0.9 wt % F-doped material were mixed with 62.5 g of Zirconium Acetate. The slurry lifetime was 66 hours.
Example 5
[0084] Fused Y/Al/Zr-Oxide-flour (95.88/0.12/4.0) was milled with 2.2 wt % Zirkonium(IV)fluoride (99.9%—Sigma Aldrich) with a planetary mill (ZrO 2 grinding jars and balls) for 10 minutes. The weighted sample was 107.6 g Y/Al/Zr-flour and 2.4 g Zirkonium(IV)fluoride per grinding jar—four jars were used. The powder mixture was calcined in a ZrO 2 -crucible at 550° C. for 3 hours using a muffle kiln (Heraeus Holding GmbH MR 170 E).
Life Time Test (Method A)
[0085] 250 g of the 0.8 wt % F-doped material were mixed with 44.8 g of Ammonium Zirconium Carbonate and 22.11 g de-ionised water. The slurry lifetime was 380 hours.
Example 6
[0086] 6.490 kg fused block material of Yttria were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; 20 kg 1.25″ grinding-balls (Yttria stabilized Zirconium Oxide other milling parameters as described in Example 1). After the addition of 0.510 kg (=7.3 wt %) Zirconiumoxyfluoride Zr 7 O 8.79 F 9.71 the powder mixture was milled for another 90 minutes. The milled product was sieved <63 μm and 399.5 g were calcined in a ZrO 2 -crucible at 400° C. for 4 hours using a muffle kiln (Heraeus Holding GmbH MR 170 E).
Life Time Test (Method A)
[0087] 250 g of the 1.9 wt %-F-doped material were mixed with 75 g of Ammonium Zirconium Carbonate. A significant increase of the measured torque could not be observed for more than 335 hours. Afterwards the experiment was stopped.
Example 7
[0088] Yttium-Oxide-flour was milled with 2.7 wt % Lithium fluoride (99.995%—Sigma Aldrich) with a planetary mill (ZrO 2 grinding jars and balls) for 10 minutes. The weighted sample was 97.3 g Yttria and 2.7 g Lithium fluoride per grinding jar. The powder mixture (398.7 g) was calcined in a ZrO 2 -crucible at 400° C. for 4 hours using a muffle kiln (Heraeus Holding GmbH MR 170 E).
Life Time Test (Method A)
[0089] 250 g of the 1.7 wt %-F-doped material were mixed with 75 g of Ammonium Zirconium Carbonate. The first significant increase in slope was observed at 10 hours. (See FIG. 9 —Example 6 in comparison to Example 7—Yttria doped with LiF.)
Example 8
[0090] 6.787 kg fused block material of Y/Al/Zr (95.88/0.12/4.0) were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; milling parameters as described in Example 1). After the addition of 213 g (=3 wt %) Yttrium-Fluoride the powder mixture was milled for another 90 minutes. The milled product was sieved <75 tun and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 550° C. that was maintained for 8 hours.
Life Time Test (Method B)
[0091] 1200 g of 1.0 wt % F-doped Y/Al/Zr were mixed with 300 g of Zirconium Acetate. After one hour the initial viscosity was 400 cSt. The slurry lifetime added to 72 hours, at this point the start viscosity has doubled ( FIG. 10 ).
Example 9
[0092] 6.664 kg fused block material of Y/Al/Zr-Oxide (95.88/0.12/4.0) were milled for 60 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; milling parameters as described in Example 1). After the addition of 336 g (=4.8 wt %) Zirconiumoxyfluoride Zr 7 O 8.79 F 9.71 the powder mixture was milled for another 90 minutes. The milled product was sieved <63 μm and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 450° C. that was maintained for 4 hours.
Life Time Test (Method B)
[0093] 1200 g of 1.1 wt % F-doped Y/Al/Zr were mixed with 300 g of Zirconium Acetate. After 171.5 hours the initial viscosity of 295 cSt rose up to 547 cSt. This means that the viscosity increased by 85% after 171.5 hours. ( FIG. 11 )
Example 10
[0094] 6.348 kg fused block material of Y/Al/Zr (95.88/0.12/4.0) were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; milling parameters as described in Example 1). After the addition of 652 g (=9.3 wt %) Zirconiumoxyfluoride Zr 7 O 8.79 F 9.71 the powder mixture was milled for another 120 minutes. The milled product was sieved <63 μm and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 650° C., that was held for 13 hours.
Life Time Test (Method B)
[0095] 1200 g of 2.2 wt % F-doped Y/Al/Zr were mixed with 360 g of Ammonium Zirconium Carbonate. The initial viscosity of 314 cSt doubled after 28.7 hours.
Example 11
[0096] Powder production according to Example 10. The heating rate of the calcination was 1.1° C./min up to a temperature of 450° C., that was maintained for 7 hours.
Life Time Test (Method B)
[0097] 1200 g of 2.4 wt % F-doped Y/Al/Zr were mixed with 360 g of Ammonium Zirconium Carbonate. After 70.3 hours the initial viscosity of 232 cSt doubled (see FIG. 12 ).
X-Ray-Diffraction (XRD) Analysis
[0098] A XRD-analysis of the material described in Example 11 was made. The detected phases are Y 2 O 3 , ZrO 2 , YOF and Zr 0.72 Y 0.28 O 1.862 ( FIG. 13 ).
Transmission Electron Microscopy (TEM)-Analysis
[0099] A TEM analysis of the material described in Example 11 was made at the Austrian Centre for Electron Microscopy and Nanoanalysis in Graz. Therefore a lamella out of a grain, that showed a Fluorine-peak at the precedent Energy dispersive X-ray spectroscopy (EDX), was removed using Focused Ion Beam (FIB).
[0100] Via electron energy loss spectroscopy a Fluorine-signal could be detected at the grain boundary area. (see FIG. 14 ). 200 nm below the boundary area, there exist no Fluorine-peak. At the so called Jump-ratio image (eliminating the background signal by dividing the signal image by a background image) a 170 nm wide layer along the grain boundary is apparent (FIG. 15 —elemental map of oxygen) that is verified as Yttrium-Oxy-Fluoride in the following. At the diffraction images of the inside of the grain Y 2 O 3 can be detected ( FIG. 16 ) and at the diffraction image of the grain boundary the chemical compound Yttrium-Oxyfluoride (YOF) can definitely be verified ( FIG. 17 ). Via EDX the element Zirconium can also be detected in the layer at the surface of the grain.
Example 12
[0101] 6.520 kg fused block material of Y/Al/Zr (95.88/0.12/4.0) were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; milling parameters as described in Example 1). After the addition of 480 g (=6.9 wt %) Zirconiumoxyfluoride Zr 7 O 8.79 F 9.71 the powder mixture was milled for another 120 minutes. The milled product was sieved <63 μm and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 400° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0102] 1100 g of 1.7 wt % F-doped Y/Al/Zr were mixed with 304.7 g of Ammonium Zirconium Carbonate. The formulated slurry showed a lifetime of 44.9 hours.
Example 13
[0103] 6.974 kg fused block material of Y/Al/Zr (95.88/0.12/4.0) were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; 20 kg 1.25″ grinding-balls (Yttria stabilized Zirconium Oxide—other milling parameters as described in Example 1). After the addition of 0.026 kg (=0.37 wt %) Zirconiumoxyfluoride Zr 7 O 8.79 F 9.71 the powder mixture was milled for another 120 minutes. The milled product was sieved <63 μm and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 400° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0104] 1200 g of 0.1 wt % F-doped Y/Al/Zr were mixed with 360 g of Ammonium Zirconium Carbonate. The formulated slurry showed a lifetime of 21.6 hours.
Example 14
[0105] 5.212 kg fused block material of Y/Al/Zr (95.88/0.12/4.0) were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; 20 kg 1.25″ grinding-balls (Yttria stabilized Zirconium Oxide—other milling parameters as described in Example 1). After the addition of 1.788 kg (=25.5 wt %) Zirconiumoxyfluoride Zr 7 O 8.79 F 9.71 the powder mixture was milled for another 120 minutes. The milled product was sieved <63 μm and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 400° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0106] 1200 g of 6.9 wt % F-doped Y/Al/Zr were mixed with 440 g of Ammonium Zirconium Carbonate. After a certain time the volume of the slurry was too small to realise Zahncup Nr. 5 measurements. Therefore Rheometer measurements (measuring gap=1 mm) were made. First every weekday, afterwards approximately every week one respectively two measurements were realised. A tendency of slight increase of viscosity could be observed after 110 days, but no significant increase of the viscosity of the formulated slurry could be observed for 152 days. Afterwards the experiment was stopped.
Example 15
[0107] 6.490 kg fused block material of Yttria were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; 20 kg 1.25″ grinding-balls (Yttria stabilized Zirconium Oxide—other milling parameters as described in Example 1). After the addition of 0.510 kg (=7.3 wt %) Zirconiumoxyfluoride Zr 7 O 8.79 F 9.71 the powder mixture was milled for another 90 minutes. The milled product was sieved <63 μm and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 400° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0108] 1200 g of 1.9 wt % F-doped Yttriumoxide were mixed with 360 g of Ammonium Zirconium Carbonate. After 74.1 hours the initial viscosity doubled.
Example 16
[0109] The production of the F-doped Yttria was carried out as described in Example 15. The heating rate of the calcination was 1.1° C./min up to a temperature of 1100° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0110] 1200 g of 1.9 wt % F-doped Yttriumoxide were mixed with 360 g of Ammonium Zirconium Carbonate. Due to the temperature treatment at 1100° C. relatively strong agglomerates were formed, in order to disperse the particles homogenously and to break down the agglomerates, powder and binder were mixed additionally to the agitator with an Ultra Turrax T25 (60 sec 17500 l/min and 20 sec 21500 l/min). In this case the initial viscosity is taken from the measurement at 4 hours after the beginning of the experiment. Due to the sample preparation the slurry viscosity at 1 hour was lower (temperature of the slurry was increased) than the arisen balanced viscosity after 4 hours (292 cSt). After 26.5 hours the viscosity has doubled.
Example 17
[0111] The production of the F-doped Yttria was carried out as described in Example 15. The heating rate of the calcination was 1.1° C./min up to a temperature of 900° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0112] 1200 g of 2.0 wt % F-doped Yttriumoxide were mixed with 360 g of Ammonium Zirconium Carbonate. Due to the temperature treatment at 900° C. relatively strong agglomerates were formed, in order to disperse the particles homogenously and to break down the agglomerates, powder and binder were mixed additionally to the agitator with an Ultra Turrax T25 (30 sec 17500 l/min and 10 sec 21500 l/min).
[0113] The slurry showed a lifetime of 26.9 hours.
Example 18
[0114] The production of the F-doped Yttria was carried out as described in Example 15. The heating rate of the calcinations was 1.1° C./min up to a temperature of 800° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0115] 1200 g of 1.9% F-doped Yttriumoxide were mixed with 360 g of Ammonium Zirconium Carbonate. Due to the temperature treatment at 800° C. agglomerates were formed, in order to disperse the particles homogenously and to break down the agglomerates, powder and binder were mixed additionally to the agitator with an Ultra Turrax T25 (30 sec 13500 l/min)
[0116] The slurry showed a lifetime of 33.4 hours.
Example 19
[0117] The production of the F-doped Yttria was carried out as described in Example 15. The heating rate was 1.1° C./min up to a temperature of 300° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0118] 1200 g of 2.0% F-doped Yttriumoxide were mixed with 360 g of Ammonium Zirconium Carbonate. The slurry showed a lifetime of 50.3 hours.
Example 20
[0119] 6.569 kg fused block material of Yttria were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; 20 kg 1.25″ grinding-balls (Yttria stabilized Zirconium Oxide—other milling parameters as described in Example 1). After the addition of 0.431 kg (=6.2 wt %) Yttrium fluoride YF 3 the powder mixture was milled for another 90 minutes. The milled product was sieved <63 μm and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 400° C., that was held for 4 hours.
Life Time Test (Method B)
[0120] 1200 g of 2.0% F-doped Yttriumoxide were mixed with 360 g of Ammonium Zirconium Carbonate. The slurry showed a lifetime of 35.7 hours.
Example 21
[0121] The production of the F-doped Yttria was carried out as described in Example 20. The heating rate of the calcination was 1.1° C./min up to a temperature of 1100° C., that was maintained for 2 hours.
Life Time Test (Method B)
[0122] 1200 g of 2.0% F-doped Yttriumoxide were mixed with 360 g of Ammonium Zirconium Carbonate. Due to the temperature treatment at 1100° C. relatively strong agglomerates were formed, in order to disperse the particles homogenously and to break down the agglomerates, powder and binder were mixed additionally to the agitator with an Ultra Turrax T25 (2 min 13500 l/min). After 17.1 hours the viscosity has doubled.
Example 22
[0123] The production of the F-doped Yttria was carried out as described in Example 20. The heating rate of the calcination was 1.1° C./min up to a temperature of 900° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0124] 1200 g of 1.9% F-doped Yttriumoxide were mixed with 360 g of Ammonium Zirconium Carbonate.
[0125] Due to the temperature treatment at 900° C. relatively strong agglomerates were formed, in order to disperse the particles homogenously and to break down the agglomerates, powder and binder were mixed additionally to the agitator with an Ultra Turrax T25 (30 sec 13500 l/min and 10 sec 17500 l/min).
[0126] The shiny showed a lifetime of 16.3 hours.
Example 23
[0127] The production of the F-doped Yttria was carried out as described in Example 20. The heating rate of the calcination was 1.1° C./min up to a temperature of 800° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0128] 1200 g of 1.9% F-doped Yttriumoxide were mixed with 360 g of Ammonium Zirconium Carbonate. Due to the temperature treatment at 800° C. agglomerates were formed, in order to disperse the particles homogenously and to break down the agglomerates, powder and binder were mixed additionally to the agitator with an Ultra Turrax T25 (30 sec 13500 l/min)
[0129] The slurry showed a lifetime of 26.1 hours.
Example 24
[0130] The production of the F-doped Yttria was carried out as described in Example 20. The heating rate of the calcination was 1.1° C./min up to a temperature of 300° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0131] 1200 g of 2.1% F-doped Yttriumoxide were mixed with 360 g of Ammonium Zirconium Carbonate. The viscosity doubled after 26.7 hours.
Example 25
[0132] 6.649 kg fused block material of Y/Al/Zr (95.88/0.12/4.0) were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; 20 kg 1.25″ grinding-balls (Yttria stabilized Zirconium Oxide—other milling parameters as described in Example 1). After the addition of 0.351 kg (=5.0 wt %) Lanthanum fluoride the powder mixture was milled for another 120 minutes. The milled product was sieved <63 μm and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 550° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0133] 1200 g of 1.3% F-doped Y/Al/Zr were mixed with 360 g of Ammonium Zirconium Carbonate. The slurry showed a lifetime of 47.0 hours.
Example 26
[0134] 6.570 kg fused block material of Y/Al/Zr (95.88/0.12/4.0) were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; 20 kg 1.25″ grinding-balls (Yttria stabilized Zirconium Oxide—other milling parameters as described in Example 1). After the addition of 0.430 kg (=6.1 wt %). Ytterbium fluoride the powder mixture was milled for another 120 minutes. The milled product was sieved <63 μm and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 550° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0135] 1200 g of 1.6% F-doped Y/Al/Zr were mixed with 360 g of Ammonium Zirconium Carbonate. The slurry showed a lifetime of 44.7 hours.
Example 27
[0136] 6.617 kg fused block material of Y/Al/Zr (50/25/25) were milled for 30 minutes in a ball mill (ZOZ GmbH TYP COMB 03-A03; milling parameters as described in Example 1). After the addition of 0.383 kg (=5.5 wt %) Zirconiumoxyfluoride Zr 7 O 8.79 F 9.71 the powder mixture was milled for another 120 minutes. The milled product was sieved <63 μm and then calcined (Nabertherm C250; 1.5 kg per Al 2 O 3 (0.9)-mullite(0.1)-crucible). The heating rate was 1.1° C./min up to a temperature of 400° C., that was maintained for 4 hours.
Life Time Test (Method B)
[0137] 1200 g of 1.7% F-doped Y/Al/Zr were mixed with 380 g of Ammonium Zirconium Carbonate. After a certain time the volume of the slurry was too small to realise Zahncup Nr. 5 measurements. Therefore Rheometer measurements (measuring gap=1 mm) were made. First every weekday, afterwards approximately every week one respectively two measurements were realised. No significant increase of the viscosity of the formulated slurry could be observed for 150 days. Afterwards the experiment was stopped.
[0138] The summary of the results is presented in Table 1.
BRIEF DESCRIPTION OF THE DRAWINGS
[0139] FIG. 1 shows the results of the slurry-lifetime-test (Method A) with Y/Al/Zr-Oxide in Ammonium Zirconium Carbonate and de-ionized water. (graph—time versus torque)
[0140] FIG. 2 —shows the results of the slurry-lifetime-test (Method A) with Y/Al/Zr-Oxide in Zirconium-Acetate and de-ionized water. (graph—time versus torque)
[0141] FIG. 3 shows the results of the slurry-lifetime-test (Method B) with Y/Al/Zr-Oxide in Ammonium Zirconium Carbonate. (graph—time versus cinematic viscosity respectively time versus dynamic viscosity)
[0142] FIG. 4 shows the results of the slurry-lifetime-test (Method B) with Y/Al/Zr-Oxide in Zirconium-Acetate. (graph—time versus cinematic viscosity respectively time versus dynamic viscosity)
[0143] FIG. 5 shows the results of the slurry-lifetime-test (Method B) with Yttria in Ammonium. Zirconium Carbonate. (graph—time versus cinematic viscosity respectively time versus dynamic viscosity)
[0144] FIG. 6 shows the results of the slurry-lifetime-test (Method A) with 0.8 wt % F-doped Y/Al/Zr-Oxide in Zirconium-Acetate and de-ionized water. (graph—time versus torque).
[0145] FIG. 7 shows the results of the slurry-lifetime-tests (Method A) in comparison of Y/Al/Zr-Oxide to 0.8 wt % F-doped Y/Al/Zr-Oxide in Ammonium Zirconium Carbonate and de-ionized water. (graph—time versus torque)
[0146] FIG. 8 shows the results of the slurry-lifetime-test (Method A) with 1.0 wt % F-doped Y/Al/Zr-Oxide in Ammonium Zirconium Carbonate and de-ionized water. (graph—time versus torque)
[0147] FIG. 9 shows the results of the slurry-lifetime-tests (Method A) in comparison of 1.9 wt % F-doped Yttria (Zirconium oxyfluoride) to 1.7 wt % F-doped Yttria (Lithium fluoride) in Ammonium Zirconium Carbonate. (graph—time versus torque)
[0148] FIG. 10 shows the results of the slurry-lifetime-test (Method B) with 1.0 wt % F-doped Y/Al/Zr-Oxide in Zirconium-Acetate. (graph—time versus cinematic viscosity)
[0149] FIG. 11 shows the results of the slurry-lifetime-test (Method B) with 1.1 wt % F-doped Y/Al/Zr-Oxide in Zirconium-Acetate. (graph—time versus cinematic viscosity)
[0150] FIG. 12 shows the results of the slurry-lifetime-test (Method B) with 2.4 wt % F-doped Y/Al/Zr-Oxide in Ammonium Zirconium Carbonate. (graph—time versus cinematic viscosity)
[0151] FIG. 13 shows the XRD-analysis of 2.4 wt % F-doped Y/Al/Zr-Oxide.
[0152] FIG. 14 is the TEM—picture of 2.4 wt % F-doped Y/Al/Zr-Oxide, where via electron energy loss spectroscopy a Fluorine-signal can be detected at the grain boundary area. 200 nm below the boundary area, there exists no Fluorine-peak.
[0153] FIG. 15 . is the Jump-ratio image (elemental maping of oxygen) of 2.4 wt % F-doped Y/Al/Zr-Oxide, where a 170 nm wide layer of YOF can be observed along the grain boundary.
[0154] FIG. 16 is the diffraction image of the inside of the grain of 2.4 wt % F-doped Y/Al/Zr-Oxide, where Y 2 O 3 can be verified.
[0155] FIG. 17 is the diffraction image of the boundary grain of 2.4 wt % F-doped Y/Al/Zr-Oxide, where YOF can be verified.
[0000]
TABLE 1
Summary of the results
heating
rate
calcination
dwell
Raw material
Dopant
Fluorine
[° C./
temperature
time
Test
binder
Ratio
Slurry
Example
flour
flour
[wt %]
min]
[° C.]
[h]
method
system
binder:flour(:H 2 O)
lifetime [h]
Comparative
Y/Al/Zr-Oxide
—
—
—
—
—
Method A
Ammonium
1:5.58:0.49
0.9
Example 1
(95.88/0.12/4)
Zirconium
Carbonate
Comparative
Y/Al/Zr-Oxide
—
—
—
—
—
Method A
Zirconium
1:5.58:0.49
0.7
Example 2
(95.88/0.12/4)
Acetate
1
Y/Al/Zr-Oxide
YF 3
0.8
5
550
6 h
Method A
Zirconium
1:5.58:0.49
41
(95.88/0.12/4)
50 min
Acetate
2
Y/Al/Zr-Oxide
YF 3
0.8
5
550
6 h
Method A
Ammonium
1:5.58:0.49
56
(95.88/0.12/4)
50 min
Zirconium
Carbonate
3
Y/Al/Zr-Oxide
Zirkonyl-
1.0
—
550
3
Method A
Ammonium
1:5.58:0.49
124
(95.88/0.12/4)
fluoride
Zirconium
Carbonate
4
Y/Al/Zr-Oxide
YF 3
0.9
5
540
8
Method A
Zirconium
1:4
66
(95.88/0.12/4)
Acetate
5
Y/Al/Zr-Oxide
ZrF 4
0.8
—
550
3
Method A
Ammonium
1:5.58:0.49
380
(95.88/0.12/4)
Zirconium
Carbonate
6
Y 2 O 3
Zr 7 O 8.79 F 9.71
1.9
—
400
4
Method A
Ammonium
1:3.3
>335
Zirconium
Carbonate
7
Y2O3
LiF
1.7
—
400
4
Method A
Ammonium
1:3.3
10
Zirconium
Carbonate
Comparative
Y/Al/Zr-Oxide
—
—
—
—
—
Method B
Ammonium
1:3.3
<3
Example 3
(95.88/0.12/4)
Zirconium
Carbonate
Comparative
Y/Al/Zr-Oxide
—
—
—
—
—
Method B
Zirconium
1:4
<35
min
Example 4
(95.88/0.12/4)
Acetate
Comparative
Y 2 O 3
—
—
—
—
—
Method B
Ammonium
1:3.3
<3
Example 5
Zirconium
Carbonate
8
Y/Al/Zr-Oxide
YF 3
1.0
1.1
550
8
Method B
Zirconium
1:4
72
(95.88/0.12/4)
Acetate
9
Y/Al/Zr-Oxide
Zr 7 O 8.79 F 9.71
1.1
1.1
450
4
Method B
Zirconium
1:4
After 171.5
(95.88/0.12/4)
Acetate
hours start-
η increased
by 85%
10
Y/Al/Zr-Oxide
Zr 7 O 8.79 F 9.71
2.2
1.1
650
13
Method B
Ammonium
1:3.3
28.7
(95.88/0.12/4)
Zirconium
Carbonate
11
Y/Al/Zr-Oxide
Zr 7 O 8.79 F 9.71
2.4
1.1
450
7
Method B
Ammonium
1:3.3
70.3
(95.88/0.12/4)
Zirconium
Carbonate
12
Y/Al/Zr-Oxide
Zr 7 O 8.79 F 9.71
1.7
1.1
400
4
Method B
Ammonium
1:3.6
44.9
(95.88/0.12/4)
Zirconium
Carbonate
13
Y/Al/Zr-Oxide
Zr 7 O 8.79 F 9.71
0.1
1.1
400
4
Method B
Ammonium
1:3.3
21.6
(95.88/0.12/4)
Zirconium
Carbonate
14
Y/Al/Zr-Oxide
Zr 7 O 8.79 F 9.71
6.9
1.1
400
4
Method B
Ammonium
1:2.7
>110
days
(95.88/0.12/4)
Zirconium
Carbonate
15
Y 2 O 3
Zr 7 O 8.79 F 9.71
1.9
1.1
400
4
Method B
Ammonium
1:3.3
74.1
Zirconium
Carbonate
16
Y 2 O 3
Zr 7 O 8.79 F 9.71
1.9
1.1
1100
4
Method B
Ammonium
1:3.3
26.5
Zirconium
Carbonate
17
Y 2 O 3
Zr 7 O 8.79 F 9.71
2.0
1.1
900
4
Method B
Ammonium
1:3.3
26.9
Zirconium
Carbonate
18
Y 2 O 3
Zr 7 O 8.79 F 9.71
1.9
1.1
800
4
Method B
Ammonium
1:3.3
33.4
Zirconium
Carbonate
19
Y 2 O 3
Zr 7 O 8.79 F 9.71
2.0
1.1
300
4
Method B
Ammonium
1:3.3
50.3
Zirconium
Carbonate
20
Y 2 O 3
YF 3
2.0
1.1
400
4
Method B
Ammonium
1:3.3
35.7
Zirconium
Carbonate
21
Y 2 O 3
YF 3
2.0
1.1
1100
2
Method B
Ammonium
1:3.3
17.1
Zirconium
Carbonate
22
Y 2 O 3
YF 3
1.9
1.1
900
4
Method B
Ammonium
1:3.3
16.3
Zirconium
Carbonate
23
Y 2 O 3
YF 3
1.9
1.1
800
4
Method B
Ammonium
1:3.3
26.1
Zirconium
Carbonate
24
Y 2 O 3
YF 3
2.1
1.1
300
4
Method B
Ammonium
1:3.3
26.7
Zirconium
Carbonate
25
Y/Al/Zr-Oxide
LaF 3
1.3
1.1
550
4
Method B
Ammonium
1:3.3
47.0
(95.88/0.12/4)
Zirconium
Carbonate
26
Y/Al/Zr-Oxide
YbF 3
1.6
1.1
550
4
Method B
Ammonium
1:3.3
44.7
(95.88/0.12/4)
Zirconium
Carbonate
27
Y/Al/Zr-Oxide
Zr 7 O 8.79 F 9.71
1.7
1.1
400
4
Method B
Ammonium
1:3.2
>150
days
(50/25/25)
Zirconium
Carbonate | Method for producing a mold for use in casting reactive metals comprising preparing a slurry of a yttria-based refractory composition and a binder, and using said slurry as a mold facecoat by applying said slurry onto a surface of a mold pattern, wherein said yttria-based refractory composition is obtainable by (a) mixing particles of a yttria-based ceramic material and a fluorine containing dopant, and (b) heating the resulting mixture to effect fluorine-doping of said yttria-based ceramic material. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a capacitor discharge type ignition system for an internal combustion engine, and more particularly an ignition system with overrun prevention capability to prevent the overrun of the engine by retarding an ignition timing.
2. Description of the Prior Art
An ignition system having an ignition angle retarding circuit to prevent the overrun of the engine has been known by, for example, Japanese Published Unexamined Patent Application No. 55-5451. In the known ignition system, an auxiliary capacitor is charged in parallel with the charging of a main capacitor (or a charging capacitor) and discharged through a discharging circuit connected to a base of a switching transistor which is connected in parallel with a gate-cathode circuit of a main thyristor (or an ignition control thyristor) so that the switching transistor is rendered conductive for only a predetermined time period. When an ignition signal overlaps with the predetermined conduction time period of the switching transistor as the rotational speed of a reverse electromotive force of a generator coil serving as the ignition signal, the ignition timing is delayed by the overlapped period. In this case, it is important to maintain the constant conduction period independently of the rotational speed of the engine. To this end, design and manufacture approaches to keep constant a peak value of the charge voltage of the auxiliary capacitor, a capacitance of the auxiliary capacitor and a resistance of the discharging path for the auxiliary capacitor have been devised but they have not been satisfactory.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an ignition system which is an improvement over the prior art ignition system with overrun prevention capability, is less affected by variance in performance of a magneto and other components which are mass-produced, is free from variation of an engine rotational speed at which the retardation of the ignition timing begins and provides a sufficient amount of retardation angle.
In accordance with the present invention, in order to assure that the angle retardation always begins at the predetermined engine rotational speed in an overrunning region independently of the variance of performance of the components, the conduction period of the switching transistor of the switching circuit which prevents the ignition signal from being applied to the gate-cathode circuit of the main thyristor always pertains for a constant time interval from a predetermined reference time point independently of the rotational speed of the engine. To this end, a control circuit for controlling the conduction period of the switching transistor comprises an integration circuit which is fed from a constant voltage supply which is established by a constant voltage circuit including a Zener diode to produce an output voltage which increases with time in accordance with the applied constant voltage, and a pair of transistors which compares the output voltage of the integration circuit with a voltage of a voltage divider which produces a constant voltage determined by the applied constant voltage so that each of the transistors conducts during a time period in which one of the voltages is larger than the other. Since both the output voltages of the integration circuit and the voltage divider are proportional to the applied constant voltage, the affect by the variation of the applied constant voltage due to the variance in the absolute value of the Zener voltage of the Zener diode is eliminated. The bases of the pair of transistors are connected to the output terminals of the integration circuit and the voltage divider, respectively, which are parallel to the constant voltage circuit, and the transistors are connected in parallel with the constant voltage circuit through a common emitter resistor and separate collector resistors. The transistor having its base connected to the output terminal of the voltage divider is first turned on, and as the output voltage of the integration circuit exceeds the output voltage of the voltage divider after a certain time period, the other transistor is turned on to flip the on-off condition. In response thereto, the switching transistor of the switching circuit conducts upon the turn-on of the one transistor of the control circuit and the conduction period terminates upon the turn-on of the other transistor. The conduction period is therefore constant independently of the rotational speed of the engine. The ignition signal to trigger the main thyristor is a backward component of an electromotive force generated by the generator coil of the magneto. It is generated in synchronism with the rotation of the engine. In a normal rotation region of the engine, it is generated after the termination of the conduction period of the switching circuit, but in an overrunning region the period of the ignition signal is shorted so that a leading edge of the ignition signal overlaps a trailing edge of the conduction period of the switching circuit. The overlapped portion of the ignition signal is not applied to the gate-cathode circuit of the main thyristor. Accordingly, the ignition timing is lagged by the time interval or crank angle corresponding to the overlapped period so that the engine output is reduced and the rotational speed is reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a circuit diagram of a first embodiment of the present invention.
FIGS. 2 and 3 show signal waveforms at various points for explaining the operation of the first embodiment.
FIG. 4 shows a circuit diagram of a second embodiment.
FIG. 5 shows a circuit diagram of a third embodiment.
FIG. 6 shows signal waveforms at various points for explaining the operation of the third embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be explained with reference to the accompanying drawings. FIG. 1 shows a first embodiment which is similar to a conventional capacitor discharge type ignition system except circuit sections A, B and C (to be described later). It includes a magneto 1, 2, 3, a main capacitor 33, a main thyristor 31 and an ignition coil 34, 35, 36. The magneto comprises a rotor 1, a core 2 and a generator coil 3. The main capacitor 33 is charged by a forward electromotive force generated by the generator coil 3 and a backward electromotive force is used as an ignition signal source to trigger the main thyristor 31. A charge in the main capacitor 33 is discharged through the main thyristor 31 and the primary winding 34 of the ignition coil to induce a high voltage in the secondary winding 36.
A circuit section for preventing the overrun comprises a constant voltage circuit A for supplying a constant voltage source for the operation of the circuit section, a control circuit B for generating a control signal to render the switching transistor conductive for a predetermined time period from a preset time point, and a switching circuit C which conducts only for a predetermined time period independently of the rotational speed of the engine to bypass the portion of the ignition signal which overlaps the conduction period in order to prevent the overlapped portion from being applied to the gate-cathode circuit of the main thyristor. The constant voltage circuit A comprises an auxiliary capacitor 10 which is charged parallelly with the main capacitor 33 and a Zener diode 12 connected in parallel therewith through a resistor 11. A constant voltage is produced across the Zener diode 12. The control circuit B comprises an integration circuit including a resistor 13 and a capacitor 15 and a voltage divider including a pair of resistors 16 and 21, connected in parallel with the Zener diode 12, respectively, and a pair of transistors 17 and 18. Bases of the transistors 17 and 18 are connected to output terminals P and Q of the integration circuit and the voltage divider, respectively, and emitters of the transistors 17 and 18 are connected to a common resistor 19. One of the voltages appearing at the output terminals P and Q increases with time while the other is a constant reference voltage. Both voltages are proportional to the constant voltage applied from the constant voltage circuit. Since those voltages are compared with each other, any variance in the absolute value of the Zener voltage of the Zener diode 12 is permissible. The transistor 18 is turned on while the voltage at the terminal Q of the voltage divider is larger than the voltage at the terminal P of the integration circuit, and the transistor 17 is turned on and the transistor 18 is turned off when the voltage at the terminal P of the integration circuit is larger. The switching circuit C includes a switching transistor 26 connected to a gate circuit of the main thyristor 31 and a transistor 23 for driving the switching transistor 26. When the transistor 18 of the control circuit B is on, the switching transistor 26 is turned on through the driving transistor 23, and when the transistor 17 is turned on the switching transistor 26 is turned off.
Referring to FIGS. 1 and 2, the operation is now explained. The rotor 1 of the magneto has two or three pole pieces, N, S, N as is conventional so that a forward electromotive force (or voltage) V 1 is generated in the generator coil 3 and backward electromotive forces (or voltages) V 2 and V 3 are generated before and after V 1 in each cycle of the engine rotation, as shown in (A) in FIG. 2. The backward electromotive force V 2 which is generated immediately before the forward electromotive force V 1 is used as the ignition signal source of the main thyristor 31. The main capacitor 33 is charged by the forward electromotive force V 1 through the diode 8 while the auxiliary capacitor 10 of the constant voltage circuit A is charged through the diode 7 which branches from the anode of the diode 8. The charge stored in the auxiliary capacitor 10 discharges through the resistor 11 and the Zener diode 12 so that a constant voltage is developed across the Zener diode 12. In the integration circuit 13, 15 to which the constant voltage (Zener voltage) is applied, the capacitor 15 is charged through the resistor 13 with a predetermined time constant so that the voltage at the output terminal P or the base voltage of the transistor 17 rises gradually. On the other hand, the voltage at the output terminal Q of the voltage divider 16, 21 or the base voltage of the transistor 18 is fixed to a constant voltage which is deviced by dividing the Zener voltage of the Zener diode 12 by the resistors 16 and 21.
First, the voltage at the terminal P is higher than that at the terminal Q and a current flows in the base of the transistor 18 to turn it on. As a result the transistor 17 is turned off and no current flows in the base. As the transistor 18 conducts, a current flows through the resistor 20 connected to the collector to produce a potential difference across the resistor 20. Since the base of the driving transistor (PNP) 23 is connected to the junction of the collector of the transistor 18 and the resistor 20 through the resistor 22 and the emitter is connected to the other terminal of the resistor 20, a current flows into the base of the transistor 23 due to the potential difference across the resistor 20 to turn on the transistor 23. A current flows through the emitter-collector circuit of the transistor 23 and the resistors 24 and 25 connected in series therewith and a current flows into the base of the switching transistor 26 having its base connected to the junction of the resistors 24 and 25, through the transistor 23 and the resistor 24 to turn on the transistor 26.
The backward electromotive force of the generator coil 3 which serves as the ignition signal to trigger the main thyristor 31 flows into the gate-cathode circuit of the main thyristor 31 through the diode 27, the resistor 28 and the diode 29 which are connected between the generator coil 3 and the gate of the main thyristor 31. Since the collector emitter circuit of the switching transistor 26 is connected to the junction of the resistor 28 and the diode 27 and the cathode of the main thyristor 31, if the switching transistor 26 is on at the time when the ignition signal is applied, the ignition signal is bypassed through the resistor 28 and the collector-emitter circuit of the switching transistor 26 so that it returns to the generator coil 3 through the resistor 5 and the diode 4. As a result, the ignition signal is prevented from being applied to the gate-cathode circuit of the main thyristor 31 and hence the main thyristor 31 is not triggered.
As the capacitor 15 of the integration circuit is charged up to raise the voltage at the terminal P so that it exceeds the voltage at the terminal Q of the voltage divider, a current flows into the base of the transistor 17 to turn it on and turn off the transistor 18. Since the base of the transistor 18 is directly connected to the collector of the transistor 17 and the resistor 16 of the voltage divider is connected between the collector of the transistor 17 and the cathode of the Zener diode 12, the base voltage of the transistor 18 further drops when the transistor 17 is turned on and a current flows through the resistor 16 to insure positive flipping of the on and off conditions of the transistors 17 and 18. As the transistor 18 is turned off, the potential difference across the resistor 20 disappears so that no base current flows in the driving transistor 23 resulting in the turn-off of the transistor 23. As the transistor 23 is turned off, no base current flows in the switching transistor 26 and the conduction of the transistor 26 is terminated.
FIG. 2 in (B) shows a waveform of the base-emitter voltage of the switching transistor 26 to illustrate the conduction period of the transistor 26. A period T o of the conduction period indicates a time period from the start of the discharge current from the auxiliary capacitor 10 to the resistor 25 connected between the base and the emitter of the switching transistor 26 through the transistor 23 and the resistor 24 as a result of the turn-on of the transistor 18 and the resulting turn-on the transistor 23, to the time when the forward electromotive force v 1 shown in (A) in FIG. 2 reaches the peak value (which substantially corresponds to the time when the charging of the main capacitor 33 completes). This time period T o varies with the rotational speed of the engine. However, a time period T following to the time period T o is a fixed period which is independent from the rotational speed of the engine, as described above.
When the rotational speed of the engine is in a normal rotational speed region, the first backward electromotive force v 2 in the next sequential cycle which serves as the ignition signal is generated after the termination of the conduction period (T o +T) of the switching transistor 26 as shown in (A) and (B) in FIG. 2. Accordingly, the backward electromotive force v 2 is applied to the gate-cathode circuit of the main thyristor 31, and when it reaches a trigger voltage Vth the main thyristor 31 is triggered so that a high secondary voltage as shown in (C) in FIG. 2 is induced in the secondary winding 36 of the ignition coil. As the main thyristor 31 conducts, the charge in the auxiliary capacitor 10 of the constant voltage circuit A is discharged through the diode 9 and the main thyristor 31 to be ready for the charging in the next cycle.
As the rotational speed of the engine increases beyond the normal rotational speed region, a period Pe of the electromotive force generated in the generator coil 3 is gradually shortened. In an overrunning region, a trailing edge of the conduction period of the switching transistor 26 overlaps a leading edge of the backward electromotive force V 2 of the next cycle which serves as the ignition signal source, as shown in (A) and (B) in FIG. 3 (because the conduction period T is constant independently of the rotational speed). Since the ignition signal is not applied to the gate-cathode of the main thyristor 31 during the overlapping period α but applied after the termination of the overlapping period, the ignition timing is delayed or retarded by the overlapping period α. It should be noted that an effective duration of the ignition signal (a duration during which V 2 is larger than the trigger voltage Vth) must be longer than the desired retardation angle α.
FIG. 4 shows a circuit diagram of a second embodiment. It differs from the first embodiment of FIG. 1 only in a constant voltage circuit A' of the control circuit. In the present embodiment, no separate auxiliary capacitor 10 in FIG. 1 is provided but the main capacitor 33 carries out the function of the auxiliary capacitor 10 in FIG. 1. A portion of charge stored in the main capacitor 33 is discharged through the resistor 11 and the Zener diode 12 so that a constant voltage is developed across the Zener diode 12 as is done in FIG. 1. Because the auxiliary capacitor 10 is eliminated, the diodes 7 and 9 (FIG. 1) which form the charging and discharging paths of the auxiliary capacitor 10 are not necessary. In the present embodiment, when the rotational speed of the engine is low and the electromotive force of the magneto has a sufficient margin, a simpler circuit than that of FIG. 1 may be used to attain the same effect.
FIG. 5 shows a circuit diagram of a third embodiment which attains a larger retardation rate than that of the first embodiment shown in FIG. 1. It differs from FIG. 1 in that the diode 9 which forms the discharging path for discharging the charge in the auxiliary capacitor 10 of the constant voltage circuit A of the control circuit (A, B, C) when the main thyristor 31 conducts is eliminated, and the cathode of the diode 14 which forms the discharging path of the capacitor 15 of the integration circuit B' is connected to a cathode of a diode 57 which is connected in series with the main thyristor 31 between the main thyristor 31 and the main capacitor 33. As a result, the charge in the auxiliary capacitor 10 of the constant voltage circuit A" is not discharged when the main thyristor 31 conducts but remains until the next cycle. As a result, when the charge in the capacitor 15 of the integration circuit B' discharges through the diode 14 and the main thyristor 31 by the conduction of the main thyristor 31 and then the ignition operation completes and the main thyristor 31 is turned off, the auxiliary capacitor 10 immediately starts to charge up the capacitor 15. Since the voltage at the terminal Q of the voltage divider also remains unchanged, the ignition prevention signal (i.e. the conduction of the switching transistor 26) starts to rise simultaneously. The diode 57 functions to prevent the current to flow into the capacitor 15 through the resistor 13 from flowing into the main capacitor 33.
Referring to FIG. 6, the manner of the retardation of the ignition angle is explained. In the normal rotational speed of the engine, the operation is the same as that of the first embodiment shown in FIG. 1, but when the rotational speed of the engine reaches the overrunning region or exceeds the predetermined retardation starting rotational speed, the period of the electromotive force generated in the generator coil 3 is shortened so that the electromotive force assumes a broken line waveform shown in (A) in FIG. 6. (A solid line shows a position in the normal rotational speed). FIG. 6 in (B) shows the conduction period T' of the switching transistor 26. The time period T' is constant independently of the rotational speed of the engine and starts immediately after the conduction period of the main thyristor 31 or the ignition operation. In a first cycle, the ignition angle is retarded by a period θ during which the trailing edge of the constant conduction period T' of the switching transistor 26 shown in (B) in FIG. 6 overlaps the leading edge of the ignition signal (the electromotive force V 2 ' shown in (A) in FIG. 6 is shown in (C) in FIG. 6 with its phase reversed) and the high voltage is induced in the secondary winding 36 of the ignition coil as shown in (D) in FIG. 6 to carry out the ignition operation. The angle retardation in a second cycle is 2θ because the constant conduction period T' in the second cycle starts after the angle retardation of θ in the previous cycle as shown in (E) in FIG. 6. (Strictly speaking, the conduction period of the main thyristor 31 exists after the angle retardation of θ but it may be neglected because it is shorter than the period T'.) In third and fourth cycles, an angle of θ is retarded, respectively, in addition to the angle retardation in the previous cycle so that the angle is retarded by 3θ and 4θ, respectively. In this manner, as the engine cycle is repeated, the retardation rate increases and is more rapidly accelerated. As a result, the rise of the engine rotational speed is prevented at a rotational speed which is very close to the retardation start rotational speed. In this case, however, it is necessary that the effective duration of the ignition signal V 2 ' (that is, the time period during which the signal is larger than the threshold value Vth) be sufficiently long.
As described hereinabove, according to the present invention, since the angle retardation starts as soon as the engine rotational speed reaches the predetermined rotational speed (retardation-start-rotational-speed) independently of the variance in the performance of the mass-produced components to prevent the engine rotational speed from entering the overrunning region, the constant conduction period of the switching transistor 26 does not vary. The factors which relate to the stability of the constant conduction period are the variance in the charge voltage of the auxiliary capacitor 10, that is, the variances in the magnetic force of the rotor 1 of the magneto, a gap between the rotor 1 and the core 2 and the characteristic of the generator coil 3, and the variance in the capacitance of the auxiliary capacitor 10. Another factor is the exact and positive control of the on-off timing of the driving transistor 23 for the switching transistor 26. For those factors, in accordance with the present invention, the constant voltage circuit including the Zener diode 12 is used and the pair of transistors 17 and 18 which are complementarily turned on and off and the integration circuit and the voltage divider for controlling the transistors are used in order to compensate for the variance in the characteristic of the Zener diode 12 and control the turn-on and turn-off of the switching transistor 26 and control the driving transistor 23. Accordingly, the stable, retardation-start-rotational-speed is obtained without the affect of the electromotive force of the magneto and independently of the variance in the characteristics of the components. | An ignition system of the capacitor discharge type and capable of preventing overrunning of an internal combustion engine includes a control circuit to render a switching transistor connected to a gate-cathode circuit of a main thyristor conductive for a predetermined period of time to interrupt a backward or reverse phase voltage generated by a magneto and serving as an ignition signal for the main thyristor from being applied thereto. The control circuit includes an integrator circuit connected in parallel with a constant voltage source to develop a voltage increasing with time and includes a voltage divider of the constant voltage source to provide a reference voltage. A transistor circuit of the control circuit compares the output voltage of the integrator circuit and the output voltage of the voltage divider and the transistor circuit maintains a control signal to be applied to the transistor circuit until the output of the integrator circuit reaches the reference voltage of the divider. The period of time during which the control signal is applied to the switching circuit to maintain the switching circuit being conductive is precisely constant irrespective of a variation in rotational speed of the engine. When the rotational speed of the engine increases and exceeds a normal rotational speed region, the occurrence of the ignition signal or the backward voltage of the magneto becomes early to cause the leading portion of the ignition signal to overlap with the end portion of the predetermined period of time resulting in retardation of the ignition timing and preventing overrunning of the engine. | 5 |
FIELD OF INVENTION
The present invention relates generally to the counters utilized with a Medium Access Controller (MAC) in a Repeater for attribute storage and more particularly to the architecture of such counters within the Repeater.
BACKGROUND OF THE INVENTION
In traditional Ethernet (802.3 10BASE5) and Cheapernet (802.3 10BASE2) a coaxial cable provides the linear bus to which all nodes are connected. Signalling is accomplished using a current synch technique with a center conductor used for the signal and a shield used as a ground reference. Twisted pair Ethernet (802.3 10BASE-T) utilizes standard voice grade telephone cable, employing separate transmit and receive pairs. The system uses a star topology. At the center of a star is a repeater. The repeater performs signal amplitude and timing restoration. It takes the incoming bitstream and repeats it to all the ports connected to it. In this sense the repeater acts as a logical coaxial cable so that any node connected to the network will see another node's transmission. Differential signalling is employed with one pair acting as the transmit path and the other pair acting as the receive path.
While repeaters are used in traditionally wired coaxial Ethernet as a means to extend the networks physical distance limit, in the IEEE 802.3 10BASE-T, the Standard mandates the use of a repeater to actually provide the connectivity function if more than two nodes are required. Although the physical signalling on the cabling differs, the functionality of the repeater is identical in either coaxial or twisted pair networks as is the frame or packet format that is used to pass messages between the participating nodes on the network.
The drawing of FIG. 1 shows a representative ethernet packet. Each packet comprises a series of 8-bit bytes of digital information. Each packet is preceded by a seven byte preamble composed of alternating 1s and 0s. The preamble is followed by a one byte long start frame delimiter (SFD) which presents the following eight bit sequence: 10101011. After the SFD, follows a packet that can vary in length from 64 to 1518 bytes. In particular, six bytes (48 bits) of destination address immediately follow the preamble. The destination address designates the intended destination of the packet. After the destination address, follow six bytes of source address which designate the source of the packet. After that, there are two bytes that designate the packet length. Then follow between 46 and 1500 bytes of data. Finally, there are four bytes which constitute the frame checking sequence (FCS) for checking errors.
Since all packets that are transmitted between stations must pass through repeaters, the repeater is the ideal place in which to gather network statistics. These statistics are called attributes.
A media access controller which disassemble the packet performs address checking, error detection, etc. placed within the repeater will allow network statistics to be gathered at the repeater.
The IEEE repeater management standard 802.3K requires attributes related to the packet to be stored in 32 bit counters. The gathering and storing of these attributes can be implemented in hardware or software. A software implementation processor would require significant processor overhead in the operation of the repeater. Hence, for efficiency reasons it is important to implement the statistic gathering and storing in hardware. However, to implement all the attributes as 32 bit counters would not be cost effective because the counters would occupy a significant amount of silicon.
Hence, what is needed is a system for implementing the 32 bit counter to store attributes that is a cost effective solution in accordance with the standard. What is also needed are counters for storing attributes that occupy a minimum amount of space on an integrated circuit. Finally, what is needed are 32 bit counters that are in conformance with the IEEE 802.3K standard. The present invention meets these needs.
SUMMARY OF THE INVENTION
The present invention, through the separation of the storage section from the incrementor, provides a plurality of counters that occupy significantly less space. In placing all the storage cells together allows for a dense implementation of the memory as in a RAM. The number of incrementors required is determined by the number of attributes that must be incremented for any given period of time. Hence, if only one attribute is incremented at a time, only one incrementor is required, if two at a time, then two incrementors are required and so on. Hence multiple 32 bit counters are not required.
This system provides for a cost effective approach for implementing the 32 bit counters required for attribute storage. In addition, it utilizes significantly less silicon area than by having individual 32 bit counters and does not have the overhead constraints of implementing the counters in software.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a representative 802.3 packet;
FIG. 2 is a block diagram of preferred embodiment of the counter in accordance with the present invention.
DETAILED DESCRIPTION
The present invention relates to counters for use with a Media Access Controller (MAC) within a repeater in a local area network. 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 preferred embodiment will be readily apparent to those skilled in the art. Accordingly, the present invention should only be limited by the genetic principles and features described herein.
A counter implies a storage section and an incrementor section. In the present invention, rather than combining the storage and incrementor sections together to form individual counters, all the storage is combined together and separated from the incrementor. The advantage of partitioning the counters in such a way is that all the counters occupy less space. Placing all the storage together allows for a dense implementation of the storage cells. In this design, the storage cells are implemented as RAM. In addition, if there is no need to increment multiple attributes at the same time only one incrementor is needed to service all the storage cells further reducing the area needed to implement the counters.
Finally, it should be understood by one of ordinary skill in the art that this architecture can be extended by replacing the incrementor with any other complex functions to form complicated "counters".
Referring now to FIG. 2, the counter 8 comprises RAM 12 which is coupled to a latch 14 which in turn is coupled to incrementor 18. The latch 14 also provides data to four tristate buffers 22, 24, 26 and 28 which are in turn coupled to an internal bus 30. The incrementor 18 is coupled to multiplexer 20 which also receives signals from internal bus 30. The multiplexer is also coupled to latch 16 which in turn is coupled to RAM 12.
A media access controller (MAC) 10 responsive to appropriate signals on an expansion port which comprises packet data controls RAM 12 via line 34, MAC 10 also is coupled to the internal bus 30.
In this embodiment, latches 14 and 16 are 32 bit latches, and the incrementor 18 is a 32 bit incrementor. It should be understood however by one of ordinary skill in the art that these devices can be of various sizes and there use would be within the spirit and scope of the present invention. To more fully understand the present invention refer now to the following discussion in conjunction with FIG. 2.
MAC 10 controls RAM 12 and RAM 12 is a 32×64 bit memory in this implementation. When a packet is received, MAC 10 extracts information from packet and determines which attributes should be updated. Once the MAC 10 determines which attributes to increment it reads the attribute value from the RAM 12 and places the value into a latch 14. The value in latch 14 is then sent to a 32 bit incrementor 18. The result of the incrementor 18 is stored in a second 32 bit latch 16. The value in the second latch 16 is written back into the RAM 12. Note that the incremented values do not have to be written back into the same RAM location, although they usually are. (The RAM locations must be on the same RAM however.) The operation requires 2 clock cycles--1 to read, 1 to write. The read/write cycle is repeated until all the attributes that need to be updated are updated. Note that the path that the data flows is through the incrementor 18 and not through the internal bus.
For most attributes, the attribute value is incremented by one for each update. There are three (3) other types of attributes. Two are the octet and total octet attribute which may be incremented by more than 1 per update. The other is the source address (SA) attribute. The old SA attribute is replaced by the new SA attribute.
The octet attribute requires that the counter increment by more than 1 per update, one might think an adder is needed to update the octet attribute. However, the octet attribute counts the number of bytes in a frame, and the total octet attribute counts the number of bytes in a packet. Since it takes 8 bit times for a byte to arrive and it takes only 2 bit times to increment an attribute (or 2×2=4 bit times to increment both attributes) the octet count can be incremented as the bytes are arriving. However, since the octet attributes are updated only when certain conditions occur, the previous octet count can not be overwritten until it is determined that the new octet count should be written.
With this architecture, the value from one RAM location can be transferred into another RAM location via the incrementor (same RAM). So in order to update the octet and total octet attributes the value is transferred into a temporary register in the RAM, the temporary register increments once per 8 bit times, and the data is transferred back into the original location when it is determined that the octet attribute should be updated. Note that any transfer whether to different locations or the same location would cause the value to increment by 1. Note that the final transfer from the temporary location back into the original location will add 1 too many to the final octet count. To compensate for this, the transfer into the temporary register should occur on the 16th bit of the frame or packet and not on the 8th bit. (i.e. the first byte is not counted because it will be compensated for by the final transfer.)
Source Address
The source address can be transferred between the RAM 12 and the MAC 10 via the internal bus (IBUS). The transfer occurs 8 bits at a time via internal bus 30. The source address always passes through the 32 bit latch 16 via multiplexer 20 in order to allow 8 bit accesses.
Through this architecture, counters can be implemented efficiently while maintaining compatibility with the IEEE standards. In addition, this improved counter is a cost effective solution to counters utilized to store attributes for repeater management.
Although the present invention has been described in accordance with the embodiments shown in the figures, one of ordinary skill in the art recognizes there could be variations to the embodiments and those variations would be within the spirit and scope of the present invention. Accordingly, many modifications may be made by one of ordinary skills in the art without departing from the spirit and scope of present invention, the scope of which is defined solely by the appended claims. | A counter for attribute stored in an Ethernet system is partitioned such that the storage section is separated from the incrementors section. In so doing, counters are implemented in a significantly less space than if the counters were implemented as individual counters. The counter utilizes random access memory as the storage section and a 32 bit incrementor. As the incrementor section along with a pair of latches to implement the counter. | 7 |
FIELD OF THE INVENTION
The present invention is related to U.S. provisional applications Ser. Nos. 60/047,177, filed May 20, 1997, 60/033,579, filed Dec. 19, 1996, and 60/025,123, filed Aug. 29, 1996, the contents of which are hereby incorporated by reference.
The present invention provides novel compounds and derivatives thereof, their synthesis, and their use as vitronectin receptor ligands. More particularly, the compounds of the present invention are αvβ3 antagonists, (αvβ5 antagonists or dual αvβ3/αvβ5 antagonists useful for inhibiting bone resorption, treating and preventing osteoporosis, and inhibiting vascular restenosis, diabetic retinopathy, macular degeneration, angiogenesis, atherosclerosis, inflammation and tumor growth.
BACKGROUND OF THE INVENTION
This invention relates to compounds for inhibiting bone resorption that is mediated by the action of a class of cells known as osteoclasts.
Osteoclasts are multinucleated cells of up to 400 μm in diameter that resorb mineralized tissue, chiefly calcium carbonate and calcium phosphate, in vertebrates. They are actively motile cells that migrate along the surface of bone. They can bind to bone, secrete necessary acids and proteases and thereby cause the actual resorption of mineralized tissue from the bone.
More specifically, osteoclasts are believed to exist in at least two physiological states. In the secretory state, osteoclasts are flat, attach to the bone matrix via a tight attachment zone (sealing zone), become highly polarized, form a ruffled border, and secrete lysosomal enzymes and protons to resorb bone. The adhesion of osteoclasts to bone surfaces is an important initial step in bone resorption. In the migratory or motile state, the osteoclasts migrate across bone matrix and do not take part in resorption until they attach again to bone.
Integrins are transmembrane, heterodimeric, glycoproteins which interact with extracellular matrix and are involved in osteoclast attachment, activation and migration. The most abundant integrin in osteoclasts (rat, chicken, mouse and human) is the vitronectin receptor, or αvβ3, thought to interact in bone with matrix proteins that contain the RGD sequence. Antibodies to αvβ3 block bone resorption in vitro indicating that this integrin plays a key role in the resorptive process. There is increasing evidence to suggest that αvβ3 ligands can be used effectively to inhibit osteoclast mediated bone resoption in vivo in mammals.
The current major bone diseases of public concern are osteoporosis, hypercalcemia of malignancy, osteopenia due to bone metastases, periodontal disease, hyperparathyroidism, periarticular erosions in rheumatoid arthritis, Paget's disease, immobilization-induced osteopenia, and glucocorticoid treatment.
All these conditions are characterized by bone loss, resulting from an imbalance between bone resorption (breakdown) and bone formation, which continues throughout life at the rate of about 14% per year on the average. However, the rate of bone turnover differs from site to site, for example, it is higher in the trabecular bone of the vertebrae and the alveolar bone in the jaws than in the cortices of the long bones. The potential for bone loss is directly related to turnover and can amount to over 5% per year in vertebrae immediately following menopause, a condition which leads to increased fracture risk.
There are currently 20 million people with detectable fractures of the vertebrae due to osteoporosis in the United States. In addition, there are 250,000 hip fractures per year attributed to osteoporosis. This clinical situation is associated with a 12% mortality rate within the first two years, while 30% of the patients require nursing home care after the fracture.
Individuals suffering from all the conditions listed above would benefit from treatment with agents which inhibit bone resorption.
Additionally, αvβ3 ligands have been found to be useful in treating and/or inhibiting restenosis (recurrence of stenosis after corrective surgery on the heart valve), atherosclerosis, diabetic retinopathy, macular degeneration and angiogenesis (formation of new blood vessels). Moreover, it has been postulated that the growth of tumors depends on an adequate blood supply, which in turn is dependent on the growth of new vessels into the tumor; thus, inhibition of angiogenesis can cause tumor regression in animal models. (See, Harrison's Principles of Internal Medicine, 12th ed., 1991). αvβ3 antagonists, which inhibit angiogenesis, are therefore useful in the treatment of cancer for inhibiting tumor growth. (See e.g., Brooks et al., Cell, 79:1157-1164 (1994)).
Moreover, compounds of this invention can also inhibit neovascularization by acting as antagonists of the integrin receptor αvβ5. A monoclonal antibody for αvβ5 has been shown to inhibit VEGF-induced angiogenesis in rabbit cornea and the chick chorioallantoic membrane model; M. C. Friedlander, et.al., Science 270, 1500-1502, 1995. Thus, compounds that antagonize αvβ5 are useful for treating and preventing macular degeneration, diabetic retinopathy, and tumor growth.
In addition, certain compounds of this invention antagonize both the αvβ3 and αvβ5 receptors. These compounds, referred to as "dual αvβ3/αvβ5 antagonists," are useful for inhibiting bone resorption, treating and preventing osteoporosis, and inhibiting vascular restenosis, diabetic retinopathy, macular degeneration, angiogenesis, atherosclerosis, inflammation and tumor growth.
It is an object of the present invention to identify compounds which bind to the αvβ3 receptor, αvβ5 receptor or both the αvβ3 and αvβ5 receptors.
It is a further object of the invention to identify compounds which act as antagonists of the αvβ3 receptor. It is another object of the invention to identify αvβ3 antagonist compounds which are useful agents for inhibiting: bone resorption mediated by osteoclast cells, restenosis, atherosclerosis, inflammation, diabetic retinopathy, macular degeneration and angiogenesis in animals, preferably mammals, especially humans. Still another object of the invention is to identify αvβ3 antagonists which cause tumor regression and/or inhibit tumor growth in animals.
A further object of the invention is to identify αvβ3 antagonists useful for preventing or treating osteoporosis. An additional object of the invention is to identify αvβ3 antagonists useful for treating cancer.
It has now been found that the compounds of the present invention, αvβ3 ligands, are useful for inhibiting bone resorption in mammals. Thus, the compounds of the present invention are useful for preventing or reducing the incidence of osteoporosis. Additionally, the αvβ3 ligands of the present invention are also useful for treating and/or inhibiting restenosis, diabetic retinopathy, macular degeneration, atherosclerosis and/or angiogenesis in mammals.
SUMMARY OF THE INVENTION
The present invention provides a method of eliciting a vitronectin receptor antagonizing effect in a mammal in need thereof, comprising administering to the mammal a therapeutically effective amount of a compound of the formula ##STR1## wherein X is selected from ##STR2## a 5- or 6-membered monocyclic aromatic or nonaromatic ring system containing 0, 1, 2, 3 or 4 heteroatoms selected from N, O or S wherein the 5- or 6-membered ring system is either unsubstituted or substituted on a carbon or nitrogen atom with one or more groups chosen from R 1 , R 2 , R 15 or R 16 ;
a 9- to 10-membered polycyclic ring system, wherein one or more of the rings is aromatic, and wherein the polycyclic ring system contains 0, 1, 2, 3 or 4 heteroatoms selected from N, O or S, and wherein the polycyclic ring system is either unsubstituted or substituted on a carbon or nitrogen atom with one or more groups chosen from R 1 , R 2 , R 15 or R 16 ;
Y is selected from ##STR3## Z is a 5-11 membered aromatic or nonaromatic mono- or polycyclic ring system containing 0 to 6 double bonds, and containing 0 to 6 heteroatoms chosen from N, O and S, and wherein the ring system is either unsubstituted or substituted on a carbon or nitrogen atom with one or more groups independently selected from R 4 , R 5 , R 6 and R 7 ; provided that Z is not a 6-membered monocyclic aromatic ring system, an isoxazoline ring or an isoxazole ring;
R 1 , R 2 , R 4 , R 5 , R 13 , R 14 , R 15 and R 16 are each independently selected from hydrogen, halogen, C 1-10 alkyl, C 3-8 cycloalkyl, C 3-8 cycloheteroalkyl, C 3-8 cycloalkyl C 1-6 alkyl, C 3-8 cycloheteroalkyl C 1-6 alkyl, aryl, aryl C 1-8 alkyl, amino, amino C 1-8 alkyl, C 1-3 acylamino, C 1-3 acylamino C 1-8 alkyl, (C 1-6 alkyl) q amino, (C 1-6 alkyl) q amino C 1-8 alkyl, C 1-4 alkoxy, C 1-4 alkoxy C 1-6 alkyl, hydroxycarbonyl, hydroxycarbonyl C 1-6 alkyl, C 1-3 alkoxycarbonyl, C 1-3 alkoxycarbonyl C 1-6 alkyl, hydroxycarbonyl-C 1-6 alkyloxy, hydroxy, hydroxy C 1-6 alkyl, C 1-6 alkyloxy-C 1-6 alkyl, nitro, cyano, trifluoromethyl, trifluoromethoxy, trifluoroethoxy, C 1-8 alkyl-S(O) q , (C 1-8 alkyl) q aminocarbonyl, C 1-8 alkyloxycarbonylamino, (C 1-8 alkyl) q aminocarbonyloxy, oxo, (aryl C 1-8 alkyl) q amino, (aryl) q amino, aryl C 1-8 alkylsulfonylamino or C 1-8 alkylsulfonylamino;
R 3 is selected from
hydrogen,
aryl,
aryl-(CH 2 ) p --,
hydroxyl,
C 1-5 alkoxy,
aminocarbonyl,
C 3-8 cycloalkyl,
amino C 1-6 alkyl,
(aryl) q aminocarbonyl,
(aryl C 1-5 alkyl) q aminocarbonyl,
hydroxycarbonyl C 1-6 alkyl,
C 1-8 alkyl,
aryl C 1-6 alkyl,
(C 1-6 alkyl) q amino C 1-6 alkyl,
(aryl C 1-6 alkyl) q amino C 1-6 alkyl,
C 1-8 alkylsulfonyl,
C 1-8 alkoxycarbonyl,
aryloxycarbonyl,
aryl C 1-8 alkoxycarbonyl,
C 1-8 alkylcarbonyl,
arylcarbonyl,
aryl C 1-6 alkylcarbonyl,
(C 1-8 alkyl) q aminocarbonyl,
aminosulfonyl,
C 1-8 alkylaminosulfonyl,
(aryl) q aminosulfonylamino,
(aryl C 1-8 alkyl) q aminosulfonyl,
C 1-6 alkylsulfonyl,
arylsulfonyl,
aryl C 1-6 alkylsulfonyl,
aryl C 1-6 alkylcarbonyl,
C 1-6 alkylthiocarbonyl,
arylthiocarbonyl, or
aryl C 1-6 alkylthiocarbonyl,
wherein any of the alkyl groups may be unsubstituted or substituted with
R 13 and R 14 ;
R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are each independently selected from
hydrogen,
aryl,
aryl-(CH 2 ) p --,
aryl-(CH 2 ) n --O--(CH 2 ) m --,
aryl-(CH 2 ) n --S(O) q --(CH 2 ) m --,
aryl-(CH 2 ) n --C(O)--(CH 2 ) m --,
aryl-(CH 2 ) n --C(O)--N(R 3 )--(CH 2 ) m --,
aryl-(CH 2 ) n --N(R 3 )--C(O)--(CH 2 ) m --,
aryl-(CH 2 ) n --N(R 3 )--(CH 2 ) m --,
halogen,
hydroxyl,
C 1-8 alkylcarbonylamino,
aryl C 1-5 alkoxy,
C 1-5 alkoxycarbonyl,
(C 1-8 alkyl) q aminocarbonyl,
C 1-6 alkylcarbonyloxy,
C 3-8 cycloalkyl,
oxo,
(C 1-6 alkyl) q amino,
amino C 1-6 alkyl,
arylaminocarbonyl,
aryl C 1-5 alkylaminocarbonyl,
aminocarbonyl,
aminocarbonyl C 1-6 alkyl,
hydroxycarbonyl,
hydroxycarbonyl C 1-6 alkyl,
C 1-8 alkyl, either unsubstituted or substituted, with one or more groups selected from: halogen, hydroxyl, C 1-5 alkylcarbonylamino, aryl C 1-5 alkoxy, C 1-5 alkoxycarbonyl, aminocarbonyl, (C 1-5 alkyl) q aminocarbonyl, C 1-5 alkylcarbonyloxy, C 3-8 cycloalkyl, oxo, (C 1-3 alkyl) q amino, amino C 1-3 alkyl, (aryl) q aminocarbonyl, (aryl C 1-5 alkyl) q aminocarbonyl, aminocarbonyl, aminocarbonyl C 1-4 alkyl, hydroxycarbonyl or hydroxycarbonyl C 1-5 alkyl,
CH.tbd.C--(CH 2 ) s --,
C 1-6 alkyl-C.tbd.C--(CH 2 ) s --,
C 3-7 cycloalkyl-C.tbd.C--(CH 2 ) s --,
aryl-C.tbd.C--(CH 2 ) s --,
C 1-6 alkylaryl-C.tbd.C--(CH 2 ) s --,
CH 2 ═CH--(CH 2 ) s --,
C 1-6 alkyl-CH═CH--(CH 2 ) s --,
C 3-7 cycloalkyl-CH═CH--(CH 2 ) s --,
aryl-CH═CH--(CH 2 ) s --,
C 1-6 alkylaryl-CH═CH--(CH 2 ) s --,
C 1-6 alkyl-SO 2 --(CH 2 ) s --,
C 1-6 alkylaryl-SO 2 --(CH 2 ) s --,
C 1-6 alkoxy,
aryl C 1-6 alkoxy,
aryl C 1-6 alkyl,
(C 1-6 alkyl) q amino C 1-6 alkyl,
(aryl) q amino,
(aryl) q amino C 1-6 alkyl,
(aryl C 1-6 alkyl) q amino,
(aryl C 1-6 alkyl) q amino C 1-6 alkyl,
arylcarbonyloxy,
aryl C 1-6 alkylcarbonyloxy,
(C 1-6 alkyl) q aminocarbonyloxy,
C 1-8 alkylsulfonylamino,
arylsulfonylamino,
C 1-8 alkylsulfonylamino C 1-6 alkyl,
arylsulfonylamino C 1-6 alkyl,
aryl C 1-6 alkylsulfonylamino,
aryl C 1-6 alkylsulfonylamino C 1-6 alkyl,
C 1-8 alkoxycarbonylamino,
C 1-8 alkoxycarbonylamino C 1-8 alkyl,
aryloxycarbonylamino C 1-8 alkyl,
aryl C 1-8 alkoxycarbonylamino,
aryl C 1-8 alkoxycarbonylamino C 1-8 alkyl,
C 1-8 alkylcarbonylamino,
C 1-8 alkylcarbonylamino C 1-6 alkyl,
arylcarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylcarbonylamino,
aryl C 1-6 alkylcarbonylamino C 1-6 alkyl,
aminocarbonylamino C 1-6 alkyl,
(C 1-8 alkyl) q aminocarbonylamino,
(C 1-8 alkyl) q aminocarbonylamino C 1-6 alkyl,
(aryl) q aminocarbonylamino C 1-6 alkyl,
(aryl C 1-8 alkyl) q aminocarbonylamino,
(aryl C 1-8 alkyl) q aminocarbonylamino C 1-6 alkyl,
aminosulfonylamino C 1-6 alkyl,
(C 1-8 alkyl) q aminosulfonylamino,
(C 1-8 alkyl) q aminosulfonylamino C 1-6 alkyl,
(aryl) q aminosulfonylamino C 1-6 alkyl,
(aryl C 1-8 alkyl) q aminosulfonylamino,
(aryl C 1-8 alkyl) q aminosulfonylamino C 1-6 alkyl,
C 1-6 alkylsulfonyl,
C 1-6 alkylsulfonyl C 1-6 alkyl,
arylsulfonyl C 1-6 alkyl,
aryl C 1-6 alkylsulfonyl,
aryl C 1-6 alkylsulfonyl C 1-6 alkyl,
C 1-6 alkylcarbonyl,
C 1-6 alkylcarbonyl C 1-6 alkyl,
arylcarbonyl C 1-6 alkyl,
aryl C 1-6 alkylcarbonyl,
aryl C 1-6 alkylcarbonyl C 1-6 alkyl,
C 1-6 alkylthiocarbonylamino,
C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
arylthiocarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylthiocarbonylamino,
aryl C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
(C 1-8 alkyl) q aminocarbonyl C 1-6 alkyl,
(aryl) q aminocarbonyl C 1-6 alkyl,
(aryl C 1-8 alkyl) q aminocarbonyl, or
(aryl C 1-8 alkyl) q aminocarbonyl C 1-6 alkyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ; and provided that the carbon atom to which R 8 and R 9 are attached is itself attached to no more than one heteroatom; and provided further that the carbon atom to which R 10 and R 11 are attached is itself attached to no more than one heteroatom;
R 12 is selected from
hydrogen,
C 1-8 alkyl,
aryl,
aryl C 1-8 alkyl,
C 1-8 alkylcarbonyloxy C 1-4 alkyl,
aryl C 1-8 alkylcarbonyloxy C 1-4 alkyl,
C 1-8 alkylaminocarbonylmethylene, or
C 1-8 dialkylaminocarbonylmethylene;
m, s and t are each independently an integer from 0 to 3;
n is an integer from 1 to 3;
p is an integer from 1 to 4;
q is an integer from 0 to 2;
r is an integer from 0 to 6;
and the pharmaceutically acceptable salts thereof.
In one embodiment of the present invention is the method of eliciting a vitronectin antagonizing effect wherein
X is
a 9- to 10-membered polycyclic ring system, wherein one or more of the rings is aromatic, and wherein the polycyclic ring system contains 0, 1, 2, 3 or 4 heteroatoms selected from N, O or S, and wherein the polycyclic ring system is either unsubstituted or substituted on a carbon atom with R 1 and R 2 ; and
Z is selected from ##STR4## and all other variables are as defined above; and the pharmaceutically acceptable salts thereof. Preferably, Z is selected from ##STR5##
In a class of the invention is the method of eliciting a vitronectin antagonizing effect wherein the compound has the formula ##STR6## wherein X is selected from ##STR7## Y is selected from --(CH 2 ) r -- or --(CH 2 ) m --NR 3 --(CH 2 ) t --;
R 3 is selected from
hydrogen,
aryl-(CH 2 ) p --,
C 1-5 alkoxycarbonyl,
C 3-8 cycloalkyl,
(aryl) q aminocarbonyl,
(aryl C 1-8 alkyl) q aminocarbonyl,
C 1-8 alkyl,
aryl C 1-6 alkyl,
C 1-8 alkylsulfonyl,
arylsulfonyl,
aryl C 1-6 alkylsulfonyl,
C 1-8 alkoxycarbonyl,
aryloxycarbonyl,
aryl C 1-8 alkoxycarbonyl,
C 1-8 alkylcarbonyl,
arylcarbonyl,
aryl C 1-6 alkylcarbonyl,
(C 1-8 alkyl) q aminocarbonyl,
C 1-6 alkylsulfonyl, or
aryl C 1-6 alkylcarbonyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ;
R 4 is selected from hydrogen, C 1-6 alkyl, C 3-8 cycloalkyl, C 3-8 cycloheteroalkyl, C 3-8 cycloalkyl C 1-6 alkyl, C 3-8 cycloheteroalkyl C 1-6 alkyl, aryl or aryl C 1-8 alkyl,
R 8 is selected from
hydrogen,
aryl,
aryl-(CH 2 ) p --,
CH.tbd.C--(CH 2 ) s --,
C 1-6 alkyl-C.tbd.C--(CH 2 ) s --,
C 3-7 cycloalkyl-C.tbd.C--(CH 2 ) s --,
aryl-C.tbd.C--(CH 2 ) s --,
C 1-6 alkylaryl-C.tbd.C--(CH 2 ) s --,
CH 2 ═CH--(CH 2 ) s --,
C 1-6 alkyl-CH═CH--(CH 2 ) s --,
C 3-7 cycloalkyl-CH═CH--(CH 2 ) s --,
aryl-CH═CH--(CH 2 ) s --,
C 1-6 alkylaryl-CH═CH--(CH 2 ) s --,
C 1-6 alkyl-SO 2 --(CH 2 ) s --,
C 1-6 alkylaryl-SO 2 --(CH 2 ) s --; and
r is an integer from 0 to 3;
and all other variables are as defined above;
and the pharmaceutically acceptable salts thereof.
In a subclass of the invention is the method wherein the compound has the formula ##STR8## wherein Z is selected from ##STR9## R 8 is selected from hydrogen, ##STR10## indolyl-(CH 2 ) p --, CH.tbd.C--(CH 2 ) s --,
C 1-6 alkyl-C.tbd.C--(CH 2 ) s --,
C 3-7 cycloalkyl-C.tbd.C--(CH 2 ) s --,
aryl-C.tbd.C--(CH 2 ) s --,
C 1-6 alkylaryl-C.tbd.C--(CH 2 ) s --,
CH 2 ═CH--(CH 2 ) s --,
C 1-6 alkyl-CH═CH--(CH 2 ) s --,
C 3-7 cycloalkyl-CH═CH--(CH 2 ) s --,
aryl-CH═CH--(CH 2 ) s --,
C 1-6 alkylaryl-CH═CH--(CH 2 ) s --,
C 1-6 alkyl-SO 2 --(CH 2 ) s --,
C 1-6 alkylaryl-SO 2 --(CH 2 ) s --; and
R 12 is selected from hydrogen or C 1-8 alkyl;
s is an integer from 0 to 3;
and all other variables are as defined above;
and the pharmaceutically acceptable salts thereof.
Illustrative of the invention is the method of eliciting a vitronectin antagonizing effect wherein the compound is selected from
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]piperidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester;
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]piperin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine trifluoroacetate;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine ethyl ester;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine ethyl ester;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
Ethyl 2-oxo-3-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]tetrahydropyrimidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine;
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]tetrahydropyrimidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine;
Ethyl 2-oxo-3-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]imidazolidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine;
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]imidazolidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine;
Ethyl 2-oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(R)-(2-ethylindol-3-yl)-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(R)-(2-ethylindol-3-yl)-β-alanine;
Ethyl 3-(2-{2-oxo-3(S)-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-pyrrolidin-1-yl}-acetylamino)-3-(S)-pyridin-3-yl-propionic acid;
3-(2-{2-Oxo-3(S)-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl}-acetylamino)-3-(S)-pyridin-3-yl-propionic acid;
3-{2-[6-Oxo-1-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-hexahydro-(3aS, 6aS)pyrrolo[3,4-b]pyrrol-5-yl]-acetylamino}-3-(S)-pyridin-3-yl-propionic acid;
3-{2-[6-Oxo-1-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-hexahydro-(3aR, 6aR)pyrrolo[3,4-b]pyrrol-5-yl]-acetylamino}-3(S)-pyridin-3-yl-propionic acid;
2-Oxo-5(R)-methyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)-ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine ethyl ester;
2-Oxo-5(R)-methyl-3(S)-[2-(5 ,6,7 ,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine;
2-Oxo-5(S)-benzyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)-ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester;
2-Oxo-5(S)-benzyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
5(R)-Methyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine ethyl ester;
5(R)-Methyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine;
3(S)-(2,3-Dihydro-benzofuran-6-yl)-3-(2-{2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetylamino)-propionic acid ethyl ester; or
3(S)-(2,3-Dihydro-benzofuran-6-yl)-3-(2-{2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetylamino)-propionic acid;
3-{2-(2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]pyrrolidin-1-yl)-acetylamino}-3(S)-quinolin-3-yl-propionic acid;
3-(2-(5(S)-Ethyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrolidin-1-yl)-acetylamino)-3-(S)-quinolin-3-yl-propionic acid trifluoroacetate;
3-(2-{6-Methyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-2H-pyridin-1-yl}-acetylamino)-3(S)-pyridin-3-yl-propionic acid bis trifluoroacetate; or
3-(2-{6-Methyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]napthyridin-2-ylmethyl)-amino]-2H-pyridin-1-yl}-acetylamino)-3(S)-pyridin-3-yl-propionic acid ethyl ester;
and the pharmaceutically acceptable salts thereof.
Preferably, the compound is selected from
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]piperin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine trifluoroacetate;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
2-Oxo-3(R)-[2-(5,6,7, 8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
2-Oxo-3-[2-(5 ,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]imidazolidin-1-yl-acetyl-3-(S)-pyridin-3-yl-β-alanine;
2-Oxo-3-[2-(5 ,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]-tetrahydropyrimidin-1-yl-acetyl-3-(S)-pyridin-3-yl-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(R)-(2-ethylindol-3-yl)-β-alanine;
3-(2-{2-oxo-3(S)-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl}-acetylamino)-3-(S)-pyridin-3-yl-propionic acid;
3-{2-[6-Oxo-1-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-hexahydro-(3aS, 6aS)pyrrolo[3,4-b]pyrrol-5-yl]-acetylamino}-3-(S)-pyridin-3-yl-propionic acid;
3-{2-[6-Oxo-1-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-hexahydro-(3aR, 6aR)pyrrolo[3,4-b]pyrrol-5-yl]-acetylamino}-3-(S)-pyridin-3-yl-propionic acid;
2-Oxo-5(R)-methyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine;
2-Oxo-5(S)-benzyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
5(R)-Methyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine; or
3(S)-(2,3-Dihydro-benzofuran-6-yl)-3-(2-{2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetylamino)-propionic acid;
and the pharmaceutically acceptable salts thereof.
Exemplifying the invention is the method wherein the vitronectin receptor antagonizing effect is an αvβ3 antagonizing effect. An illustration of the invention is the method wherein the αvβ3 antagonizing effect is selected from inhibition of: bone resorption, restenosis, angiogenesis, diabetic retinopathy, macular degeneration, inflammation or tumor growth. Preferably, the αvβ3 antagonizing effect is the inhibition of bone resorption.
An example of the invention is the method wherein the vitronectin receptor antagonizing effect is an αvβ5 antagonizing effect. More specifically, the αvβ5 antagonizing effect is selected from inhibition of: restenosis, angiogenesis, diabetic retinopathy, macular degeneration, inflammation or tumor growth.
Illustrating the invention is the method wherein the vitronectin receptor antagonizing effect is a dual αvβ3/αvβ5 antagonizing effect. More particularly, the dual αvβ3/αvβ5 antagonizing effect is selected from inhibition of: bone resorption, restenosis, angiogenesis, diabetic retinopathy, macular degeneration, inflammation or tumor growth.
In a second embodiment of the present invention is a method of eliciting an αvβ3 antagonizing effect in a mammal in need thereof, comprising administering to the mammal a therapeutically effective amount of a compound of the formula ##STR11## wherein X is selected from ##STR12## a 5- or 6-membered monocyclic aromatic or nonaromatic ring system containing 0, 1, 2, 3 or 4 heteroatoms selected from N, O or S wherein the 5- or 6-membered ring system is either unsubstituted or substituted on a carbon atom with R 1 and R 2 , or
a 9- to 10-membered polycyclic ring system, wherein one or more of the rings is aromatic, and wherein the polycyclic ring system contains 0, 1, 2, 3 or 4 heteroatoms selected from N, O or S, and wherein the polycyclic ring system is either unsubstituted or substituted on a carbon atom with R 1 and R 2 ;
Y is selected from ##STR13## Z is a 5-11 membered aromatic or nonaromatic mono- or polycyclic ring system containing 0 to 6 double bonds, and containing 0 to 6 heteroatoms chosen from N, O and S, and wherein the ring system is either unsubstituted or substituted on a carbon or nitrogen atom with one or more groups independently selected from R 4 , R 5 , R 6 and R 7 ; provided that Z is not a 6-membered monocyclic aromatic ring system; preferably, Z is selected from ##STR14## R 1 , R 2 , R 4 , R 5 , R 13 and R 14 are each independently selected from hydrogen, halogen, C 1-10 alkyl, C 3-8 cycloalkyl, aryl, aryl C 1-8 alkyl, amino, amino C 1-8 alkyl, C 1-3 acylamino, C 1-3 acylamino C 1-8 alkyl, C 1-6 alkylamino, C 1-6 alkylamino-C 1-8 alkyl, C 1-6 dialkylamino, C 1-6 dialkylamino C 1-8 alkyl, C 1-4 alkoxy, C 1-4 alkoxy C 1-6 alkyl, hydroxycarbonyl, hydroxycarbonyl C 1-6 alkyl, C 1-3 alkoxycarbonyl, C 1-3 alkoxycarbonyl C 1-6 alkyl, hydroxycarbonyl-C 1-6 alkyloxy, hydroxy or hydroxy C 1-6 alkyl;
R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are each independently selected from
hydrogen,
aryl,
--(CH 2 ) p -aryl,
halogen,
hydroxyl,
C 1-8 alkylcarbonylamino,
aryl C 1-5 alkoxy,
C 1-5 alkoxycarbonyl,
aminocarbonyl,
C 1-8 alkylaminocarbonyl,
C 1-6 alkylcarbonyloxy,
C 3-8 cycloalkyl,
oxo,
amino,
C 1-6 alkylamino,
amino C 1-6 alkyl,
arylaminocarbonyl,
aryl C 1-5 alkylaminocarbonyl,
aminocarbonyl,
aminocarbonyl C 1-6 alkyl,
hydroxycarbonyl,
hydroxycarbonyl C 1-6 alkyl,
C 1-8 alkyl, either unsubstituted or substituted, with one or more groups selected from: halogen, hydroxyl, C 1-5 alkylcarbonylamino, aryl C 1-5 alkoxy, C 1-5 alkoxycarbonyl, aminocarbonyl, C 1-5 alkylaminocarbonyl, C 1-5 alkylcarbonyloxy, C 3-8 cycloalkyl, oxo, amino, C 1-3 alkylamino, amino C 1-3 alkyl, arylaminocarbonyl, aryl C 1-5 alkylaminocarbonyl, aminocarbonyl, aminocarbonyl C 1-4 alkyl, hydroxycarbonyl, or hydroxycarbonyl C 1-5 alkyl,
--(CH 2 ) s C.tbd.CH,
--(CH 2 ) s C.tbd.C--C 1-6 alkyl,
--(CH 2 ) s C.tbd.C--C 3-7 cycloalkyl,
--(CH 2 ) s C.tbd.C-aryl,
--(CH 2 ) s C.tbd.C--C 1-6 alkylaryl,
--(CH 2 ) s CH═CH 2 ,
--(CH 2 ) s CH═CH C 1-6 alkyl,
--(CH 2 ) s CH═CH--C 3-7 cycloalkyl,
--(CH 2 ) s CH═CH aryl,
--(CH 2 ) s CH═CH C 1-6 alkylaryl,
--(CH 2 ) s SO 2 C 1-6 alkyl,
--(CH 2 ) s SO 2 C 1-6 alkylaryl,
C 1-6 alkoxy,
aryl C 1-6 alkoxy,
aryl C 1-6 alkyl,
C 1-6 alkylamino C 1-6 alkyl,
arylamino,
arylamino C 1-6 alkyl,
aryl C 1-6 alkylamino,
aryl C 1-6 alkylamino C 1-6 alkyl,
arylcarbonyloxy,
aryl C 1-6 alkylcarbonyloxy,
C 1-6 dialkylamino,
C 1-6 dialkylamino C 1-6 alkyl,
C 1-6 alkylaminocarbonyloxy,
C 1-8 alkylsulfonylamino,
C 1-8 alkylsulfonylamino C 1-6 alkyl,
arylsulfonylamino C 1-6 alkyl,
aryl C 1-6 alkylsulfonylamino,
aryl C 1-6 alkylsulfonylamino C 1-6 alkyl,
C 1-8 alkoxycarbonylamino,
C 1-8 alkoxycarbonylamino C 1-8 alkyl,
aryloxycarbonylamino C 1-8 alkyl,
aryl C 1-8 alkoxycarbonylamino,
aryl C 1-8 alkoxycarbonylamino C 1-8 alkyl,
C 1-8 alkylcarbonylamino,
C 1-8 alkylcarbonylamino C 1-6 alkyl,
arylcarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylcarbonylamino,
aryl C 1-6 alkylcarbonylamino C 1-6 alkyl,
aminocarbonylamino C 1-6 alkyl,
C 1-8 alkylaminocarbonylamino,
C 1-8 alkylaminocarbonylamino C 1-6 alkyl,
arylaminocarbonylamino C 1-6 alkyl,
aryl C 1-8 alkylaminocarbonylamino,
aryl C 1-8 alkylaminocarbonylamino C 1-6 alkyl,
aminosulfonylamino C 1-6 alkyl,
C 1-8 alkylaminosulfonylamino,
C 1-8 alkylaminosulfonylamino C 1-6 alkyl,
arylaminosulfonylamino C 1-6 alkyl,
aryl C 1-8 alkylaminosulfonylamino,
aryl C 1-8 alkylaminosulfonylamino C 1-6 alkyl,
C 1-6 alkylsulfonyl,
C 1-6 alkylsulfonyl C 1-6 alkyl,
arylsulfonyl C 1-6 alkyl,
aryl C 1-6 alkylsulfonyl,
aryl C 1-6 alkylsulfonyl C 1-6 alkyl,
C 1-6 alkylcarbonyl,
C 1-6 alkylcarbonyl C 1-6 alkyl,
arylcarbonyl C 1-6 alkyl,
aryl C 1-6 alkylcarbonyl,
aryl C 1-6 alkylcarbonyl C 1-6 alkyl,
C 1-6 alkylthiocarbonylamino,
C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
arylthiocarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylthiocarbonylamino,
aryl C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
C 1-8 alkylaminocarbonyl C 1-6 alkyl,
arylaminocarbonyl C 1-6 alkyl,
aryl C 1-8 alkylaminocarbonyl, or
aryl C 1-8 alkylaminocarbonyl C 1-6 alkyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ; and provided that the carbon atom to which R 8 and R 9 are attached is itself attached to no more than one heteroatom; and provided further that the carbon atom to which R 10 and R 11 are attached is itself attached to no more than one heteroatom;
R 12 is selected from
hydrogen,
C 1-8 alkyl,
aryl,
aryl C 1-8 alkyl,
hydroxy,
C 1-8 alkoxy,
aryloxy,
aryl C 1-6 alkoxy,
C 1-8 alkylcarbonyloxy C 1-4 alkoxy,
aryl C 1-8 alkylcarbonyloxy C 1-4 alkoxy,
C 1-8 alkylaminocarbonylmethyleneoxy, or
C 1-8 dialkylaminocarbonylmethyleneoxy;
m is an integer from 0 to 3;
n is an integer from 1 to 3;
p is an integer from 1 to 4;
q is an integer from 0 to 2;
r is an integer from 0 to 6;
s is an integer from 0 to 3; and
t is an integer from 0 to 3;
and the pharmaceutically acceptable salts thereof.
In a third embodiment of the invention is a method of eliciting an αvβ3 antagonizing effect in a mammal in need thereof, comprising administering to the mammal a therapeutically effective amount of a compound of the formula ##STR15## wherein X is selected from ##STR16## a 5- or 6-membered monocyclic aromatic or nonaromatic ring system containing 0, 1, 2, 3 or 4 heteroatoms selected from N, O or S wherein the 5- or 6-membered ring system is either unsubstituted or substituted on a carbon atom with R 1 and R 2 , or
a 9- to 10-membered polycyclic ring system, wherein one or more of the rings is aromatic, and wherein the polycyclic ring system contains 0, 1, 2, 3 or 4 heteroatoms selected from N, O or S, and wherein the polycyclic ring system is either unsubstituted or substituted on a carbon atom with R 1 and R 2 ;
Y is selected from ##STR17## Z is a 5-11 membered aromatic or nonaromatic mono- or polycyclic ring system containing 0 to 6 double bonds, and containing 0 to 6 heteroatoms chosen from N, O and S, and wherein the ring system is either unsubstituted or substituted on a carbon or nitrogen atom with one or more groups independently selected from R 4 , R 5 , R 6 and R 7 ; provided that Z is not a 6-membered monocyclic aromatic ring system; preferably Z is selected from ##STR18## R 1 , R 2 , R 4 , R 5 , R 13 and R 14 are each independently selected from hydrogen, halogen, C 1-10 alkyl, C 3-8 cycloalkyl, aryl, aryl C 1-8 alkyl, amino, amino C 1-8 alkyl, C 1-3 acylamino, C 1-3 acylamino C 1-8 alkyl, C 1-6 alkylamino, C 1-6 alkylamino-C 1-8 alkyl, C 1-6 dialkylamino, C 1-6 dialkylamino C 1-8 alkyl, C 1-4 alkoxy, C 1-4 alkoxy C 1-6 alkyl, hydroxycarbonyl, hydroxycarbonyl C 1-6 alkyl, C 1-3 alkoxycarbonyl, C 1-3 alkoxycarbonyl C 1-6 alkyl, hydroxycarbonyl-C 1-6 alkyloxy, hydroxy, hydroxy C 1-6 alkyl, C 1-6 alkyloxy-C 1-6 alkyl, nitro, cyano, trifluoromethyl, trifluoromethoxy, trifluoroethoxy, C 1-8 alkyl-S(O) q , C 1-8 aminocarbonyl, C 1-8 dialkylaminocarbonyl, C 1-8 alkyloxycarbonylamino, C 1-8 alkylaminocarbonyloxy or C 1-8 galkylsulfonylamino;
R 3 is selected from
hydrogen,
aryl,
--(CH 2 ) p -aryl,
hydroxyl,
C 1-5 alkoxycarbonyl,
aminocarbonyl,
C 3-8 cycloalkyl,
amino C 1-6 alkyl,
arylaminocarbonyl,
aryl C 1-5 alkylaminocarbonyl,
hydroxycarbonyl C 1-6 alkyl,
C 1-8 alkyl,
aryl C 1-6 alkyl,
C 1-6 alkylamino C 1-6 alkyl,
aryl C 1-6 alkylamino C 1-6 alkyl,
C 1-6 dialkylamino C 1-6 alkyl,
C 1-8 alkylsulfonyl,
C 1-8 alkoxycarbonyl,
aryloxycarbonyl,
aryl C 1-8 alkoxycarbonyl,
C 1-8 alkylcarbonyl,
arylcarbonyl,
aryl C 1-6 alkylcarbonyl,
C 1-8 alkylaminocarbonyl,
aminosulfonyl,
C 1-8 alkylaminosulfonyl,
arylaminosulfonylamino,
aryl C 1-8 alkylaminosulfonyl,
C 1-6 alkylsulfonyl,
arylsulfonyl,
aryl C 1-6 alkylsulfonyl,
aryl C 1-6 alkylcarbonyl,
C 1-6 alkylthiocarbonyl,
arylthiocarbonyl, or
aryl C 1-6 alkylthiocarbonyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ;
R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are each independently selected from
hydrogen,
aryl,
--(CH 2 ) p -aryl,
halogen,
hydroxyl,
C 1-8 alkylcarbonylamino,
aryl C 1-5 alkoxy,
C 1-5 alkoxycarbonyl,
aminocarbonyl,
C 1-8 alkylaminocarbonyl,
C 1-6 alkylcarbonyloxy,
C 3-8 cycloalkyl,
oxo,
amino,
C 1-6 alkylamino,
amino C 1-6 alkyl,
arylaminocarbonyl,
aryl C 1-5 alkylaminocarbonyl,
aminocarbonyl,
aminocarbonyl C 1-6 alkyl,
hydroxycarbonyl,
hydroxycarbonyl C 1-6 alkyl,
C 1-8 alkyl, either unsubstituted or substituted, with one or more groups selected from: halogen, hydroxyl, C 1-5 alkylcarbonylamino, aryl C 1-5 alkoxy, C 1-5 alkoxycarbonyl, aminocarbonyl, C 1-5 alkylaminocarbonyl, C 1-5 alkylcarbonyloxy, C 3-8 cycloalkyl, oxo, amino, C 1-3 alkylamino, amino C 1-3 alkyl, arylammnocarbonyl, aryl C 1-5 alkylaminocarbonyl, aminocarbonyl, aminocarbonyl C 1-4 alkyl, hydroxycarbonyl, or hydroxycarbonyl C 1-5 alkyl,
--(CH 2 ) s C.tbd.CH,
--(CH 2 ) s C.tbd.C--C 1-6 alkyl,
--(CH 2 ) s C.tbd.C--C 3-7 cycloalkyl,
--(CH 2 ) s C.tbd.C-aryl,
--(CH 2 ) s C.tbd.C--C 1-6 alkylaryl,
--(CH 2 ) s CH═CH 2 ,
--(CH 2 ) s CH═CH C 1-6 alkyl,
--(CH 2 ) s CH═CH--C 3-7 cycloalkyl,
--(CH 2 ) s CH═CH aryl,
--(CH 2 ) s CH═CH C 1-6 alkylaryl,
--(CH 2 ) s SO 2 C 1-6 alkyl,
--(CH 2 ) s SO 2 C 1-6 alkylaryl,
C 1-6 alkoxy,
aryl C 1-6 alkoxy,
aryl C 1-6 alkyl,
C 1-6 alkylamino C 1-6 alkyl,
arylamino,
arylamino C 1-6 alkyl,
aryl C 1-6 alkylamino,
aryl C 1-6 alkylamino C 1-6 alkyl,
arylcarbonyloxy,
aryl C 1-6 alkylcarbonyloxy,
C 1-6 dialkylamino,
C 1-6 dialkylamino C 1-6 alkyl,
C 1-6 alkylaminocarbonyloxy,
C 1-8 alkylsulfonylamino,
C 1-8 alkylsulfonylamino C 1-6 alkyl,
arylsulfonylamino C 1-6 alkyl,
aryl C 1-6 alkylsulfonylamino,
aryl C 1-6 alkylsulfonylamino C 1-6 alkyl,
C 1-8 alkoxycarbonylamino,
C 1-8 alkoxycarbonylamino C 1-8 alkyl,
aryloxycarbonylamino C 1-8 alkyl,
aryl C 1-8 alkoxycarbonylamino,
aryl C 1-8 alkoxycarbonylamino C 1-8 alkyl,
C 1-8 alkylcarbonylamino,
C 1-8 alkylcarbonylamino C 1-6 alkyl,
arylcarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylcarbonylamino,
aryl C 1-6 alkylcarbonylamino C 1-6 alkyl,
aminocarbonylamino C 1-6 alkyl,
C 1-8 alkylaminocarbonylamino,
C 1-8 alkylaminocarbonylamino C 1-6 alkyl,
arylaminocarbonylamino C 1-6 alkyl,
aryl C 1-8 alkylaminocarbonylamino,
aryl C 1-8 alkylaminocarbonylamino C 1-6 alkyl,
aminosulfonylamino C 1-6 alkyl,
C 1-8 alkylaminosulfonylamino,
C 1-8 alkylaminosulfonylamino C 1-6 alkyl,
arylaminosulfonylamino C 1-6 alkyl,
aryl C 1-8 alkylaminosulfonylamino,
aryl C 1-8 alkylaminosulfonylamino C 1-6 alkyl,
C 1-6 alkylsulfonyl,
C 1-6 alkylsulfonyl C 1-6 alkyl,
arylsulfonyl C 1-6 alkyl,
aryl C 1-6 alkylsulfonyl,
aryl C 1-6 alkylsulfonyl C 1-6 alkyl,
C 1-6 alkylcarbonyl,
C1-6 alkylcarbonyl C 1-6 alkyl,
arylcarbonyl C 1- 6 alkyl,
aryl C 1-6 alkylcarbonyl,
aryl C 1-6 alkylcarbonyl C 1-6 alkyl,
C 1-6 alkylthiocarbonylamino,
C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
arylthiocarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylthiocarbonylamino,
aryl C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
C 1-8 alkylaminocarbonyl C 1-6 alkyl,
arylaminocarbonyl C 1-6 alkyl,
aryl C 1-8 alkylaminocarbonyl, or
aryl C 1-8 alkylaminocarbonyl C 1-6 alkyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ; and provided that the carbon atom to which R 8 and R 9 are attached is itself attached to no more than one heteroatom; and provided further that the carbon atom to which R 10 and R 11 are attached is itself attached to no more than one heteroatom;
R 12 is selected from
hydrogen,
C 1-8 alkyl,
aryl,
aryl C 1-8 alkyl,
hydroxy,
C 1-8 alkoxy,
aryloxy,
aryl C 1-6 alkoxy,
C 1-8 alkylcarbonyloxy C 1-4 alkoxy,
aryl C 1-8 alkylcarbonyloxy C 1-4 alkoxy,
C 1-8 alkylaminocarbonylmethyleneoxy, or
C 1-8 dialkylaminocarbonylmethyleneoxy;
m is an integer from 0 to 3;
n is an integer from 1 to 3;
p is an integer from 1 to 4;
q is an integer from 0 to 2;
r is an integer from 0 to 6; and
s is an integer from 0 to 3;
and the pharmaceutically acceptable salts thereof.
Illustrating the invention is the method wherein the αvβ3 antagonizing effect is selected from inhibition of bone resorption, inhibition of restenosis, inhibition of angiogenesis, inhibition of diabetic retinopathy, inhibition of macular degeneration, inhibition of atherosclerosis, inflammation or inhibition of tumor growth. Preferably, the αvβ3 antagonizing effect is the inhibition of bone resorption.
An illustration of the invention is a compound of the formula ##STR19## wherein X is a 9- to 10-membered polycyclic ring system, wherein one or more of the rings is aromatic, and wherein the polycyclic ring system contains 0, 1, 2, 3 or 4 heteroatoms selected from N, O or S, and wherein the polycyclic ring system is either unsubstituted or substituted on a carbon or nitrogen atom with one or more groups chosen from R 1 , R 2 , R 15 or R 16 ;
Y is selected from ##STR20## Z is a 5-11 membered aromatic or nonaromatic mono- or polycyclic ring system containing 0 to 6 double bonds, and containing 0 to 6 heteroatoms chosen from N, O and S, and wherein the ring system is either unsubstituted or substituted on a carbon or nitrogen atom with one or more groups independently selected from R 4 , R 5 , R 6 and R 7 ; provided that Z is not a 6-membered monocyclic aromatic ring system, an isoxazoline ring or an isoxazole ring;
R 1 , R 2 , R 4 , R 5 , R 13 , R 14 , R 15 and R 16 are each independently selected from hydrogen, halogen, C 1-10 alkyl, C 3-8 cycloalkyl, C 3-8 cycloheteroalkyl, C 3-8 cycloalkyl C 1-6 alkyl, C 3-8 cycloheteroalkyl C 1-6 alkyl, aryl, aryl C 1-8 alkyl, amino, amino C 1-8 alkyl, C 1-3 acylamino, C 1-3 acylamino C 1-8 alkyl, (C 1-6 alkyl) q amino, (C 1-6 alkyl) q amino C 1-8 alkyl, C 1-4 alkoxy, C 1-4 alkoxy C 1-6 alkyl, hydroxycarbonyl, hydroxycarbonyl C 1-6 alkyl, C 1-3 alkoxycarbonyl, C 1-3 alkoxycarbonyl C 1-6 alkyl, hydroxycarbonyl-C 1-6 alkyloxy, hydroxy, hydroxy C 1-6 alkyl, C 1-6 alkyloxy-C 1-6 alkyl, nitro, cyano, trifluoromethyl, trifluoromethoxy, trifluoroethoxy, C 1-8 alkyl-S(O) q , (C 1-8 alkyl) q aminocarbonyl, C 1-8 alkyloxycarbonylamino, (C 1-8 alkyl) q aminocarbonyloxy, oxo, (aryl C 1-8 alkyl) q amino, (aryl) q amino, aryl C 1-8 alkylslfonylamino or C 1-8 alkylsulfonylamino;
R 3 is selected from
hydrogen,
aryl,
aryl-(CH 2 ) p --,
hydroxyl,
C 1-5 alkoxy,
aminocarbonyl,
C 3-8 cycloalkyl,
amino C 1-6 alkyl,
(aryl) q aminocarbonyl,
(aryl C 1-5 alkyl) q aminocarbonyl,
hydroxycarbonyl C 1-6 alkyl,
C 1-8 alkyl,
aryl C 1-6 alkyl,
(C 1-6 alkyl) q amino C 1-6 alkyl,
(aryl C 1-6 alkyl) q amino C 1-6 alkyl,
C 1-8 alkylsulfonyl,
C 1-8 alkoxycarbonyl,
aryloxycarbonyl,
aryl C 1-8 alkoxycarbonyl,
C 1-8 alkylcarbonyl,
arylcarbonyl,
aryl C 1-6 alkylcarbonyl,
(C 1-8 alkyl) q aminocarbonyl,
aminosulfonyl,
C 1-8 alkylaminosulfonyl,
(aryl) q aminosulfonylamino,
(aryl C 1-8 alkyl) q aminosulfonyl,
C 1-6 alkylsulfonyl,
arylsulfonyl,
aryl C 1-6 alkylsulfonyl,
aryl C 1-6 alkylcarbonyl,
C 1-6 alkylthiocarbonyl,
arylthiocarbonyl, or
aryl C 1-6 alkylthiocarbonyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ;
R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are each independently selected from
hydrogen,
aryl,
aryl-(CH 2 ) p --,
aryl-(CH 2 ) n --O--(CH 2 ) m --,
aryl-(CH 2 ) n --S(O) q --(CH 2 ) m --,
aryl-(CH 2 ) n --C(O)--(CH 2 ) m --,
aryl-(CH 2 ) n --C(O)--N(R 3 )--(CH 2 ) m --,
aryl-(CH 2 ) n --N(R 3 )--C(O)--(CH 2 ) m --,
aryl-(CH 2 ) n --N(R 3 )--(CH 2 ) m --,
halogen,
hydroxyl,
C 1-8 alkylcarbonylamino,
aryl C 1-5 alkoxy,
C 1-5 alkoxycarbonyl,
(C 1-8 alkyl) q aminocarbonyl,
C 1-6 alkylcarbonyloxy,
C 3-8 cycloalkyl,
oxo,
(C 1-6 alkyl) q amino,
amino C 1-6 alkyl,
arylaminocarbonyl,
aryl C 1-5 alkylaminocarbonyl,
aminocarbonyl,
aminocarbonyl C 1-6 alkyl,
hydroxycarbonyl,
hydroxycarbonyl C 1-6 alkyl,
C 1-8 alkyl, either unsubstituted or substituted, with one or more groups selected from: halogen, hydroxyl, C 1-5 alkylcarbonylamino, aryl C 1-5 alkoxy, C 1-5 alkoxycarbonyl, aminocarbonyl, (C 1-5 alkyl) q aminocarbonyl, C 1-5 alkylcarbonyloxy, C 3-8 cycloalkyl, oxo, (C 1-3 alkyl) q amino, amino C 1-3 alkyl, (aryl) q aminocarbonyl, (aryl C 1-5 alkyl) q aminocarbonyl, aminocarbonyl, aminocarbonyl C 1-4 alkyl, hydroxycarbonyl or hyydroxycarbonyl C 1-5 alkyl,
CH.tbd.C--(CH 2 ) s --,
C 1-6 alkyl-C.tbd.C--(CH 2 ) s --,
C 3-7 cycloalkyl-C.tbd.C--(CH 2 ) s --,
aryl-C.tbd.C--(CH 2 ) s --,
C 1-6 alkylaryl-C.tbd.C--(CH 2 ) s --,
CH 2 ═CH--(CH 2 ) s --,
C 1-6 alkyl-CH═CH--(CH 2 ) s --,
C 3-7 cycloalkyl-CH═CH--(CH 2 ) s --,
aryl-CH═CH--(CH 2 ) s --,
C 1-6 alkylaryl-CH═CH--(CH 2 ) s --,
C 1-6 alkyl-SO 2 --(CH 2 ) s --,
C 1-6 alkylaryl-SO 2 --(CH 2 ) s --,
C 1-6 alkoxy,
aryl C 1-6 alkoxy,
aryl C 1-6 alkyl,
(C 1-6 alkyl) q amino C 1-6 alkyl,
(aryl) q amino,
(aryl) q amino C 1-6 alkyl,
(aryl C 1-6 alkyl) q amino,
(aryl C 1-6 alkyl) q amino C 1-6 alkyl,
arylcarbonyloxy,
aryl C 1-6 alkylcarbonyloxy,
(C 1-6 alkyl) q aminocarbonyloxy,
C 1-8 alkylsulfonylamino,
arylsulfonylamino,
C 1-8 alkylsulfonylamino C 1-6 alkyl,
arylsulfonylamino C 1-6 alkyl,
aryl C 1-6 alkylsulfonylamino,
aryl C 1-6 alkylsulfonylamino C 1-6 alkyl,
C 1-8 alkoxycarbonylamino,
C 1-8 alkoxycarbonylamino C 1-8 alkyl,
aryloxycarbonylamino C 1-8 alkyl,
aryl C 1-8 alkoxycarbonylamino,
aryl C 1-8 alkoxycarbonylamino C 1-8 alkyl,
C 1-8 alkylcarbonylamino,
C 1-8 alkylcarbonylamino C 1-6 alkyl,
arylcarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylcarbonylamino,
aryl C 1-6 alkylcarbonylamino C 1-6 alkyl,
aminocarbonylamino C 1-6 alkyl,
(C 1-8 alkyl) q aminocarbonylamino,
(C 1-8 alkyl) q aminocarbonylamino C 1-6 alkyl,
(aryl) q aminocarbonylamino C 1-6 alkyl,
(aryl C 1-8 alkyl) q aminocarbonylamino,
(aryl C 1-8 alkyl) q aminocarbonylamino C 1-6 alkyl,
aminosulfonylamino C 1-6 alkyl,
(C 1-8 alkyl) q aminosulfonylamino,
(C 1 -8 alkyl) q aminosulfonylamino C 1-6 alkyl,
(aryl) q aminosulfonylamino C 1-6 alkyl,
(aryl C 1-8 alkyl) q aminosulfonylamino,
(aryl C 1-8 alkyl) q aminosulfonylamino C 1-6 alkyl,
C 1-6 alkylsulfonyl,
C 1-6 alkylsulfonyl C 1-6 alkyl,
arylsulfonyl C 1-6 alkyl,
aryl C 1-6 alkylsulfonyl,
aryl C 1-6 alkylsulfonyl C 1-6 alkyl,
C 1-6 alkylcarbonyl,
C 1-6 alkylcarbonyl C 1-6 alkyl,
arylcarbonyl C 1-6 alkyl,
aryl C 1-6 alkylcarbonyl,
aryl C 1-6 alkylcarbonyl C 1-6 alkyl,
C 1-6 alkylthiocarbonylamino,
C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
arylthiocarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylthiocarbonylamino,
aryl C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
(C 1-8 alkyl) q aminocarbonyl C 1-6 alkyl,
(aryl) q aminocarbonyl C 1-6 alkyl,
(aryl C 1-8 alkyl) q aminocarbonyl, or
(aryl C 1-8 alkyl) q aminocarbonyl C 1-6 alkyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ; and provided that the carbon atom to which R 8 and R 9 are attached is itself attached to no more than one heteroatom; and provided further that the carbon atom to which R 10 and R 11 are attached is itself attached to no more than one heteroatom;
R 12 is selected from
hydrogen,
C 1-8 alkyl,
aryl,
aryl C 1-8 alkyl,
C 1-8 alkylcarbonyloxy C 1-4 alkyl,
aryl C 1-8 alkylcarbonyloxy C 1-4 alkyl,
C 1-8 alkylaminocarbonylmethylene, or
C 1-8 dialkylaminocarbonylmethylene;
m, s and t are each independently an integer from 0 to 3;
n is an integer from 1 to 3;
p is an integer from 1 to 4;
q is an integer from 0 to 2;
r is an integer from 0 to 6;
and the pharmaceutically acceptable salts thereof.
Particularly illustrative of the invention is the cohmpound wherein Z is a 5-11 membered nonaromatic mono- or polycyclic ring system containing 0 to 6 double bonds, and containing 0 to 6 heteroatoms chosen from N, O and S, and wherein the ring system is either unsubstituted or substituted on a carbon or nitrogen atom with one or more groups independently selected from R 4 , R 5 , R 6 and R 7 ; and all other variables are as defined above.
Exemplifying the invention is the compound wherein Z is selected from ##STR21## and the pharmaceutically acceptable salts thereof. Preferably Z is selected from ##STR22##
An example of the invention is the compound of the formula ##STR23## wherein X is selected from ##STR24## Y is selected from --(CH 2 ) r -- or --(CH 2 ) m --NR 3 --(CH 2 ) t --;
R 3 is selected from
hydrogen,
aryl-(CH 2 ) p --,
C 1-5 alkoxycarbonyl,
C 3-8 cycloalkyl,
(aryl) q aminocarbonyl,
(aryl C 1-5 alkyl) q aminocarbonyl,
C 1-8 alkyl,
aryl C 1-6 alkyl,
C 1-8 alkylsulfonyl,
arylsulfonyl,
aryl C 1-6 alkylsulfonyl,
C 1-8 alkoxycarbonyl,
aryloxycarbonyl,
aryl C 1-8 alkoxycarbonyl,
C 1-8 alkylcarbonyl,
arylcarbonyl,
aryl C 1-6 alkylcarbonyl,
(C 1-8 alkyl) q aminocarbonyl,
C 1-6 alkylsulfonyl, or
aryl C 1-6 alkylcarbonyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ;
R 4 is selected from
hydrogen, C 1-6 alkyl, C 3-8 cycloalkyl, C 3-8 cycloheteroalkyl,
C 3-8 cycloalkyl C 1-6 alkyl, C 3-8 cycloheteroalkyl C 1-6 alkyl,
aryl or aryl C 1-8 alkyl,
R 8 is selected from
hydrogen,
aryl,
aryl-(CH 2 ) p --,
CH.tbd.C--(CH 2 ) s --,
C 1-6 alkyl-C.tbd.C--(CH 2 ) s --,
C 3-7 cycloalkyl-C.tbd.C--(CH 2 ) s --,
aryl-C.tbd.C--(CH 2 ) s --,
C 1-6 alkylaryl-C.tbd.C--(CH 2 ) s --,
CH 2 ═CH--(CH 2 ) s --,
C 1-6 alkyl-CH═CH--(CH 2 ) s --,
C 3-7 cycloalkyl-CH═CH--(CH 2 ) s --,
aryl-CH═CH--(CH 2 ) s --,
C 1-6 alkylaryl-CH═CH--(CH 2 ) s --,
C 1-6 alkyl-SO 2 --(CH 2 ) s --,
C 1-6 alkylaryl-SO 2 --(CH 2 ) s --; and
r is an integer from 0 to 3;
wherein all other variables are as defined above;
and the pharmaceutically acceptable salts thereof.
Further illustrating the invention is the compound of the formula ##STR25## wherein Z is selected from ##STR26## R 8 is selected from hydrogen, ##STR27## indolyl-(CH 2 ) p --, CH.tbd.C--(CH 2 ) s --,
C 1-6 alkyl-C.tbd.C--(CH 2 ) s --,
C 3-7 cycloalkyl-C.tbd.C--(CH 2 ) s --,
aryl-C.tbd.C--(CH 2 ) s --,
C 1-6 alkylaryl-C.tbd.C--(CH 2 ) s --,
CH 2 ═CH--(CH 2 ) s --,
C 1-6 alkyl-CH═CH--(CH 2 ) s --,
C 3-7 cycloalkyl-CH═CH--(CH 2 ) s --,
aryl-CH═CH--(CH 2 ) s --,
C 1-6 alkylaryl-CH═CH--(CH 2 ) s --,
C 1-6 alkyl-SO 2 --(CH 2 ) s --,
C 1-6 alkylaryl-SO 2 --(CH 2 ) s --; and
R 12 is selected from hydrogen or C 1-8 alkyl; and s is an integer from 0 to 3; and all other variables are as defined above; and the pharmaceutically acceptable salts thereof.
Further exemplifying the invention is the compound selected from
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]piperidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester;
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]piperin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine trifluoroacetate;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine ethyl ester;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]-pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine ethyl ester;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]-pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
Ethyl 2-oxo-3-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]-tetrahydropyrimidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine;
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl}ethyl]-tetrahydropyrimidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine;
Ethyl 2-oxo-3-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]imidazolidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine;
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl}ethyl]-imidazolidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine;
Ethyl 2-oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(R)-(2-ethylindol-3-yl)-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(R)-(2-ethylinddol-3-yl)-β-alanine;
Ethyl 3-(2-{2-oxo-3(S)-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-pyrrolidin-1-yl}-acetylamino)-3-(S)-pyridin-3-yl-propionic acid;
3-(2-{2-Oxo-3(S)-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl}-acetylamino)-3-(S)-pyridin-3-yl-propionic acid;
3-{2-[6-Oxo-1-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-hexahydro-(3aS,6aS) p yrrolo[3,4-b]pyrrol-5-yl]-acetylamino}-3-(S)-pyridin-3-yl-propionic acid;
3-{2-[6-Oxo-1-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-hexahydro-(3aR, 6aR)pyrrolo[3,4-b]pyrrol-5-yl]-acetylamino}-3-(S)-pyridin-3-yl-propionic acid;
2-Oxo-5(R)-methyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)-ethyl]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine ethyl ester;
2-Oxo-5(R)-methyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine;
2-Oxo-5(S)-benzyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)-ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester;
2-Oxo-5(S)-benzyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
5(R)-Methyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine ethyl ester;
5(R)-Methyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine;
3(S)-(2,3-Dihydro-benzofuran-6-yl)-3-(2-{2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}acetylamino)-propionic acid ethyl ester; or
3(S)-(2,3-Dihydro-benzofuran-6-yl)-3-(2-{2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetylamino)-propionic acid;
and the pharmaceutically acceptable salts thereof.
Preferably, the compound is selected from
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]piperin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine trifluoroacetate;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine;
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl}ethyl]-imidazolidin-1-yl-acetyl-3-(S)-pyridin-3-yl-β-alanine;
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl}ethyl]-tetrahydropyrimidin-1-yl-acetyl-3-(S)-pyridin-3-yl-β-alanine;
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(R)-(2-ethylindol-3-yl)-β-alanine;
3-(2-{2-Oxo-3(S)-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl}-acetylamino)-3-(S)-pyridin-3-yl-propionic acid;
3-{2-[6-Oxo-1-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-hexahydro-(3aS, 6aS)pyrrolo[3,4-b]pyrrol-5-yl]-acetylamino}-3-(S)-pyridin-3-yl-propionic acid; or
3-{2-[6-Oxo-1-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-hexahydro-(3aR, 6aR)pyrrolo[3,4-b]pyrrol-5-yl]-acetylamino-}-3-(S)-pyridin-3-yl-propionic acid;
2-Oxo-5(R)-methyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine;
2-Oxo-5(S)-benzyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine;
5(R)-Methyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl)acetyl-3(S)-alkynyl-β-alanine; or
3(S)-(2,3-Dihydro-benzofuran-6-yl)-3-(2-{2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetylamino)-propionic acid;
and the pharmaceutically acceptable salts thereof.
An additional example of the invention is a compound of the formula ##STR28## wherein X is a 9- to 10-membered polycyclic ring system, wherein one or more of the rings is aromatic, and wherein the polycyclic ring system contains 0, 1, 2, 3 or 4 heteroatoms selected from N, O or S, and wherein the polycyclic ring system is either unsubstituted or substituted on a carbon atom with R 1 and R 2 ;
Y is selected from ##STR29## Z is a 5-11 membered aromatic or nonaromatic mono- or polycyclic ring system containing 0 to 6 double bonds, and containing 0 to 6 heteroatoms chosen from N, O and S, and wherein the ring system is either unsubstituted or substituted on a carbon or nitrogen atom with one or more groups independently selected from R 4 , R 5 , R 6 and R 7 ; provided that Z is not a 6-membered monocyclic aromatic ring system; preferably, Z is selected from ##STR30## R 1 , R 2 , R 3 , R 4 , R 5 , R 13 and R 14 are each independently selected from hydrogen, halogen, C 1-10 alkyl, C 3-8 cycloalkyl, aryl, aryl C 1-8 alkyl, amino, amino C 1-8 alkyl, C 1-3 acylamino, C 1-3 acylamino C 1-8 alkyl, C 1-6 alkylamino, C 1-6 alkylamino-C 1-8 alkyl, C 1-6 dialkylamino, C 1-6 dialkylamino C 1-8 alkyl, C 1-4 alkoxy, C 1-4 alkoxy C 1-6 alkyl, hydroxycarbonyl, hydroxycarbonyl C 1-6 alkyl, C 1-3 alkoxycarbonyl, C 1-3 alkoxycarbonyl C 1-6 alkyl, hydroxycarbonyl-C 1-6 alkyloxy, hydroxy or hydroxy C 1-6 alkyl;
R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are each independently selected from
hydrogen,
aryl,
--(CH 2 ) p -aryl,
halogen,
hydroxyl,
C 1-8 alkylcarbonylamino,
aryl C 1-5 alkoxy,
C 1-5 alkoxycarbonyl,
aminocarbonyl,
C 1-8 alkylaminocarbonyl,
C 1-6 alkylcarbonyloxy,
C 3-8 cycloalkyl,
oxo,
amino,
C 1-6 alkylamino,
amino C 1-6 alkyl,
arylaminocarbonyl,
aryl C 1-5 alkylaminocarbonyl,
aminocarbonyl,
aminocarbonyl C 1-6 alkyl,
hydroxycarbonyl,
hydroxycarbonyl C 1-6 alkyl,
C 1-8 alkyl, either unsubstituted or substituted, with one or more groups selected from: halogen, hydroxyl, C 1-8 5 alkylcarbonylamino, aryl C 1-5 alkoxy, C 1-5 alkoxycarbonyl, aminocarbonyl, C 1-5 alkylaminocarbonyl, C 1-5 alkylcarbonyloxy, C 3-8 cycloalkyl, oxo, amino, C 1-3 alkylamino, amino C 1-3 alkyl, arylaminocarbonyl, aryl C 1-5 alkylaminocarbonyl, aminocarbonyl, aminocarbonyl C 1-4 alkyl, hydroxycarbonyl, or hydroxycarbonyl C 1-5 alkyl,
--(CH 2 ) s C.tbd.CH,
--(CH 2 ) s C.tbd.C--C 1-6 alkyl,
--(CH 2 ) s C.tbd.C--C 3-7 cycloalkyl,
--(CH 2 ) s C.tbd.C-aryl,
--(CH 2 ) s C.tbd.C--C 1-6 alkylaryl,
--(CH 2 ) s CH═CH 2 ,
--(CH 2 ) s CH═CH C 1-6 alkyl,
--(CH 2 ) s CH═CH--C 3-7 cycloalkyl,
--(CH 2 ) s CH═CH aryl,
--(CH 2 ) s CH═CH C 1-6 alkylaryl,
--(CH 2 ) s SO 2 C 1-6 alkyl, or
--(CH 2 ) s SO 2 C 1-6 alkylaryl;
C 1-6 alkoxy,
aryl C 1-6 alkoxy,
aryl C 1-6 alkyl,
C 1-6 alkylamino C 1-6 alkyl,
arylamino,
arylamino C 1-6 alkyl,
aryl C 1-6 alkylamino,
aryl C 1-6 alkylamino C 1-6 alkyl,
arylcarbonyloxy,
aryl C 1-6 alkylcarbonyloxy,
C 1-6 dialkylamino,
C 1-6 dialkylamino C 1-6 alkyl,
C 1-6 alkylaminocarbonyloxy,
C 1-8 alkylsulfonylamino,
C 1-8 alkylsulfonylamino C 1-6 alkyl,
arylsulfonylamino C 1-6 alkyl,
aryl C 1-6 alkylsulfonylamino,
aryl C 1-6 alkylsulfonylamino C 1-6 alkyl,
C 1-8 alkoxycarbonylamino,
C 1-8 alkoxycarbonylamino C 1-8 alkyl,
aryloxycarbonylamino C 1-8 alkyl,
aryl C 1-8 alkoxycarbonylamino,
aryl C 1-8 alkoxycarbonylamino C 1-8 alkyl,
C 1-8 alkylcarbonylamino,
C 1-8 alkylcarbonylamino C 1-6 alkyl,
arylcarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylcarbonylamino,
aryl C 1-6 alkylcarbonylamino C 1-6 alkyl,
aminocarbonylamino C 1-6 alkyl,
C 1-8 alkylaminocarbonylamino,
C 1-8 alkylaminocarbonylamino C 1-6 alkyl,
arylaminocarbonylamino C 1-6 alkyl,
aryl C 1-8 alkylaminocarbonylamino,
aryl C 1-8 alkylaminocarbonylamino C 1-6 alkyl,
aminosulfonylamino C 1-6 alkyl,
C 1-8 alkylaminosulfonylamino,
C 1-8 alkylaminosulfonylamino C 1-6 alkyl,
arylaminosulfonylamino C 1-6 alkyl,
aryl C 1-8 alkylaminosulfonylamino,
aryl C 1-8 alkylaminosulfonylamino C 1-6 alkyl,
C 1-6 alkylsulfonyl,
C 1-6 alkylsulfonyl C 1-6 alkyl,
arylsulfonyl C 1-6 alkyl,
aryl C 1-6 alkylsulfonyl,
aryl C 1-6 alkylsulfonyl C 1-6 alkyl,
C 1-6 alkylcarbonyl,
C 1-6 alkylcarbonyl C 1-6 alkyl,
arylcarbonyl C 1-6 alkyl,
aryl C 1-6 alkylcarbonyl,
aryl C 1-6 alkylcarbonyl C 1-6 alkyl,
C 1-6 alkylthiocarbonylamino,
C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
arylthiocarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylthiocarbonylamino,
aryl C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
C 1-8 alkylaminocarbonyl C 1-6 alkyl,
arylaminocarbonyl C 1-6 alkyl,
aryl C 1-8 alkylaminocarbonyl, or
aryl C 1-8 alkylaminocarbonyl C 1-6 alkyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ; and provided that the carbon atom to which R 8 and R 9 are attached is itself attached to no more than one heteroatom; and provided further that the carbon atom to which R 10 and R 11 are attached is itself attached to no more than one heteroatom;
R 12 is selected from
hydrogen,
C 1-8 alkyl,
aryl,
aryl C 1-8 alkyl,
hydroxy,
C 1-8 alkoxy,
aryloxy,
aryl C 1-6 alkoxy,
C 1-8 alkylcarbonyloxy C 1-4 alkoxy,
aryl C 1-8 alkylcarbonyloxy C 1-4 alkoxy,
C 1-8 alkylaminocarbonylmethyleneoxy, or
C 1-8 dialkylaminocarbonylmethyleneoxy;
m is an integer from 0 to 3;
n is an integer from 1 to 3;
p is an integer from 1 to 4;
q is an integer from 0 to 2;
r is an integer from 0 to 6; and
s is an integer from 0 to 3;
and the pharmaceutically acceptable salts thereof.
An additional illustration of the invention is a compound of the formula ##STR31## wherein X is a 9- to 10-membered polycyclic ring system, wherein one or more of the rings is aromatic, and wherein the polycyclic ring system contains 0, 1, 2, 3 or 4 heteroatoms selected from N, O or S, and wherein the polycyclic ring system is either unsubstituted or substituted on a carbon atom with R 1 and R 2 ;
Y is selected from ##STR32## Z is a 5-11 membered aromatic or nonaromatic mono- or polycyclic ring system containing 0 to 6 double bonds, and containing 0 to 6 heteroatoms chosen from N, O and S, and wherein the ring system is either unsubstituted or substituted on a carbon or nitrogen atom with one or more groups independently selected from R 4 , R 5 , R 6 and R 7 ; provided that Z is not a 6-membered monocyclic aromatic ring system; preferably, Z is selected from ##STR33## R 1 , R 2 , R 4 , R 5 , R 13 and R 14 are each independently selected from hydrogen, halogen, C 1-10 alkyl, C 3-8 cycloalkyl, aryl, aryl C 1-8 alkyl, amino, amino C 1-8 alkyl, C 1-3 acylamino, C 1-3 acylamino C 1-8 alkyl, C 1-6 alkylamino, C 1-6 alkylamino-C 1-8 alkyl, C 1-6 dialkylamino, C 1-6 dialkylamino C 1-8 alkyl, C 1-4 alkoxy, C 1-4 alkoxy C 1-6 alkyl, hydroxycarbonyl; hydroxycarbonyl C 1-6 alkyl, C 1-3 alkoxycarbonyl, C 1-3 alkoxycarbonyl C 1-6 alkyl, hydroxycarbonyl-C 1-6 alkyloxy, hydroxy, hydroxy C 1-6 alkyl, C 1-6 alkyloxy-C 1-6 alkyl, nitro, cyano, trifluoromethyl, trifluoromethoxy, trifluoroethoxy, C 1-8 alkyl-S(O) q , C 1-8 aminocarbonyl, C 1-8 dialkylaminocarbonyl, C 1-8 alkyloxycarbonylamino, C 1-8 alkylaminocarbonyloxy or C 1-8 alkylsulfonylamino;
R 3 is selected from
hydrogen,
aryl,
--(CH 2 ) p -aryl,
hydroxyl,
C 1-5 alkoxycarbonyl,
aminocarbonyl,
C 3-8 cycloalkyl,
amino C 1-6 alkyl,
arylaminocarbonyl,
aryl C 1-5 alkylaminocarbonyl,
hydroxycarbonyl C 1-6 alkyl,
C 1-8 alkyl,
aryl C 1-6 alkyl,
C 1-6 alkylamino C 1-6 alkyl,
aryl C 1-6 alkylamino C 1-6 alkyl,
C 1-6 dialkylamino C 1-6 alkyl,
C 1-8 alkylsulfonyl,
C 1-8 alkoxycarbonyl,
aryloxycarbonyl,
aryl C 1-8 alkoxycarbonyl,
C 1-8 alkylcarbonyl,
arylcarbonyl,
aryl C 1-6 alkylcarbonyl,
C 1-8 alkylaminocarbonyl,
aminosulfonyl,
C 1-8 alkylaminosulfonyl,
arylaminosulfonylamino,
aryl C 1-8 alkylaminosulfonyl,
C 1-6 alkylsulfonyl,
arylsulfonyl,
aryl C 1-6 alkylsulfonyl,
aryl C 1-6 alkylcarbonyl,
C 1-6 alkylthiocarbonyl,
arylthiocarbonyl, or
aryl C 1-6 alkylthiocarbonyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ;
R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are each independently selected from
hydrogen,
aryl,
--(CH 2 ) p -aryl,
halogen,
hydroxyl,
C 1-8 alkylcarbonylamino,
aryl C 1-5 alkoxy,
C 1-5 alkoxycarbonyl,
aminocarbonyl,
C 1-8 alkylaminocarbonyl,
C 1-6 alkylcarbonyloxy,
C 3-8 cycloalkyl,
oxo,
amino,
C 1-6 alkylamino,
amino C 1-6 alkyl,
arylaminocarbonyl,
aryl C 1-5 alkylaminocarbonyl,
aminocarbonyl,
aminocarbonyl C 1-6 alkyl,
hydroxycarbonyl,
hydroxycarbonyl C 1-6 alkyl,
C 1-8 alkyl, either unsubstituted or substituted, with one or more groups selected from: halogen, hydroxyl, C 1-5 alkylcarbonylamino, aryl C 1-5 alkoxy, C 1-5 alkoxycarbonyl, aminocarbonyl, C 1-5 alkylaminocarbonyl, C 1-5 alkylcarbonyloxy, C 3-8 cycloalkyl, oxo, amino, C 1-3 alkylamino, amino C 1-3 alkyl, arylaminocarbonyl, aryl C 1-5 alkylaminocarbonyl, aminocarbonyl, aminocarbonyl C 1-4 alkyl, hydroxycarbonyl, or hydroxycarbonyl C 1-5 alkyl,
--(CH 2 ) s C.tbd.CH,
--(CH 2 ) s C.tbd.C--C 1-6 alkyl,
--(CH 2 ) s C.tbd.C--C 3-7 cycloalkyl,
--(CH 2 ) s C.tbd.C-aryl,
--(CH 2 ) s C.tbd.C--C 1-6 alkylaryl,
--(CH 2 ) s CH═CH 2 ,
--(CH 2 ) s CH═CH C 1-6 alkyl,
--(CH 2 ) s CH═CH--C 3-7 cycloalkyl,
--(CH 2 ) s CH═CH aryl,
--(CH 2 ) s CH═CH C 1-6 alkylaryl,
--(CH 2 ) s SO 2 C 1-6 alkyl, or
--(CH 2 ) s SO 2 C 1-6 alkylaryl;
C 1-6 alkoxy,
aryl C 1-6 alkoxy,
aryl C 1-6 alkyl,
C 1-6 alkylamino C 1-6 alkyl,
arylamino,
arylamino C 1-6 alkyl,
aryl C 1-6 alkylamino,
aryl C 1-6 alkylamino C 1-6 alkyl,
arylcarbonyloxy,
aryl C 1-6 alkylcarbonyloxy,
C 1-6 dialkylamino,
C 1-6 dialkylamino C 1-6 alkyl,
C 1-6 alkylaminocarbonyloxy,
C 1-8 alkylsulfonylamino,
C 1-8 alkylsulfonylamino C 1-6 alkyl,
arylsulfonylamino C 1-6 alkyl,
aryl C 1-6 alkylsulfonylamino,
aryl C 1-6 alkylsulfonylamino C 1-6 alkyl,
C 1-8 alkoxycarbonylamino,
C 1-8 alkoxycarbonylamino C 1-8 alkyl,
aryloxycarbonylamino C 1-8 alkyl,
aryl C 1-8 alkoxycarbonylamino,
aryl C 1-8 alkoxycarbonylamino C 1-8 alkyl,
C 1-8 alkylcarbonylamino,
C 1-8 alkylcarbonylamino C 1-6 alkyl,
arylcarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylcarbonylamino,
aryl C 1-6 alkylcarbonylamino C 1-6 alkyl,
aminocarbonylamino C 1-6 alkyl,
C 1-8 alkylaminocarbonylamino,
C 1-8 alkylaminocarbonylamino C 1-6 alkyl,
arylaminocarbonylamino C 1-6 alkyl,
aryl C 1-8 alkylaminocarbonylamino,
aryl C 1-8 alkylaminocarbonylamino C 1-6 alkyl,
aminosulfonylamino C 1-6 alkyl,
C 1-8 alkylaminosulfonylamino,
C 1-8 alkylaminosulfonylamino C 1-6 alkyl,
arylaminosulfonylamino C 1-6 alkyl,
aryl C 1-8 alkylaminosulfonylamino,
aryl C 1-8 alkylaminosulfonylamino C 1-6 alkyl,
C 1-6 alkylsulfonyl,
C 1-6 alkylsulfonyl C 1-6 alkyl,
arylsulfonyl C 1-6 alkyl,
aryl C 1-6 alkylsulfonyl,
aryl C 1-6 alkylsulfonyl C 1-6 alkyl,
C 1-6 alkylcarbonyl,
C 1-6 alkylcarbonyl C 1-6 alkyl,
arylcarbonyl C 1-6 alkyl,
aryl C 1-6 alkylcarbonyl,
aryl C 1-6 alkylcarbonyl C 1-6 alkyl,
C 1-6 alkylthiocarbonylamino,
C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
arylthiocarbonylamino C 1-6 alkyl,
aryl C 1-6 alkylthiocarbonylamino,
aryl C 1-6 alkylthiocarbonylamino C 1-6 alkyl,
C 1-8 alkylaminocarbonyl C 1-6 alkyl,
arylaminocarbonyl C 1-6 alkyl,
aryl C 1-8 alkylaminocarbonyl, or
aryl C 1-8 alkylaminocarbonyl C 1-6 alkyl,
wherein any of the alkyl groups may be unsubstituted or substituted with R 13 and R 14 ; and provided that the carbon atom to which R 8 and R 9 are attached is itself attached to no more than one heteroatom; and provided further that the carbon atom to which R 10 and R 11 are attached is itself attached to no more than one heteroatom;
R 12 is selected from
hydrogen,
C 1-8 alkyl,
aryl,
aryl C 1-8 alkyl,
hydroxy,
C 1-8 alkoxy,
aryloxy,
aryl C 1-6 alkoxy,
C 1-8 alkylcarbonyloxy C 1-4 alkoxy,
aryl C 1-8 alkylcarbonyloxy C 1-4 alkoxy,
C 1-8 alkylaminocarbonylmethyleneoxy, or
C 1-8 dialkylaminocarbonylmethyleneoxy;
m is an integer from 0 to 3;
n is an integer from 1 to 3;
p is an integer from 1 to 4;
q is an integer from 0 to 2;
r is an integer from 0 to 6; and
s is an integer from 0 to 3;
and the pharmaceutically acceptable salts thereof.
More particularly illustrating the invention is a pharmaceutical composition comprising any of the compounds described above and a pharmaceutically acceptable carrier. Another example of the invention is a pharmaceutical composition made by combining any of the compounds described above and a pharmaceutically acceptable carrier. Another illustration of the invention is a process for making a pharmaceutical composition comprising combining any of the compounds described above and a pharmaceutically acceptable carrier.
Further illustrating the invention is a method of treating and/or preventing a condition mediated by antagonism of a vitronectin receptor in a mammal in need thereof, comprising administering to the mammal a therapeutically effective amount of any of the compounds described above. Preferably, the condition is selected from bone resorption, osteoporosis, restenosis, diabetic retinopathy, macular degeneration, angiogenesis, atherosclerosis, inflammation, cancer and tumor growth. More preferably, the condition is selected from osteoporosis and cancer. Most preferably, the condition is osteoporosis.
More specifically exemplifying the invention is a method of eliciting a vitronectin antagonizing effect in a mammal in need thereof, comprising administering to the mammal a therapeutically effective amount of any of the compounds or any of the pharmaceutical compositions described above. Preferably, the vitronectin antagonizing effect is an αvpβ3 antagonizing effect; more specifically the αvβ3 antagonizing effect is selected from inhibition of bone resorption, inhibition of restenosis, inhibition of atherosclerosis, inhibition of angiogenesis, inhibition of diabetic retinopathy, inhibition of macular degeneration, inhibition of inflammation or inhibition of tumor growth. Most preferably, the αvβ3 antagonizing effect is inhibition of bone resorption. Alternatively, the vitronectin antagonizing effect is an αvβ5 antagonizing effect or a dual αvβ3/αvβ5 antagonizing effect. Examples of αvβ5 antagonizing effects are inhibition of: restenosis, atherosclerosis, angiogenesis, diabetic retinopathy, macular degeneration, inflammation or tumor growth. Examples of dual αvβ3/αvβ5 antagonizing effects are inhibition of: bone resorption, restenosis, atherosclerosis, angiogenesis, diabetic retinopathy, macular degeneration, inflammation or tumor growth.
Additional examples of the invention are methods of inhibiting bone resorption and of treating and/or preventing osteoporosis in a mammal in need thereof, comprising administering to the mammal a therapeutically effective amount of any of the compounds or any of the pharmaceutical compositions described above.
Further exemplifying the invention is any of the compositions described above, further comprising a therapeutically effective amount of a second bone resorption inhibitor; preferably, the second bone resorption inhibitor is alendronate.
More particularly illustrating the invention is any of the methods of treating and/or preventing osteoporosis and/or of inhibiting bone resoption described above, wherein the compound is administered in combination with a second bone resorption inhibitor; preferably, the second bone resorption inhibitor is alendronate.
Additional illustrations of the invention are methods of treating hypercalcemia of malignancy, osteopenia due to bone metastases, periodontal disease, hyperparathyroidism, periarticular erosions in rheumatoid arthritis, Paget's disease, immobilization-induced osteopenia, and glucocorticoid treatment in a mammal in need thereof, comprising administering to the mammal a therapeutically effective amount of any of the compounds or any of the pharmaceutical compositions described above.
More particularly exemplifying the invention is the use of any of the compounds described above in the preparation of a medicament for the treatment and/or prevention of osteoporosis in a mammal in need thereof. Still further exemplifying the invention is the use of any of the compounds described above in the preparation of a medicament for the treatment and/or prevention of: bone resorption, tumor growth, cancer, restenosis, atherosclerosis, diabetic retinopathy, macular degeneration, inflammation and/or angiogenesis.
Additional illustrations of the invention are methods of treating tumor growth in a mammal in need thereof, comprising administering to the mammal a therapeutically effective amount of a compound described above and one or more agents known to be cytotoxic or antiproliferative, e.g., taxol and doxorubicin.
DETAILED DESCRIPTION OF THE INVENTION
Representative compounds of the present invention are integrin antagonists which display submicromolar affinity for the human αvβ3 receptor. Compounds of this invention are therefore useful for treating mammals suffering from a bone condition caused or mediated by increased bone resorption, who are in need of such therapy. Pharmacologically effective amounts of the compounds, including pharamaceutically acceptable salts thereof, are administered to the mammal, to inhibit the activity of mammalian osteoclasts.
The compounds of the present invention are administered in dosages effective to antagonize the αvβ3 receptor where such treatment is needed, as, for example, in the prevention or treatment of osteoporosis. For use in medicine, the salts of the compounds of this invention refer to non-toxic "pharmaceutically acceptable salts." Other salts may, however, be useful in the preparation of the compounds according to the invention or of their pharmaceutically acceptable salts. Salts encompassed within the term "pharmaceutically acceptable salts" refer to non-toxic salts of the compounds of this invention which are generally prepared by reacting the free base with a suitable organic or inorganic acid. Representative salts include the following:
Acetate, Benzenesulfonate, Benzoate, Bicarbonate, Bisulfate, Bitartrate, Borate, Bromide, Calcium, Camsylate, Carbonate, Chloride, Clavulanate, Citrate, Dihydrochloride, Edetate, Edisylate, Estolate, Esylate, Fumarate, Gluceptate, Gluconate, Glutamate, Glycollylarsanilate, Hexylresorcinate, Hydrabamine, Hydrobromide, Hydrochloride, Hydroxynaphthoate, Iodide, Isothionate, Lactate, Lactobionate, Laurate, Malate, Maleate, Mandelate, Mesylate, Methylbromide, Methylnitrate, Methylsulfate, Mucate, Napsylate, Nitrate, N-methylglucamine ammonium salt, Oleate, Oxalate, Pamoate (Embonate), Palmitate, Pantothenate, Phosphate/diphosphate, Polygalacturonate, Salicylate, Stearate, Sulfate, Subacetate, Succinate, Tannate, Tartrate, Teoclate, Tosylate, Triethiodide and Valerate. Furthermore, where the compounds of the invention carry an acidic moiety, suitable pharmaceutically acceptable salts thereof may include alkali metal salts, e.g., sodium or potassium salts; alkaline earth metal salts, e.g., calcium or magnesium salts; and salts formed with suitable organic ligands, e.g., quaternary ammonium salts.
The compounds of the present invention, may have chiral centers and occur as racemates, racemic mixtures, diastereomeric mixtures, and as individual diastereomers, or enantiomers with all isomeric forms being included in the present invention. Therefore, where a compound is chiral, the separate enantiomers, substantially free of the other, are included within the scope of the invention; further included are all mixtures of the two enantiomers. Also included within the scope of the invention are polymorphs and hydrates of the compounds of the instant invention.
The present invention includes within its scope prodrugs of the compounds of this invention. In general, such prodrugs will be functional derivatives of the compounds of this invention which are readily convertible in vivo into the required compound. Thus, in the methods of treatment of the present invention, the term "administering" shall encompass the treatment of the various conditions described with the compound specifically disclosed or with a compound which may not be specifically disclosed, but which converts to the specified compound in vivo after administration to the patient. Conventional procedures for the selection and preparation of suitable prodrug derivatives are described, for example, in "Design of Prodrugs," ed. H. Bundgaard, Elsevier, 1985. Metabolites of these compounds include active species produced upon introduction of compounds of this invention into the biological milieu.
The term "therapeutically effective amount" shall mean that amount of a drug or pharmaceutical agent that will elicit the biological or medical response of a tissue, system, animal or human that is being sought by a researcher or clinician.
The term "vitronectin receptor antagonist," as used herein, refers to a compound which binds to and antagonizes either the αvβ3 receptor or the αvβ5 receptor, or a compound which binds to and antagonizes both the αvβ3 and αvβ5 receptors (i.e., a dual αvβ3/αvβ5 receptor antagonist).
The term "bone resorption," as used herein, refers to the process by which osteoclasts degrade bone.
The term "alkyl" shall mean straight or branched chain alkanes of one to ten total carbon atoms, or any number within this range (i.e., methyl, ethyl, 1-propyl, 2-propyl, n-butyl, s-butyl, t-butyl, etc.).
The term "alkenyl" shall mean straight or branched chain alkenes of two to ten total carbon atoms, or any number within this range.
The term "alkynyl" shall mean straight or branched chain alkynes of two to ten total carbon atoms, or any number within this range.
The term "cycloalkyl" shall mean cyclic rings of alkanes of three to eight total carbon atoms, or any number within this range (i.e., cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl).
The term "cycloheteroalkyl," as used herein, shall mean a 3- to 8-membered fully saturated heterocyclic ring containing one or two heteroatoms chosen from N, O or S. Examples of cycloheteroalkyl groups include, but are not limited to piperidinyl, pyrrolidinyl, azetidinyl, morpholinyl, piperazinyl.
The term "alkoxy," as used herein, refers to straight or branched chain alkoxides of the number of carbon atoms specified (e.g., C 1-5 alkoxy), or any number within this range (i.e., methoxy, ethoxy, etc.).
The term "aryl," as used herein, refers to a monocyclic or polycyclic system composed of 5- and 6-membered fully unsaturated or partially unsaturated rings, such that the system comprises at least one fully unsaturated ring, wherein the rings contain 0, 1, 2, 3 or 4 heteroatoms chosen from N, O or S, and either unsubstituted or substituted with one or more groups independently selected from hydrogen, halogen, C 1-10 alkyl, C 3-8 cycloalkyl, aryl, aryl C 1-8 alkyl, amino, amino C 1-8 alkyl, C 1-3 acylamino, C 1-3 acylamino C 1-8 alkyl, C 1-6 alkylamino, C 1-6 alkylamino C 1-8 alkyl, C 1-6 dialkylamino, C 1-6 dialkylamino-C 1-8 alkyl, C 1-4 alkoxy, C 1-4 alkoxy C 1-6 alkyl, hydroxycarbonyl, hydroxycarbonyl C 1-6 alkyl, C 1-5 alkoxycarbonyl, C 1-3 alkoxycarbonyl C 1-6 alkyl, hydroxycarbonyl C 1-6 alkyloxy, hydroxy, hydroxy C 1-6 alkyl, cyano, trifluoromethyl, oxo or C 1-5 alkylcarbonyloxy. Examples of aryl include, but are not limited to, phenyl, naphthyl, pyridyl, pyrazinyl, pyrimidinyl, imidazolyl, benzimidazolyl, indolyl, thienyl, furyl, dihydrobenzofuryl, benzo(1,3) dioxolane, oxazolyl, isoxazolyl and thiazolyl, which are either unsubstituted or substituted with one or more groups independently selected from hydrogen, halogen, C 1-10 alkyl, C 3-8 cycloalkyl, aryl, aryl C 1-8 alkyl, amino, amino C 1-8 alkyl, C 1-3 acylamino, C 1-3 acylamino C 1-8 alkyl, C 1-6 alkylamino, C 1-6 alkylamino-C 1-8 alkyl, C 1-6 dialkylamino, C 1-6 dialkylamino C 1-8 alkyl, C 1-4 alkoxy, C 1-4 alkoxy C 1-6 alkyl, hydroxycarbonyl, hydroxycarbonyl C 1-6 alkyl, C 1-5 alkoxycarbonyl, C 1-3 alkoxycarbonyl C 1-6 alkyl, hydroxycarbonyl C 1-6 alkyloxy, hydroxy, hydroxy C 1-6 alkyl, cyano, trifluoromethyl, oxo or C 1-5 alkylcarbonyloxy. Preferably, the aryl group is unsubstituted, mono-, di-, tri- or tetra-substituted with one to four of the above-named substituents; more preferably, the aryl group is unsubstituted, mono-, di- or tri-substituted with one to three of the above-named substituents; most preferably, the aryl group is unsubstituted, mono- or di-substituted with one to two of the above-named substituents.
Whenever the term "alkyl" or "aryl" or either of their prefix roots appear in a name of a substituent (e.g., aryl C 0-8 alkyl) it shall be interpreted as including those limitations given above for "alkyl" and "aryl." Designated numbers of carbon atoms (e.g., C 1-10 ) shall refer independently to the number of carbon atoms in an alkyl or cyclic alkyl moiety or to the alkyl portion of a larger substituent in which alkyl appears as its prefix root.
The terms "arylalkyl" and "alkylaryl" include an alkyl portion where alkyl is as defined above and to include an aryl portion where aryl is as defined above. The C 0-m or C 1-m designation where m may be an integer from 1-10 or 2-10 respectively refers to the alkyl component of the arylalkyl or alkylaryl unit. Examples of arylalkyl include, but are not limited to, benzyl, fluorobenzyl, chlorobenzyl, phenylethyl, phenylpropyl, fluorophenylethyl, chlorophenylethyl, thienylmethyl, thienylethyl, and thienylpropyl. Examples of alkylaryl include, but are not limited to, toluene, ethylbenzene, propylbenzene, methylpyridine, ethylpyridine, propylpyridine and butylpyridine.
When substituent R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , R 11 , R 12 , R 13 or R 14 includes the definition C 0 (e.g., aryl C 0-8 alkyl), the group modified by C 0 is not present in the substituent. Similarly, when any of the variables m, q, r or s is zero, then the group modified by the variable is not present; for example, when s is zero, the group "--(CH 2 ) s C.tbd.CH" is "--C.tbd.CH". In addition, the substituent "(C 1-6 alkyl) q amino" where q is zero, one or two, refers to an amino, C 1-6 alkylamino and C 1-6 dialkylamino group, respectively. When a C 1-6 dialkylamino substituent is intended, the C 1-6 alkyl groups can be the same (e.g., dimethylamino) or different (e.g., N(CH 3 )(CH 2 CH 3 )). Similarly, the substituent "(aryl) q amino" or ["(aryl C 1-6 alkyl) q amino"], where q is zero, one or two, refers to an amino, arylamino and diarylamino group, [or an amino, aryl C 1-6 alkylamino or di-(aryl C 1-6 alkyl)amino] respectively, where the aryl [or aryl C 1-6 alkyl] groups in a diarylamino [or di-(aryl C 1-6 alkyl)amino] substituent can be the same or different.
The term "halogen" shall include iodine, bromine, chlorine and fluorine.
The term "oxy" means an oxygen (O) atom. The term "thio" means a sulfur (S) atom. The term "oxo" shall mean ═O.
The term "substituted" shall be deemed to include multiple degrees of substitution by a named substitutent. Where multiple substituent moieties are disclosed or claimed, the substituted compound can be independently substituted by one or more of the disclosed or claimed substituent moieties, singly or plurally. By independently substituted, it is meant that the (two or more) substituents can be the same or different.
Under standard nonmenclature used throughout this disclosure, the terminal portion of the designated side chain is described first, followed by the adjacent functionality toward the point of attachment. For example, a C 1-5 alkylcarbonylamino C 1-6 alkyl substituent is equivalent to ##STR34##
The present invention is also directed to combinations of the compounds of the present invention with one or more agents useful in the prevention or treatment of osteoporosis. For example, the compounds of the instant invention may be effectively administered in combination with effective amounts of other agents used in the treatment of osteoporosis such as bisphosphonate bone resorption inhibitors; preferably, the bone resorption inhibitor is the bisphosphonate alendronate, now sold as FOSAMAX®. Preferred combinations are simultaneous or alternating treatments of an αvβ3 receptor antagonist of the present invention and FOSAMAX®.
In addition, the integrin (αvβ3) antagonist compounds of the present invention may be effectively administered in combination with a growth hormone secretagogue in the therapeutic or prophylactic treatment of disorders in calcium or phosphate metabolism and associated diseases. These diseases include conditions which can benefit from a reduction in bone resorption. A reduction in bone resorption should improve the balance between resorption and formation, reduce bone loss or result in bone augmentation. A reduction in bone resorption can alleviate the pain associated with osteolytic lesions and reduce the incidence and/or growth of those lesions. These diseases include: osteoporosis (including estrogen deficiency, immobilization, glucocorticoid induced and senile), osteodystrophy, Paget's disease, myositis ossificans, Bechterew's disease, malignant hypercalcemia, metastatic bone disease, periodontal disease, cholelithiasis, nephrolithiasis, urolithiasis, urinary calculus, hardening of the arteries (sclerosis), arthritis, bursitis, neuritis and tetany. Increased bone resorption can be accompanied by pathologically high calcium and phosphate concentrations in the plasma, which would be alleviated by this treatment. Similarly, the present invention would be useful in increasing bone mass in patients with growth hormone deficiency. Thus, preferred combinations are simultaneous or alternating treatments of an αvβ3 receptor antagonist of the present invention and a growth hormone secretagogue, optionally including a third component comprising FOSAMAX®.
In addition, the vitronectin receptor antagonist compounds of the present invention may be effectively administered in combination with one or more agents known to be cytoxic or antiproliferative, e.g, taxol and doxorubicin.
In accordance with the method of the present invention, the individual components of the combination can be administered separately at different times during the course of therapy or concurrently in divided or single combination forms. The instant invention is therefore to be understood as embracing all such regimes of simultaneous or alternating treatment and the term "administering" is to be interpreted accordingly. It will be understood that the scope of combinations of the compounds of this invention with other agents useful for treating αvβ3 related conditions includes in principle any combination with any pharmaceutical composition useful for treating osteoporosis.
As used herein, the term "composition" is intended to encompass a product comprising the specified ingredients in the specified amounts, as well as any product which results, directly or indirectly, from combination of the specified ingredients in the specified amounts.
The compounds of the present invention can be administered in such oral dosage forms as tablets, capsules (each of which includes sustained release or timed release formulations), pills, powders, granules, elixers, tinctures, suspensions, syrups and emulsions. Likewise, they may also be administered in intravenous (bolus or infusion), intraperitoneal, topical (e.g., ocular eyedrop), subcutaneous, intramuscular or transdermal (e.g., patch) form, all using forms well known to those of ordinary skill in the pharmaceutical arts. An effective but non-toxic amount of the compound desired can be employed as an αvβ3 inhibitor.
The dosage regimen utilizing the compounds of the present invention is selected in accordance with a variety of factors including type, species, age, weight, sex and medical condition of the patient; the severity of the condition to be treated; the route of administration; the renal and hepatic function of the patient; and the particular compound or salt thereof employed. An ordinarily skilled physician, veterinarian or clinician can readily determine and prescribe the effective amount of the drug required to prevent, counter or arrest the progress of the condition.
Oral dosages of the present invention, when used for the indicated effects, will range between about 0.01 mg per kg of body weight per day (mg/kg/day) to about 100 mg/kg/day, preferably 0.01 to 10 mg/kg/day, and most preferably 0.1 to 5.0 mg/kg/day. For oral administration, the compositions are preferably provided in the form of tablets containing 0.01, 0.05, 0.1, 0.5, 1.0, 2.5, 5.0, 10.0, 15.0, 25.0, 50.0, 100 and 500 milligrams of the active ingredient for the symptomatic adjustment of the dosage to the patient to be treated. A medicament typically contains from about 0.01 mg to about 500 mg of the active ingredient, preferably, from about 1 mg to about 100 mg of active ingredient. Intravenously, the most preferred doses will range from about 0.1 to about 10 mg/kg/minute during a constant rate infusion. Advantageously, compounds of the present invention may be administered in a single daily dose, or the total daily dosage may be administered in divided doses of two, three or four times daily. Furthermore, preferred compounds for the present invention can be administered in intranasal form via topical use of suitable intranasal vehicles, or via transdermal routes, using those forms of transdermal skin patches well known to those of ordinary skill in the art. To be administered in the form of a transdermal delivery system, the dosage administration will, of course, be continuous rather than intermittant throughout the dosage regimen.
In the methods of the present invention, the compounds herein described in detail can form the active ingredient, and are typically administered in admixture with suitable pharmaceutical diluents, excipients or carriers (collectively referred to herein as `carrier` materials) suitably selected with respect to the intended form of administration, that is, oral tablets, capsules, elixirs, syrups and the like, and consistent with conventional pharmaceutical practices.
For instance, for oral administration in the form of a tablet or capsule, the active drug component can be combined with an oral, non-toxic, pharmaceutically acceptable, inert carrier such as lactose, starch, sucrose, glucose, methyl cellulose, magnesium stearate, dicalcium phosphate, calcium sulfate, mannitol, sorbitol and the like; for oral administration in liquid form, the oral drug components can be combined with any oral, non-toxic, pharmaceutically acceptable inert carrier such as ethanol, glycerol, water and the like. Moreover, when desired or necessary, suitable binders, lubricants, disintegrating agents and coloring agents can also be incorporated into the mixture. Suitable binders include starch, gelatin, natural sugars such as glucose or beta-lactose, corn sweeteners, natural and synthetic gums such as acacia, tragacanth or sodium alginate, carboxymethylcellulose, polyethylene glycol, waxes and the like. Lubricants used in these dosage forms include sodium oleate, sodium stearate, magnesium stearate, sodium benzoate, sodium acetate, sodium chloride and the like. Disintegrators include, without limitation, starch, methyl cellulose, agar, bentonite, xanthan gum and the like.
The compounds of the present invention can also be administered in the form of liposome delivery systems, such as small unilamellar vesicles, large unilamellar vesicles and multilamellar vesicles. Liposomes can be formed from a variety of phospholipids, such as cholesterol, stearylamine or phosphatidylcholines.
Compounds of the present invention may also be delivered by the use of monoclonal antibodies as individual carriers to which the compound molecules are coupled. The compounds of the present invention may also be coupled with soluble polymers as targetable drug carriers. Such polymers can include polyvinylpyrrolidone, pyran copolymer, polyhydroxypropylmethacrylamide-phenol, polyhydroxyethylaspartamide-phenol, or polyethyleneoxide-polylysine substituted with palmitoyl residues. Furthermore, the compounds of the present invention may be coupled to a class of biodegradable polymers useful in achieving controlled release of a drug, for example, polylactic acid, polyglycolic acid, copolymers of polyactic and polyglycolic acid, polyepsilon caprolactone, polyhydroxy butyric acid, polyorthoesters, polyacetals, polydihydropyrans, polycyanoacrylates and crosslinked or amphipathic block copolymers of hydrogels.
In the schemes and examples below, various reagent symbols and abbreviations have the following meanings:
AcOH: Acetic acid.
BH 3 ·DMS: Borane·dimethylsulfide.
BOC(Boc): t-Butyloxycarbonyl.
BOP: Benzotriazol-1-yloxytris(dimethylamino)-phosphonium hexafluorophosphate.
CBZ(Cbz): Carbobenzyloxy or benzyloxycarbonyl.
CDI: Carbonyldiimidazole.
CH 2 Cl 2 : Methylene chloride.
CHCl 3 : Chloroform.
DEAD: Diethyl azodicarboxylate.
DIAD: Diisopropyl azodicarboxylate.
DIBAH or DIBAL-H: Diisobutylaluminum hydride.
DIPEA: Diisopropylethylamine.
DMAP: 4-Dimethylaminopyridine.
DME: 1,2-Dimethoxyethane.
DMF: Dimethylformamide.
DMSO: Dimethylsulfoxide.
DPFN: 3,5-Dimethyl-1-pyrazolylformamidine nitrate.
EDC: 1-(3-Dimethylaminopropyl)-3-ethylcarbodiimide.
EtOAc: Ethyl acetate.
EtOH: Ethanol.
HOAc: Acetic acid.
HOAT: 1-Hydroxy-7-azabenzotriazole
HOBT: 1-Hydroxybenzotriazole.
LDA: Lithium diisopropylamide.
MeOH: Methanol.
NEt 3 : Triethylamine.
NMM: N-methylmorpholine.
PCA·HCl: Pyrazole carboxamidine hydrochloride.
Pd/C: Palladium on activated carbon catalyst.
Ph: Phenyl.
pTSA p-Toluene sulfonic acid.
TEA: Triethylamine.
TFA: Trifluoroacetic acid.
THF: Tetrahydrofuran.
TLC: Thin Layer Chromatography.
TMEDA: N,N,N',N'-Tetramethylethylenediamine.
TMS: Trimethylsilyl.
The novel compounds of the present invention were prepared according to the procedure of the following schemes and examples, using appropriate materials and are further exemplified by the following specific examples. The most preferred compounds of the invention are any or all of those specifically set forth in these examples. These compounds are not, however, to be construed as forming the only genus that is considered as the invention, and any combination of the compounds or their moieties may itself form a genus. The following examples further illustrate details for the preparation of the compounds of the present invention. Those skilled in the art will readily understand that known variations of the conditions and processes of the following preparative procedures can be used to prepare these compounds. All temperatures are degrees Celsius unless otherwise noted.
The following Schemes and Examples describe procedures for making representative compounds of the present invention. Moreover, by utilizing the procedures described in detail in PCT International Application Publication Nos. WO95/32710, published Dec. 7, 1995, and WO95/17397, published Jun. 29, 1995, in conjunction with the disclosure contained herein, one of ordinary skill in the art can readily prepare additional compounds of the present invention claimed herein.
More specifically, procedures for preparing the N-terminus of the compounds of the present invention are described in WO 95/32710. Additionally, for a general review describing the synthesis of β-alanines which can be utilized as the C-terminus of the compounds of the present invention, see Cole, D. C., Recent Stereoselective Synthetic Approaches to β-Amino Acids, Tetrahedron, 1994, 50, 9517-9582; Juaristi, E, et al., Enantioselective Synthesis of β-Amino Acids, Aldrichemica Acta, 1994, 27, 3. In particular, synthesis of the 3-methyl β-alanine is taught in Duggan, M. F. et al., J. Med. Chem., 1995, 38, 3332-3341; the 3-ethynyl β-alanine is taught in Zablocki, J. A., et al., J. Med. Chem., 1995, 38, 2378-2394; the 3-pyrid-3-yl β-alanine is taught in Rico, J. G. et al., J. Org. Chem., 1993, 58, 7948-7951; and the 2-amino and 2-toslylamino β-alanines are taught in Xue, C-B, et al., Biorg. Med. Chem. Letts., 1996, 6, 339-344. ##STR35## 2-Oxo-3-(3-oxobutyl)piperidine (1-3)
A stirred solution of TMEDA (3.0 g, 20 mmol), 0.5 M LDA (6 mL, in THF), and THF (10 mL) at -78° C. was treated with 1-1 (1.7 g, 10 mmol) (for preparation, see: JOC, 1990, 55, 3682) to effect an orange solution.
After 1 h, the iodide 1-2 (2.4 g, 10 mmol) (J. Org. Chem., 1983, 48, 5381) was added to the orange solution and the resulting solution stirred for 2 h at -78° C., 3 h at -15° C. and then 16 h at ambient temperature. The reaction mixture was concentrated and then treated with 1N HCl (30 mL). The mixture was then basified with 1N NaOH/brine followed by extraction with EtOAc (3×). The combined extracts were dried (MgSO 4 ) and concentrated to give a yellow oil. Flash chromatography (silica, EtOAc→10% CH 3 OH/EtOAc) gave 1-3 as a colorless solid.
TLC R f 0.42 (silica, 10% CH 3 OH/EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 5.75 (bs, 1H), 3.28 (m, 2H), 2.64 (t, 7 Hz, 2H), 2.30-1.50 (m, 7H), 2.16 (s, 3H).
2-Oxo-3-[2-([1,8]-naphthyridin-2-yl)ethyl]piperidine (1-5)
A solution of 1-3 (0.25 g, 1.5 mmol), L-proline (85 mg, 0.75 mmol), 1-4 (0.18 g, 1.5 mmol) (for preparation see: Synth. Commun. 1987, 17, 1695), and ethanol (10 mL) was refluxed for 24 hr. The cooled solution was concentrated and the residue purified by flash chromatography (silica, EtOAc→20% CH 3 OH/EtOAc) to give 1-5 as a solid.
TLC R f =0.32 (silica, 20% CH 3 OH/EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 9.08 (m, 1H), 8.16 (m, 1H), 8.10 (d, J=8 Hz, 1H), 7.50 (d, J=8 Hz, 1H), 7.45 (m, 1H), 5.64 (bs, 1H), 3.31 (m, 2H), 3.18 (m, 2H), 2.50-1.60 (m, 7H).
Ethyl 2-Oxo-3-[2-([1,8]-naphthyridin-2-yl)ethyl]piperidin-1-yl-acetate (1-6)
A solution of 1-5 (0.28 g, 1.1 mmol) and DMF (10 mL) at -15° C. was treated with NaN(TMS) 2 (1.2 mL, 1.2 mmol, 1M in hexanes) to give a red solution. After 30 min, the red solution was treated with ethyl bromoacetate (128 μL, 1.2 mmol), followed by continued stirring for 1 h. The reaction mixture was then quenched with sat. NH 4 Cl and then extracted with EtOAc (3×). The combined extracts were washed with brine, dried (MgSO 4 ), and concentrated. Flash chromatography (silica, 10% CH 3 OH/EtOAc) gave 1-6 as a yellow gum.
TLC R f =0.50 (silica, 10% CH 3 OH/EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 9.07 (m, 1H), 8.16 (m, 1H), 8.10 (d, J=8 Hz, 1H), 7.50 (d, J=8 Hz, 1H), 7.44 (m, 1H), 4.30-3.90 (m, 4H), 3.50-3.30 (m, 2H), 3.17 (m, 2H), 2.46 (m, 2H), 2.20-1.70 (m, 5H), 1.28 (t, J=7 Hz, 3H).
Ethyl 2-Oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]-naphthyridin-2-yl)ethyl]piperidin-1-yl-acetate (1-7)
A mixture of 1-6 (102 mg, 0.3 mmol), 10% Pd/C (50 mg), and EtOAc (25 mL) was stirred under a hydrogen atmosphere (1 atm) for 24 h. The catalyst was then removed by filtration through celite and the filtrate concentrated. Flash chromatography (silica, 20% CH 3 OH/EtOAc) gave 1-7 as a yellow gum.
TLC R f =0.45 (silica, 30% CH 3 OH/EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 7.05 (d, J=6 Hz, 1H), 6.41 (d, J=6 Hz, 1H), 4.80 (bs, 1H), 4.18 (q, J=7 Hz, 2H), 4.08 (m, 2H), 3.37 (m, 4H), 2.80-1.60 (m, 13H), 1.26 (t, 7 Hz, 3H).
2-Oxo-3-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]piperidin-1-yl-acetic acid (1-8)
A solution of 1-7 (71 mg, 0.21 mmol) and 6N HCl (15 mL) was stirred at 55° C. for 2 h, followed by concentration to give 1-8 as a pale yellow gum. TLC R f =0.09 (silica, 20% CH 3 OH/EtOAc)
2-Oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]-naphthyridin-2-yl)ethyl]piper-idin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester (1-10)
A stirred mixture of 1-8 (71 mg, 0.20 mmol), 1-9 (59 mg, 0.22 mmol) (Rico et al., J. Org. Chem., 1993, 58, 7948), NMM (88 μL, 0.8 mmol), and CH 3 CN (25 mL) was treated with BOP (97 mg, 0.22 mmol). After 24 h, the reaction mixture was concentrated to dryness, dissolved in EtOAc, and then washed with H 2 O, dried (MgSO 4 ), and concentrated. Flash chromatography (silica, 10% (NH 3 /EtOH/EtOAc) gave 1-10 as a colorless gum.
TLC R f =0.9 (silica, 10% (NH 3 /EtOH)/EtOAc); 1 H NMR (300 MHz, CD 3 OD) δ 8.55 (m, 1H), 8.43 (m, 1H), 7.83 (m, 1H), 7.40 (m, 1H), 7.11 (m, 1H), 6.37 (m, 1H), 5.38 (m, 1H), 4.08 (q, J=7 Hz, 2H), 4.00 (m, 2H), 3.37 (m, 4H), 2.90 (m, 1H), 2.70-1.60 (m, 14H), 1.14 (t, J=7 Hz, 3H).
2-Oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]-naphthyridin-2-yl)ethyl]piperin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine trifluoroacetate (1-11)
A stirred solution of 1-11 (52 mg, 0.10 mmol) and 6N HCl (10 mL) was heated at 55° C. for 2 h, followed by concentration.
Preparative HPLC (VYDAC C 18 semiprep column, gradient elution: [95:5 (0.1% TFA/H 2 O/0.1% TFA/CH 3 CN) to 50:50 (0.1% TFA/H 2 O/0.1% TFA/CH 3 CN) 80 min] gave 1-11 as a colorless solid.
1 H NMR (300 MHz, CD 3 OD) δ 8.90 (s, 1H), 8.74 (d, J=5 Hz, 1H), 8.61 (d, J=8 Hz, 1H), 8.03 (m, 1H), 7.56 (d, J=7 Hz, 1H), 6.59 (d, J=7 Hz, 1H), 5.43 (m, 1H), 4.03 (m, 2H), 3.40 (m, 5H), 3.00 (m, 2H), 2.78 (m, 4H), 2.40-1.60 (m, 12H). ##STR36## (2-Oxo-3-(3-(ethylendioxy)butyl)pyrrolidin-1-yl)benzyl (2-2)
To a stirred solution of 2-1 (5.3 g, 30 mmol) and THF (100 mL) at -78° C. was added LDA (17.5 mL, 35 mmol, 2.0 M in hexanes) dropwise over a 10 minute period. After 30 min, 1-2 (5.0 g, 21 mmol) was added followed by removal of the cooling bath. After 1 h, the reaction was quenched with AcOH (10 mL) and then diluted with EtOAc, washed with sat. NaHCO 3 and brine, dried (MgSO 4 ) and concentrated. Flash chromatography (silica, 25%→75% EtOAc/hexanes) gave 2-2 as an oil.
TLC R f =0.38 (silica, EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 7.25 (m, 5H), 4.48 (d, J=15 Hz, 1H), 4.40 (d, J=15 Hz, 1H), 3.94 (s, 4H), 3.18 (m, 2H), 2.44 (m, 1H), 2.30-1.30 (m, 9H).
2-Oxo-3-(3-(ethylendioxy)butyl)pyrrolidine (2-3)
To a stirred solution of 2-2 (4.1 g, 14.2 mmol) in THF (100 mL) at -78° C. was added a solution of Li 4,4'-di-tert-butylbiphenyl (188 mL, 0.5 M in THF) in 4 portions. After 1 h, the reaction was quenched with AcOH (25 mL). The resulting mixture was diluted with EtOAc and then washed with H 2 O, sat. NaHCO 3 , and brine, dried (MgSO 4 ) and concentrated. Flash chromatography (silica, EtOAc→10% CH 3 OH/EtOAc) gave 2-3 as a yellow oil.
TLC R f =0.1 (silica, EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 6.23 (bs, 1H), 3.94 (s, 4H), 3.30 (m, 2H), 2.70 (m, 2H), 2.10-1.30 (m, 9H).
Ethyl (2-Oxo-3-(3-(ethylendioxy)butyl)pyrrolidin-1-yl)acetate (2-4)
To a rapidly stirred solution of 2-3 (0.86 g, 4.3 mmol) and THF (25 mL) at -78° C. was added NaN(TMS) 2 (5.2 mL, 5.2 mmol, 1.0 M in THF). After 20 min, ethyl bromoacetate (0.58 mL, 5.2 mmol) was added followed by removal of the cooling bath. After 1 h, the reaction mixture was diluted with EtOAc and then washed with H 2 O, sat. NaHCO 3 and brine, dried (MgSO 4 ), and concentrated to give 2-4 as a yellow oil.
TLC R f =0.53 (silica, EtOAc); 1 H NMR (300 MHz, CDC 13 ) δ 4.18 (q, J=7 Hz, 2H), 4.04 (m, 2H), 3.93 (s, 4H), 3.39 (m, 2H), 2.44 (m, 1H), 2.23 (m, 1H), 2.00-1.30 (m, 9H), 1.25 (t, J=7H, 3H).
Ethyl (2-Oxo-3-(3-oxobutyl)pyrrolidin-1-yl)acetate (2-5)
A solution of 2-4 (1.1 g, 3.9 mmol), p-TSA (5 mg) and acetone (50 mL) was heated at reflux for 1 hr. The cooled reaction mixture was diluted with EtOAc and then washed with sat. NaHCO 3 and brine, dried (MgSO 4 ), and concentration to afford 2-5 as a yellow oil.
TLC R f =0.48 (silica, EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 4.18 (q, J=7 Hz, 2H), 4.01 (s, 2H), 3.40 (m, 2H), 2.67 (t, J=7 Hz, 2H), 2.48 (m, 1H), 2.30-1.60 (m, 4H), 2.15 (s, 3H), 1.25 (t, J=7 Hz, 3H).
Ethyl (2-Oxo-3-(2-([1,8]naphthyridin-2-yl)ethyl)pyrrolidin-1-yl)-acetate (2-6)
A mixture of 2-5 (0.77 g, 3.0 mmol), 1-4 (0.55 g, 4.5 mmol, for preparation see Het, 1993, 36, 2513), L-proline (0.17 g, 1.5 mmol) and ethanol (25 mL) was heated at reflux for 20 hr. The cooled reaction mixture was concentrated and the residue purified by flash chromatography (silica, EtOAc→5% CH 3 OH/EtOAc) to give 2-6 as a yellow oil.
TLC R f =0.13 (silica, 10% CH 3 OH/EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 9.08 (m, 1H), 8.17 (m, 1H), 8.12 (d, J=8 Hz, 1H), 7.49 (d, J=8 Hz, 1H), 7.46 (m, 1H), 4.15 (q, J=7 Hz, 2H), 4.04 (m, 2H), 3.42 (m, 2H), 3.21 (t, J=8 Hz, 2H), 2.60-1.80 (m, 5H), 1.25 (t, J=7 Hz, 3H).
Ethyl (2-Oxo-3-(2-(5,6,7,8-tetrahydro-[1,8]-naphthyridin-2-yl)ethyl)pyrrolidin-1-yl)acetate (2-7)
A mixture of 2-6 (0.87 g, 2.6 mmol), 10% Pd/C (0.5 g), and CH 3 OH (25 mL) was stirred under a hydrogen atmosphere (1 atm) for 2 hr. The catalyst was then removed by filtration through a celite pad followed by concentration of the filtrate. Flash chromatogrphy (silica, EtOAc→5% CH 3 OH/EtOAc) gave 2-7 as a yellow oil.
TLC R f =0.18 (silica, 5% CH 3 OH/EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 7.05 (d, J=7 Hz, 1H), 6.40 (d, J=7 Hz, 1H), 4.83 (bs, 1H), 4.17 (q, J=7 Hz, 2H), 4.03 (m, 2H), 3.40 (m, 4H), 2.80-1.60 (m, 11H), 1.27 (t, J=7 Hz, 3H).
(2-Oxo-3-(2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl)pyrrolidin-1-yl)acetic acid hydrochloride (2-8)
A stirred mixture of 2-7 (0.45 g, 1.4 mmol) and 6N HCl (10 mL) was heated at 50° C. for 1 h, followed by concentration to give 2-8 as a yellow oil.
1 H NMR (300 MHz, CD 30 D) δ 7.60 (d, J=7 Hz, 1H), 6.66 (d, J=7 Hz, 1H), 4.05 (s, 2H), 3.50 (m, 4H), 2.83 (m, 4H), 2.54 (m, 1H), 2.32 (m, 1H), 2.10 (m, 1H), 2.00-1.75 (m, 4H).
(2-Oxo-3-(2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl)pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine ethyl ester (2-11)
To a stirred solution of 2-8 (50 mg, 0.15 mmol), 2-9 (29 mg, 0.17 mmol) (Zablocki et al., J. Med Chem., 1995, 38, 2378), NMM (83 μL, 0.75 mmol), and CH 3 CN (1 mL) was added BOP (74 mg, 0.17 mmol). After 20 h, the reaction mixture was diluted with EtOAc and then washed with sat. NaHCO 3 , H 2 O and brine, dried (MgSO 4 ), and concentrated to give 2-11 as a yellow oil.
TLC R f =0.24 (silica, 10% CH 3 OH/EtOAc).
(2-Oxo-3-(2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl)pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester (2-12)
To a stirred solution of 2-8 (50 mg, 0.15 mmol), 2-10 (44 mg, 0.17 mmol) (Rico et al., J. Org. Chem., 1993, 58, 7948), NMM (83 μL, 0.75 mmol), and CH 3 CN (1 mL) was added BOP (74 mg, 0.17 mmol). After 20 h, the reaction mixture was diluted with EtOAc and then washed with sat. NaHCO 3 , H 2 O and brine, dried (MgSO 4 ), and concentrated to give 2-12 as a brown oil.
TLC R f =0.24 (silica, 20% CH 3 OH/EtOAc).
(2-Oxo-3-(2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl)pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine (2-13)
A mixture of 2-11 (0.1 g, 0.15 mmol), 1N NaOH (300 μL, and ethanol (1 mL) was stirred at ambient temperature for 1 hr. Concentration and then flash chromatography (silica, 25:10:1:1→15:10:1:1 EtOAc/EtOH/NH 4 OH/H 2 O) gave 2-13 as a white solid.
TLC R f =0.18 (silica, 10:10:1:1 EtOAc/EtOH/NH 4 OH/H 2 O); 1 H NMR (300 MHz, CD 3 OD) δ 7.45 (m, 1H), 6.50 (m, 1H), 4.53 (m, 1H), 3.80-3.30 (m, 5H), 3.05 (m, 1H), 2.80-2.15 (m, 9H), 2.00-1.75 (m, 4H).
(2-Oxo-3-(2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl)pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine (2-14)
A mixture of 2-12 (0.1 g, 0.15 mmol), 1N NaOH (300 μL) and ethanol (1 mL) was stirred at ambient temperature for 1 hr. Concentration and the flash chromatography (silica, 25:10:1:1→15:10:1:1 EtOAc/EtOH/NH 4 OH/H 2 O) gave 2-14 as a white solid.
TLC R f =0.10 (silica, 10:10:1:1 EtOAc/EtOH/NH 4 OH/H 2 O); 1 H NMR (300 MHz, CD 3 OD) δ 8.57 (m, 1H), 8.40 (m, 1H), 7.86 (m, 1H), 7.40 (m, 2H), 6.50 (m, 1H), 5.28 (m, 1H), 4.65-4.40 (m, 1H), 3.90-1.80 (M, 19H). ##STR37## 4-(Propyl-2-ene)butyric acid (3-2)
To a stirred suspension of of methyltriphenylphosphonium bromide (67.7 g, 190 mmol) in 1 L THF at 0° C. was added a solution of sodium bis(trimethylsilyl)amide (190 mL, 190 mmol, 1M THF). After an additional 30 minutes, 3-1 ethyl 4-acetylbutyrate (Aldrich Chemical Co.)(25.0 g, 158 mmol) was added, and the mixture stirred for 18 h. The mixture was filtered, and the filtrate concentrated. The residue was triturated with hexanes, and then filtered. Following evaporative removal of the solvent, the residue was chromatographed on silica gel, eluting with 10% ethyl acetate/hexanes to give the olefin as a colorless oil. TLC R f =0.52 (10% ethyl acetate/hexanes).
1 H NMR (300 MHz, CHCl 3 ) δ 4.71 (d, 2H, J=13 Hz), 4.13 (q, 2H, J=7 Hz), 2.29 (t, 2H, J=7 Hz), 2.05 (t, 2H, J=8 Hz), 1.77 (m, 2H), 1.72 (s, 3H), 1.26 (t, 3H, J=7 Hz).
A solution of the above olefin (15.4 g, 98.6 mmol), 1 N NaOH (150 mL), and EtOH (300 mL) was stirred at ambient temperature for 2 h. Following acidification with 1 N HCl, the mixture was extracted with ether. The ether layer was washed with brine, dried over magnesium sulfate, and concentrated to give 3-2 as a colorless oil.
1 H NMR (300 MHz, CHCl 3 ) δ 4.70 (d, 2H, J=13 Hz), 2.27 (t, 2H, J=7 Hz), 2.06 (t, 2H, J=7 Hz), 1.72 (m, 5H).
(4-(Propyl-2-ene)butanoyl)4(R)-benzyl-2-oxazolidinone (3-3)
To a solution of 3-2 (6.0 g , 46.8 mmol) in THF (200 ml) at -78° C. was added triethylamine (7.19 mL , 51.5 mmol) followed by pivaloyl chloride (6.35 mL , 51.5 mmol). The mixture was warmed to 0° C. for 1 h, then recooled to -78° C. In a separate flask, of (R)-(+)-4-benzyl-2-oxazolidinone (9.15 g, 51.5 mmol) was dissolved in THF (100 mL), cooled to -78° C., and n-BuLi (32.3 mL, 51.5 mmol; 1.6 M hexanes) was added dropwise. After 10 minutes, the lithium oxazolidinone was added to the pivalic anhydride. After 10 minutes, the mixture was warmed to 0° C. for 1.5 h. The mixture was then poured into ethyl acetate, washed with aqueous sodium bicarbonate, and dried over magnesium sulfate. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, dichloromethane) to give 3-3 as a slightly yellow oil.
TLC R f =0.8 (CH 2 Cl 2 ). 1 H NMR (300 MHz, CHCl 3 ) δ 7.40-7.18 (m, 5H), 4.80-4.60 (m, 3H), 4.18 (m, 2H), 3.30 (dd, 1H, J=3.2, 13.2 Hz), 2.95 (m, 2H), 2.76 (dd, 1H, J=9.5, 13.1 Hz), 2.11 (t, 2H, J=7.5 Hz), 1.87 (m, 2H), 1.74 (s, 3H).
2-Chloroethyltriflate (3-4)
To a solution of 1.67 mL (24.8 mmol) of 2-chloroethanol and 3.47 mL (29.8 mmol) of 2,6-lutidine in 20 mL of dichloromethane at 0° C. was added 4.59 mL (27.3 mmol) of triflic anhydride. After 1 h, the mixture was diluted with hexanes, washed with ice-cold 1 N HCl, and dried over sodium sulfate. The solvents were evaporated to give 3-4 as a pink oil.
1 H NMR (300 MHz, CHCl 3 ) δ 4.69 (t, 2H, J=5.3 Hz), 3.78 (t, 2H, J=5.6 Hz).
2(S)-Chloroethyl-4-(propyl-2-ene)butanoyl-(4(R)-benzyl-2-oxazolidinone) (3-5)
To a solution of 3-3 (11.0 g, 38.3 mmol) in THF (60 mL) at -78° C. was added a solution of sodium bis(trimethylsilyl)amide (42.1 mL, 42.1 mmol; 1M/THF). After 20 min, 3-4 (16.2 ml, 115 mmol) was added over 5 min, and the resulting mixture stirred for 1.5 h at -78° C., then 2 h at -150 C. The mixture was diluted with hexanes, washed with sat. ammonium chloride, and dried over sodium sulfate. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 14% ethyl acetate/hexanes) to give 3-5 as a colorless oil. TLC R f =0.5 (20% ethyl acetate/hexanes).
1 H NMR (300 MHz, CHCl 3 ) δ 7.30-7.18 (m, 5H), 4.67 (m, 3H), 4.19 (m, 2H), 3.99 (m, 1H), 3.58 (m, 2H), 3.33 (dd, 1H, J=3.2, 12.0 Hz), 2.75 (dd, 1H, J=9.7, 13.5 Hz), 2.23 (m, 1H), 2.18-1.82 (m, 4H), 1.77-1.60 (m, 1H), 1.71 (s, 3H).
Ethyl 2-oxo-3(S)-(3-methylenebutyl)pyrrolidine (3-6)
A mixture of 3-5 (8.15 g, 23.3 mmol) and NaN 3 (4.54 g, 69.8 mmol) in DMSO (120 mL) was heated at 750° C. for 2 h. After cooling, the mixture was diluted with ether and hexanes, washed with water, and dried over sodium sulfate. Evaporative removal of the solvent gave the azide as a colorless oil.
TLC R f =0.5 (20% ethyl acetate/hexanes). 1 H NMR (300 MHz, CHCl 3 ) δ 7.30-7.22 (m, 5H), 4.69 (m, 3H), 4.17 (d, 2H, J=5.1 Hz), 3.89 (m, 1H), 3.38 (m, 3H), 2.74 (m, 1H), 2.13-1.63 (m, 6H), 1.71 (s, 3H).
To a solution of of this azide (8.0 g , 22.4 mmol) in THF (250 mL) and water (40 mL) was added triphenylphosphine (8.24 g, 31.4 mmol) in 4 portions over 5 minutes. This mixture was heated at reflux for 2 h, cooled, and evaporated. The residue was chromatographed (silica gel, 10% chloroform/ethyl acetate) to give 3-6 as a colorless oil.
TLC R f =0.40 (20% chloroform/ethyl acetate). 1 H NMR (300 MHz, CHCl 3 ) δ 6.47 (br s, 1H), 4.73 (m, 2H), 3.31 (m, 2H), 2.33 (m, 2H), 2.08 (m, 3H), 1.81 (m, 1H), 1.74 (s, 3H), 1.44 (s, 1H).
Ethyl 2-oxo-3(S)-(3-methylenebutyl)pyrrolidin-1-yl)acetate (3-7)
To a solution of 3-6 (2.50 g, 16.3 mmol) in THF (40 mL) at -78° C. was added sodium bis(trimethylsilyl)amide (17.1 mL, 17.1 mmol; 1M/THF) dropwise. After an additional 20 min, ethyl bromoacetate (2.17 mL, 19.6 mmol) was added dropwise over 3 min. After an additional 20 min, 20 mL sat. aqueous NH 4 Cl was added, and the cooling bath removed. The layers were separated, the aqueous layer washed with ether, and the combined organic extracts were dried over sodium sulfate. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 40% ethyl acetate/hexanes) to give 3-7 as a colorless oil.
TLC R f =0.85 (50% chloroform/ethyl acetate). 1 H NMR (300 MHz, CHCl 3 ) δ 4.73 (m, 2H), 4.18 (q, 2H, J=7.1 Hz), 4.06 (dd, 2H, J=17.6, 20.8 Hz), 3.42 (m, 2H), 2.44 (m, 1H), 2.27 (m, 1H), 2.12 (m, 3H), 1.75 (m, 1H), 1.74 (s, 3H), 1.50 (m, 1H), 1.28 (t, 3H, J=7.3 Hz).
Ethyl 2-oxo-3(S)-(3-oxo-butyl)pyrrolidin-1-yl)acetate (3-8)
To a solution of 3-7 (3.35 g,14.0 mmol) and N-methylmorpholine-N-oxide (3.27 g, 28.0 mmol) in THF (10 mL) and water (1 mL) was added OsO 4 (5.7 mL, 0.56 mmol; 2.5% t-butanol). After 1 h, NaIO 4 (5.99 g, 28 mmol) in warm water (30 mL) was added over 2 min, and the resulting mixture stirred for 1 h. Water was then added, and the aqueous layer washed with ether and ethyl acetate, and the combined organic extracts were dried over sodium sulfate. Evaporative removal of the solvent gave 3-8 as a dark oil containing residual OsO 4 .
TLC R f =0.78 (70:20:10 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CHCl 3 ) δ 4.19 (m, 2H, J=7.2 Hz), 4.03 (s, 2H), 3.41 (m, 2H), 2.68 (t, 2H, J=9.4 Hz) 2.45 (m, 1H), 2.27 (m, 1H), 2.17 (s, 3H), 1.97 (m, 1H), 1.78 (m, 2H), 1.28 (t, 3H, J=7.2 Hz).
Ethyl 2-oxo-3(S)-[2-([1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetate (3-9)
A mixture of 3-8 (3.25 g, 13.5 mmol), 1-4, 2-amino-3-formylpyridine (2.2 g, 18.2 mmol; for preparation see Synth. Commun. 1987, 17, 1695) and proline (0.62 g, 5.39 mmol) in absolute ethanol (45 mL) was heated at reflux for 15 h. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:25:5 chloroform/ethyl acetate/MeOH to give 3-9 as a colorless oil.
TLC R f =0.24 (70:25:5 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CHCl 3 ) δ 9.08 (m, 1H), 8.16 (m, 2H), 7.47 (m, 2H), 4.17 (m, 4H), 3.42 (m, 2H), 3.21 (t, 2H, J=6.0 Hz), 2.56 (m, 1H), 2.39 (m, 2H), 2.08 (m, 1H), 1.87 (m, 1H), 1.27 (t, 3H, J=7.1 Hz).
Ethyl 2-oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetate (3-10)
A mixture of 3-9 (3.33 g, 10.2 mmol) and 10% Pd/carbon (1.5 g) in EtOH (50 mL) was stirred under a balloon of hydrogen for 13 h. Following filtration and evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:20:10 chloroform/ethyl acetate/MeOH to give 3-10 as a colorless oil.
TLC R f =0.20 (70:20:10 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CDCl 3 ) δ 7.05 (d, 1H, J=7.3 Hz), 6.38 (d, 1H, J=7.3 Hz), 4.88 (br s, 1H), 4.17 (dd, 2H, J=7.0, 14.4 Hz), 4.04 (dd, 2H, J=17.6, 27.3 Hz), 3.40 (m, 4H), 2.69 (m, 4H), 2.51 (m, 1H), 2.28 (m, 2H), 1.90 (m, 2H), 1.78 (m, 2H), 1.27 (t, 3H, J=6.9 Hz).
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetic acid (3-11)
A mixture of 3-10 (0.60 g, 1.81 mmol) and 6N HCl (25 mL) was heated at 60° C. for 1 h. Evaporative removal of the solvent gave 3-11 as a yellow oil.
1 H NMR (300 MHz, DMSO-d 6 ) δ 8.4 (br s, 1H), 7.60 (d, 1H, J=7.3 Hz), 6.63 (d, 1H, J=7.3 Hz), 3.92 (dd, 2H, J=17.6, 25.9 Hz), 3.43 (m, 2H), 3.35 (m, 2H), 2.74 (m, 4H), 2.28 (m, 2H), 2.03 (m, 1H), 1.82 (m, 2H), 1.67 (m, 2H).
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine; ethyl ester (3-12)
A mixture of 3-11 (0.20 g, 0.588 mmol), 2-9 (0.157 g, 0.882 mmol), EDC (0.147 g, 0.765 mmol), HOBT (0.095 g, 0.706 mmol) and NMM (0.453 mL, 4.12 mmol) in CH 3 CN (3 mL) and DMF (2 mL) was stirred for 20 h. The mixture was diluted with ethyl acetate, washed with water, brine, and dried over sodium sulfate. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:20:10 chloroform/ethyl acetate/MeOH to give 3-12 as a colorless foam.
TLC R f =0.44 (70:20:10 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CDCl 3 ) δ 7.06 (d, 1H, J=7.3 Hz), 6.39 (d, 1H, J=7.3 Hz), 5.07 (m, 1H), 4.94 (br s, 1H), 4.18 (q, 2H, J=6.1 Hz), 3.95 (q, 2H, J=16.1 Hz), 3.39 (m, 4H), 2.90 (s, 1H), 2.68 (m, 6H), 2.50 (m, 1H), 2.27 (m, 3H), 1.82 (m, 4H), 1.27 (t, 3H, J=7.1 Hz).
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]-pyrrolidin-1-yl)acetyl-3(S)-ethnyl-β-alanine (3-13)
To a solution of 3-12 (0.050 g, 0.117 mmol) in EtOH (1 mL) was added 1N NaOH (0.164 ml, 0.164 mmol). After stirring for 2 h, the solvents were evaporated and the residue was chromatographed (silica gel, 25:10:1:1 ethyl acetate/EtOHlwater/NH 4 OH to give 3-13 as a colorless foam.
TLC R f =0.26 (25:10:1:1 ethyl acetate/EtOH/water/NH 4 OH). 1 H NMR (300 MHz, DMSO-d 6 ) δ 7.75 (br s, 1H), 7.14 (d, 1H, J=7.3 Hz), 6.31 (d, 1H, J=7.3 Hz), 4.74 (m, 1H), 3.90 (d, 1H, J=16.6 Hz), 3.67 (d, 1H, J=16.6 Hz), 3.23 (m, 4H), 2.57 (m, 7H), 2.30 (m, 1H), 2.11 (m, 2H), 1.73 (m, 2H), 1.59 (m, 2H).
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester (3-14)
A mixture of 3-11 (0.30 g, 0.882 mmol), 2-10 (0.354 g, 1.32 mmol), EDC (0.220 g (1.15 mmol), HOBT (0.143 g, 1.05 mmol) and NMM (0.680 mL (6.18 mmol) in CH 3 CN (5 mL) and DMF (3 mL) at 0° C. was stirred for 10 min, then allowed to warm and stir for 20 h. The mixture was diluted with ethyl acetate, washed with water, brine, and dried over sodium sulfate. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:20:10 chloroform/ethyl acetate/MeOH to give 3-14 as a colorless foam.
TLC R f =0.31 (70:20:10 chloroforn/ethyl acetate/MeOH). 1 H NMR (300 MHz, CHCl 3 ) δ 8.55 (d, 1H, J=2.2 Hz), 8.50 (dd, 1H, J=1.5, 4.6 Hz), 7.64 (m, 2H), 7.23 (m, 1H), 7.05 (d, 1H, J=7.3 Hz), 6.38 (d, 1H, J=7.3 Hz), 5.40 (m, 1H), 4.98 (br s, 1H), 4.01 (m, 4H), 3.39 (m, 4H), 2.85 (m, 2H), 2.68 (m, 4H), 2.49 (m, 1H), 2.25 (m, 2H), 1.83 (m, 4H), 1.16 (t, 3H, J=7.2 Hz).
2-Oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine (3-15)
To a solution of 3-14 (0.049 g, 0.102 mmol) in THF (1 mL) and water (0.3 mL) at 0° C. was added 1M LiOH (0.112 ml, 0.112 mmol). After warming to ambient temperature and stirring for 2 h, the solvents were evaporated and the residue was chromatographed (silica gel, 25:10:1:1 ethyl acetate/EtOH/water/NH 4 OH to give 3-15 as a colorless foam.
TLC R f =0.15 (25:10:1:1 ethyl acetate/EtOH/water/NH 4 OH). 1 H NMR (300 MHz, DMSO-d 6 ) δ 8.74 (d, 1H, J=8.3 Hz), 8.51 (m, 1H), 8.42 (m, 2H), 7.70 (d, 1H, J=8.1 Hz), 7.33 (m, 1H), 7.21 (d, 1H, J=7.3 Hz), 6.36 (d, 1H, J=7.3 Hz), 5.14 (m, 1H), 4.00 (d, 1H, J=16.8 Hz), 3.70 (d, 1H, J=16.6 Hz), 3.30 (m, 4H), 2.68 (m, 7H), 2.20 (m, 3H), 1.71 (m, 4H). ##STR38## 2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine ethyl ester (4-2)
Prepared from 4-1 (prepared by the method used to prepare 3-11, utilizing (S)-(-)-4-benzyl-2-oxazolidinone) and 2-9, by the method used to prepare 3-12.
1 H NMR (300 MHz, CHCl 3 ) δ 7.06 (d, 1H, 3=7 Hz), 6.39 (d, 1H), J=7 Hz), 5.06 (m, 1H), 4.84 (br s, 1H), 4.16 (q, 2H, J=6 Hz), 3.93 (m, 2H), 3.38 (m, 4H), 2.68 (m, 6H), 2.52 (m, 1H), 2.25 (m, 2H), 1.90 (m, 2H), 1.78 (m, 2H), 1.26 (t, 3H, J=7 Hz).
2-Oxo-3 (R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine (4-3)
Prepared from 4-2 (0.05 g, 0.11 mmol) by the method used to prepare 3-13.
1 H NMR (300 MHz, CD 3 OD, 1 drop 1N NaOD) δ 7.11 (d, 1H, J=7 Hz), 6.40 (d, 1H, J=7 Hz), 4.90 (m, 1H), 3.94 (q, 2H, J=17 Hz), 3.39 (m, 4H), 2.69 (d, 2H, J=6 Hz), 2.60 (m, 2H), 2.52 (d, J=7 Hz), 2.49 (m, 1H), 2.27 (m, 1H), 2.13 (m, 1H), 1.85 (m, 4H), 1.68 (m, 1H).
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]-pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester (4-4)
Prepared from 4-1 (0.35 g, 1.0 mimol) and 2-10 (0.33 g, 1.2 mmol) by the method used to prepare 3-14.
1 H NMR (300 MHz, CHCl 3 ) δ 8.55 (d, 1H, J=2 Hz), 8.55 (dd, 1H, J=2, 5 Hz), 7.61 (m, 1H), 7.54 (m, 1H), 7.06 (d, 1H), 6.38 (d, 1H, J=7 Hz), 5.40 (m, 1H), 4.90 (br s, 1H), 4.05 (q, 2H, J=7 Hz), 3.95 (m, 2H), 3.42 (m, 4H), 2.85 (dd, 2H, J=2, 6 Hz), 2.67 (m, 4H), 2.53 (m, 1H), 2.27 (m, 2H), 1.90 (m, 2H), 1.78 (m, 2H), 1.16 (m, 3H, J=7 Hz).
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro-[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine (4-5)
Prepared from 4-4 (0.16 g, 0.33 mmol) by the method used to prepare 3-15.
1 H NMR (300 MHz, CD 3 OD) δ 8.57 (s, 1H), 8.42 (m, 1H), 7.86 (d, 1H, J=6 Hz), 7.43 (m, 2H), 6.51 (d, 1H, J=7 Hz), 5.28 (m, 1H), 4.63 (d, 1H, J=17 Hz), 3.60 (m, 2H), 3.47 (d, 1H, J=17 Hz), 3.35 (m, 3H), 3.14 (td, 1H, J=5, 13 Hz), 2.75 (m, 5H), 2.42 (m, 1H), 2.23 (m, 1H), 1.90 (m, 4H). ##STR39## 1,3-Di-tert-buyloxycarbonyl-tetrahydropyrimidine (5-2)
A heterogeneous mixture of 5-1 (10.0 g, 100 mmol), BOC 2 O (48 g, 220 mmol), DMAP (20 mg), and CH 3 CN (500 mL) was heated for 40 hr at 65° C. followed by addition of DMF (100 mL) and then continued heating for 24 hr. The cooled reaction mixture was diluted with EtOAc and then washed with H 2 O, sat. NaHCO 3 , 1N HCl, and brine, dried (MgSO 4 ), and concentrated. The residue was triturated with hexanes to give 5-2 as a yellow solid.
TLC RF=0.93 (EtOAc); 1 HNMR (300 MHz, CDCl 3 ) δ 3.68 (t, J=7 Hz, 4H), 2.00 (m, 2H), 1.48 (s, 18 H).
Tert-Butyloxycarbonyl-tetrahydropyrimidine (5-3)
A solution of 5-2 (19.0 g, 63 mmol), Mg(ClO 4 ) 2 (2.8 g, 12.7 mmol), and CH 3 CN was heated at 50° C. for 2 hr. The cooled solution was diluted with CDCl 3 and then washed with 1N HCl, sat. NaHCO 3 , and brine, dried (MgSO 4 ), and concentrated. Flash chromatography (silica, 75% EtOAc/hexanes→EtOAc) gave 5-3 as a brown solid.
TLC RF=0.26 (silica, EtOAc); 1 HNMR (300 MHz, CDCl 3 ) δ 5.50 (bs, 1H), 3.70 (m, 2H), 3.29 (m, 2H), 1.97 (m, 2H), 1.48 (s, 9H).
Tert-Butyloxycarbonyl-2-oxo-3-(3-ethylene glycolbutyl)-tetrahydropyrimidine (5-4)
To a stirred solution of 5-3 (3.2g, 16.1 mmol) and DMF (50 mL) was added LiN(TMS) 2 (21 mL, 1M/hexanes). After 20 minutes, the iodide 1-2 (8.6 g, 35.2 mmol) in DMF (10 mL) was added and the reaction mixture heated at 50° C. for 2 hours. The cooled solution was diluted with CHCl 3 and then washed with H 2 O and brine, dried (MgSO 4 ), and concentrated. Flash chromatography (silica, 60% to 75% EtOAc/hexanes) gave 5-4 as an orange oil.
TLC RF=0.74 (silica, 70:15:15 CDCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 3.93 (s, 4H), 3.66 (t, J=6Hz, 2H), 3.,44 (m, 2H), 3.30 (m, 2H), 1.96 (m, 2H), 1.48 (s, 9H), 1.32 (s, 3H).
1-Oxo-2-(3-ethylene glycol-butyl) tetrahydro-pyrimidine (5-5)
A mixture of 5-4 (3.0 g, 9.5 mmol), TFA (1.5 mL, and toluene (30 mL) was stirred at ambient temperature for 20 minutes, concentrated and the residue azeotroped with toluene to remove excess TFA. The residue was then dissolved in toluene (30 mL) and treated with NaHCO 3 (3g), filtered, and the filtrate concentrated to give a yellow oil. Flash chromatography (silica, 70:15:15 CHCl 3 /EtOAc/ CH 3 OH) gave 5-5 as a yellow oil.
TLC RF=0.63 (silica, 70:15:15 CHCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 5.16 (bs, 1H), 3.94 (s, 4H), 3.40 (m, 2H), 3.24 (m, 4H), 1.90 (m, 2H), 1.34 (s, 3H).
Ethyl 2-oxo-3-[3-ethylene glycol-butyl]tetrahydropyrimidin-1-yl-acetate (5-6)
To a stirred solution of 5-5 (2.0 g, 9.3 mmol) and DMF (50 mL) was added LiN(TMS) 2 (12.1 mL, 1.0 M/THF). After 20 min, ethyl iodoacetate (1.66 mL, 14.0 mmol) was added followed by heating at 60° C. for 1 hr. The cooled solution was diluted with EtOAc and then washed with H 2 O, sat. NaHCO 3 , and brine, dried (MgSO 4 ), and concentrated. Flash chromatography (silica, 50% to 75% EtOAc/hexanes) gave 5-6 as a colorless oil.
TLC RF=0.72 (silica, 70:15:15 CDCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 4.18 (q, J=7 Hz, 2H), 3.93 (s, 4H), 3.42 (m, 2H), 3.34 (m, 4H), 1.98 (m, 2H), 1.92 (m, 2H), 1.34 (s, 3H), 1.25 (t, J=7 Hz, 3H).
Ethyl 2-oxo-3-[3-oxo-butyl]tetrahydro-pyrimidin-1-yl-acetate (5-7)
A solution of 5-6 (750 mg, 2.5 mmol), p-TSA (10 mg), and acetone (30 mL) was refluxed for 1 hr. The cooled solution was diluted with CDCl 3 and then washed with sat. NaHCO 3 and brine, dried (MgSO 4 ), and concentrated to give 5-7 as a yellow oil.
TLC RF=0.36 (silica, 10% CH 3 OH/EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 4.17 (q, J=7 Hz, 2H), 3.56 (m, 2H), 3.34 (m, 4H), 2.76 (t, J=7 Hz, 2H), 2.17 (s, 3H), 2.00 (m, 2H), 1.27 (t, J=7 Hz, 3H).
Ethyl 2-oxo-3-[2-naphthyridin-2-yl)ethyl]-tetrahydropyrimidin-l-yl-acetate (5-8)
A mixture of 5-7 (600 mg, 2.3 mmol), 1-4 (343 mg, 2.8 mmol), L-proline (175 mg), and ethanol (25 mL) was heated at reflux for 18 hr. The cooled reaction mixture was concentrated and the residue purified by flash chromatography (silica, 10% CH 3 OH/EtOAc) gave 5-8 as a yellow solid.
TLC RF=0.21 (silica, 10% CH 3 OH/EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 9.10 (m, 1H), 8.19 (m, 1H), 8.14 (d, J=8 Hz, 1H), 7.52 (d, J=8 Hz, 1H), 7.44 (m, 1H), 4.18 (q, J=7 Hz, 2H), 3.83 (m, 2H), 3.32 (m, 6H), 1.93 (m, 2H), 1.24 (t, J=7 Hz, 3H).
Ethyl 2-oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]-naphthyridine-2-yl)ethyl] tetrahydropyrimidine-1-yl-acetate (5-9)
A mixture of 5-8 (600 mg, 1.75 mmol), 10% Pd/C (300 mg), and ethanol (10 mL) was stirred at ambient temperature under a hydrogen atmosphere (1 atm) for 20 hr. The catalyst was removed by filtration through a celite pad and the filtrate concentrated to give 5-9 as a yellow oil.
1 H NMR (300 MHz, CDCl 3 ) δ 7.04 (d, J=8 Hz, 1H), 6.42 (d, J=8 Hz, 1H), 4.80 (bs, 1H), 4.22-4.03 (m, 4H), 3.60 (m, 2H), 2.78 (m, 2H), 2.66 (m, 2H), 1.96 (m, 4H), 1.24 (t, J=7 Hz, 3H).
2-Oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]naphthridin-2-yl)tetrahydro-pyrimidin-1-yl-acetic acid (5-10)
A solution of 5-9 (600 mg, 1.73 mmol) and 6N HCl (20 mL) was heated at 50° C. for 2 hr. The solution was concentrated followed by azeotropic removal of H 2 O with CH 3 CN to give 5-10 as a yellow solid.
1 H NMR (300 MHz, CD 3 OD) δ 7.58 (d, J=8 Hz, 1H), 6.63 (d, J=8 Hz, 1H), 3.98 (s, 2H), 3.62 (t, J=7 Hz, 2H), 3.50 (m, 2H), 3.36 (m, 4H), 2.93 (m, 2H), 2.80 (m, 2H), 2.00 (m, 4H).
Ethyl 2-oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)ethyl]-tetrahydropyrimidin-1-yl-aceetyl-3(S)-pyridin-3-yl-β-alanine (5-11)
To a stirred solution of 5-10 (250 mg, 0.70 mmol), 1-9 (210 mg, 0.77 mmol), EDC (148 mg, 0.77 mmol), HOBT (95 mg, 0.70 mmol), CH 3 CN (2 mL), and DMF (2 mL) was added NMM (542 μL, 4.9 mmol). After stirring at ambient temperature for 20 hr, the reaction mixture was diluted with EtOAc and then washed with H 2 O, sat. NaHCO 3 , brine, dried (MgSO 4 ), and concentrated. Flash chromatography (silica, 70:15:15 CHCl 3 /EtOAc/CH 3 OH) gave 5-11 as a colorless oil.
TLC RF=0.31 (silica, 70:15:15 CDCl 3 /EtOAc/CH 3 OH); H NMR (300 MHz, CDCl 3 ) δ 8.58 (m, 1H), 8.50 (m, 1H), 7.94 (m, 1H), 7.66 (m, 1H), 7.22 (m, 1H), 7.05 (d, J=8 Hz, 1H), 6.40 (d, J=8 Hz, 1H), 5.43 (m, 1H), 4.06 (q, J=7 Hz, 2H), 4.02 (m, 1H), 3.90 (m, 1H), 3.60 (m, 2H), 3.39 (m, 2H), 3.29 (m, 2H), 3.19 (m, 2H), 2.88 (m, 2H), 2.77 (m, 2H), 2.70 (m, 2H), 1.90 (m, 4H), 1.16 (t, J=7 Hz, 3H).
2-Oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl}ethyl]-tetrahydropyrimidin-1-yl-acetyl-3-(S)-pyridin-3-yl-β-alanine (5-12)
A mixture of 5-11 (100 mg, 0.22 mmol), 1N NaOH (300 μL), and ethanol (1 mL) was stirred at ambient temperature for 1 hr, followed by concentration. Flash chromatography (silica, 25:10:1:1 to 15:10:1:1 EtOAc/EtOH/NH 4 OH/H 2 O) gave 5-12 as a white solid.
TLC RF=0.22 (silica, 10:10:1:1 EtOAc/ethanol/NH 4 OH, H 2 O); 1 H NMR (300 MHz, CD 3 OD) δ 8.66 (m, 1H), 8.39 (m, 1H), 7.95 (m, 1H), 7.53 (d, J=8 Hz, 1H), 7.40 (m, 1H), 6.66 (d, J=8 Hz, 1H), 5.18 (m, 1H), 4.27 (d, J=7 Hz, 1H), 4.16 (m, 1H), 3.64 (d, J=7 Hz, 1H), 3.50-3.10 (m, 8H), 3.00-2.65 (m, 6H), 1.95 (m, 4H). ##STR40## 1,3-Di-tert-buyloxycarbonyl-imidazolidin-2-one (6-2)
A heterogeneous mixture of 6-1 (10.0 g, 116 mmol), BOC 2 O (56 g, 255 mmol), DMAP (20 mg), and CH 3 CN (400 mL) was heated for 18 hr at 60° C. The cooled reaction mixture was diluted with EtOAc and then washed with H 2 O, sat. NaHCO 3 , 1N HCl, and brine, dried (MgSO 4 ), and concentrated. The residue was triturated with hexanes to give 6-2 as a white solid.
TLC RF=0.91 (EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 3.73 (s, 4H), 1.53 (s, 18 H).
Tert-Butyloxycarbonyl-imidazolidin-2-one (6-3)
A solution of 6-2 (28.0 g, 98 mmol), Mg(CIO 4 ) 2 (4.3 g, 20 mmol), and CH 3 CN (400 mL) was heated at 50° C. for 3 hr. The cooled solution was diluted with CHCl 3 and then washed with 1N HCl, sat. naHCO 3 , and brine, dried (Mg S 4 ), and concentrated. Flash chromatography (silica, 50% EtOAc/hexanes→EtOAc) gave 6-3 as a yellow solid.
TLC RF=0.31 (silica, EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 6.27 (bs, 1H), 3.86 (m, 2H), 3.47 (m, 2H), 1.50 (s, 9H).
1-Tert-Butyloxycarbonyl-3-(3-ethylene glycol-butyl)imidazolidin-2-one (6-4)
To a stirred solution of 6-3 (4.5 g, 24 mmol) and DMF (50 mL) was added LiN(TMS) 2 (26.6 mL, 1M/hexanes). After 20 minutes, the iodide 1-2 (8.6 g, 35.2 mmol) in DMF (10 mL) was added and the reaction mixture heated at 60° C. for 4 hours. The cooled solution was diluted with CHCl 3 and then washed with H 2 O and brine, dried (MgSO 4 ), and concentrated. Flash chromatography (silica, 75% EtOAc/hexanes) gave 6-4 as an yellow solid.
TLC RF=0.71 (silica, 70:15:15 CHCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 3.93 (s, 4H), 3.75 (m, 2H), 3.36 (m, 4H), 1.90 (m, 2H), 1.53 (s, 9H), 1.34 (s, 3H).
1-(3-Ethylene glycol-butyl)imidazolidin-2-one (6-5)
A mixture of 6-4 (4.0 g, 13.3 mmol), TFA (3 mL, and toluene (60 mL) was stirred at 50° C. for 60 minutes, concentrated and the residue azeotroped with toluene to remove excess TFA. The residue was then dissolved in toluene (30 mL) and treated with NaHCO 3 (3g), filtered, and the filtrate concentrated to give a yellow oil. Flash chromatography (silica, 70:25:5 CDCl 3 /EtOAc/CH 3 OH) gave 6-5 as a white solid.
TLC RF=0.58 (silica, 70:15:15 CHCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 4.25 (bs, 1H), 3.94 (s, 4H), 3.44 (m, 4H), 3.32 (m, 2H), 1.90 (m, 2H), 1.35 (s, 3H).
Ethyl 2-oxo-3-[3-ethylene glycol-butyl]imidazolidin-1-yl-acetate (6-6)
To a stirred solution of 6-5 (2.0 g, 10 mmol) and DMF (50 mL) was added LiN(TMS) 2 (11 mL, 1.0 M/THF). After 20 min, ethyl iodoacetate (3.5 mL, 30 mmol) was added at ambient temperature. After 3 hr the solution was diluted with EtOAc and then washed with H 2 O, sat. NaHCO 3 , and brine, dried (MgSO 4 ), and concentrated. Flash chromatography (silica, 50% to 75% EtOAc/hexanes) gave 6-6 as a colorless oil.
TLC RF=0.71 (silica, 70:15:15 CDCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 4.18 (q, J=7 Hz, 2H), 3.93 (s, 4H), 3.91 (m, 2H), 3.50-3.30 (m, 6H), 1.90 (m, 2H), 1.92 (m, 2H), 1.35 (s, 3H), 1.25 (t, J=7 Hz, 3H).
Ethyl 2-oxo-3-[3-oxo-butyl]imidazolidin-1-yl-acetate (6-7)
A solution of 6-6 (1.4 g, 4.9 mmol), p-TSA (10 mg), and acetone (30 mL) was refluxed for 1 hr. The cooled solution was diluted with CHCl 3 and then washed with sat. NaHCO 3 and brine, dried (MgSO 4 ), and concentrated to give 6-7 as a yellow oil.
TLC RF=0.34 (silica, EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 4.17 (q, J=7 Hz, 2H), 3.94 (s, 2H), 3.48 (m, 2H), 3.42 (m, 4H), 2.72 (t, J=7 Hz, 2H), 2.17 (s, 3H), 1.27 (t, J=7 Hz, 3H).
Ethyl 2-oxo-3-[2-naphthyridin-2-yl)ethyl]imidazolidin-1-yl-acetate (6-8)
A mixture of 6-7 (1.0 g, 4.1 mmol), 1-4 (604 mg, 4.9 mmol), L-proline (238 mg), and ethanol (50 mL) was heated at reflux for 20 hr. The cooled reaction mixture was concentrated and the residue purified by flash chromatography (silica, 70:25:5 CDCl 3 /EtOAc/CH 3 OH) gave 6-8 as a yellow oil.
TLC RF=0.42 (silica, 70:15:15 CHCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 9.10 (m, 1H), 8.19 (m, 1H), 8.14 (d, J=8 Hz, 1H), 7.52 (d, J=8 Hz, 1H), 7.44 (m, 1H), 4.17 (q, J=7 Hz, 2H), 3.81 (m, 2H), 3.42 (m, 4H), 3.32 (m, 4H), 1.24 (t, J=7 Hz, 3H).
Ethyl 2-oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]-naphthyridine-2-yl)ethyl]imidazolidin-1-yl-acetate (6-9)
A mixture of 6-8 (1.1 g, 3.35 mmol), 10% Pd/C (500 mg), and ethanol (30 mL) was stirred at ambient temperature under a hydrogen atmosphere (1 atm) for 20 hr. The catalyst was removed by filtration through a celite pad and the filtrate concentrated to give 6-9 as a colorless oil.
TLC RF=0.11 (silica, 70:25:5 CHCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 7.04 (d, J=8 Hz, 1H), 6.42 (d, J=8 Hz, 1H), 4.80 (bs, 1H), 4.22-4.03 (m, 4H), 3.96 (s, 2H), 3.55 (m, 2H), 3.40 (m, 2H), 2.78 (m, 2H), 2.68 (m, 2H), 1.90 (m, 2H), 1.24 (t, J=7 Hz, 3H).
2-Oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]naphthridin-2-yl)imidazolidin-1-yl-acetic acid (6-10)
A solution of 6-9 (1.0 g, 3.0 mmol) and 6N HCl (40 mL) was heated at 60° C. for 1 hr. The solution was concentrated followed by azeotropic removal of H 2 O with CH 3 CN to give 6-10 as a yellow solid.
1 H NMR (300 MHz, CD 3 OD) δ 7.58 (d, J=8 Hz, 1H), 6.63 (d, J=8 Hz, 1H), 3.98 (s, 2H), 3.50 (m, 4H), 3.36 (m, 4H), 2.93 (m, 2H), 2.82 (m, 2H), 1.97 (m, 4H).
Ethyl 2-oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)ethyl]imidazolidin-1-yl-acetyl-3(S)-pyridin-3-yl-β-alanine (6-11)
To a stirred solution of 6-10 (240 mg, 0.70 mmol), 1-9 (207 mg, 0.77 mmol), EDC (269 mg, 1.4 mmol), HOBT (95 mg, 0.70 mmol), and CH 3 CN (3 mL) was added NMM (619 μL, 5.6 mmol). After stirring at ambient temperature for 20 hr, the reaction mixture was diluted with EtOAc and then washed with H 2 O, sat. NaHCO 3 , brine, dried (MgSO 4 ), and concentrated. Flash chromatography (silica, 70:15:15 CHCl 3 /EtOAc/CH 3 OH) gave 6-11 as a colorless oil.
TLC RF=0.41 (silica, 70:15:15 CDCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 8.58 (m, 1H), 8.50 (m, 1H), 7.94 (m, 1H), 7.66 (m, 1H), 7.22 (m, 1H), 7.05 (d, J=8 Hz, 1H), 6.40 (d, J=8 Hz, 1H), 5.43 (m, 1H), 4.06 (q, J=7 Hz, 2H), 3.85 (m, 1H), 3.55 (m, 2H), 3.40 (m, 2H), 3.33 (m, 4H), 2.90 (m, 2H), 2.77 (m, 2H), 2.70 (m, 2H), 1.90 (m, 2H), 1.77 (m, 2H), 1.18 (t, J=7 Hz, 3H).
2-Oxo-3-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl}ethyl]-imidazolidin-1-yl-acetyl-3-(S)-pyridin-3-yl-β-alanine (6-12)
A mixture of 6-11 (160 mg, 0.33 mmol), 1N NaOH (500 μL), and ethanol (1 mL) was stirred at ambient temperature for 1 hr, followed by concentration. Flash chromatography (silica, 25:10:1:1 to 15:10:1:1 EtOAc/EtOH/NH 4 OH/H 2 O) gave 6-12 as a white solid.
TLC RF=0.21 (silica, 10:10:1:1 EtOAc/ethanol/NH 4 OH, H 2 O); 1 H NMR (300 MHz, CD 3 OD) δ 8.66 (m, 1H), 8.39 (m, 1H), 7.95 (m, 1H), 7.53 (d, J=8 Hz, 1H), 7.40 (m, 1H), 6.66 (d, J=8 Hz, 1H), 5.22 (m, 1H), 3.93 (d, J=17 Hz, 1H), 3.74 (d, J=17 Hz, 1H), 4.00-3.20 (m, 9H), 3.00-2.65 (m, 6H), 1.89 (m, 4H). ##STR41## Ethyl 2-oxo-3(R)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2yl)ethyl]pyrrolidin-1-yl)acetyl-3(R)-(2-ethylindol-3-yl)-β-alanine (7-2)
To a stirred solution of 4-1 (175 mg, 0.52 mmol), 7-1 (214 mg, 0.72 mmol; for preparation see U.S. Pat. No. 5,321,034), EDC (197 mg, 1.0 mmol), HOBT (70 mg, 0.52 mmol), and CH 3 CN (3 mL) was added NMM (498 μL, 4.1 mmol). After stirring at ambient temperature for 20 hr, the reaction mixture was diluted with EtOAc and then washed with H 2 O, sat. NaHCO 3 , brine, dried (MgSO 4 ), and concentrated. Flash chromatography (silica, 70:25:5 CHCl 3 /EtOAc/CH 3 OH) gave 7-2 as a white solid.
TLC RF=0.11 (silica, 70:25:5 CHCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 8.29 (bs, 1H), 7.55 (d, J=7 Hz, 1H), 7.36 (d, J=7 Hz, 1H), 7.20-7.00 (m, 3H), 6.63 (d, J=7 Hz, 1H), 6.39 (d, J=7 Hz, 1H), 4.30 (m, 1H), 4.10 (q, J=7 Hz, 2H), 3.94 (d, J=17 Hz, 1H), 3.83 (d, J=17 Hz, 1H), 3.36 (m, 4H), 2.80 (m, 2H), 2.69 (m, 3H), 2.53 (d, J=6 Hz, 2H), 2.50 (m, 1H), 2.24 (m, 2H), 1.93 (m, 4H), 1.75 (m, 2H), 1.18 (t, J=7 Hz, 3H).
2-Oxo-3(R)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(R)-(2-ethylindol-3-yl)-β-alanine (7-3)
A mixture of 7-2 (60 mg, 0.11 mmol), 1N NaOH (132 μL), and ethanol (1 mL) was stirred at ambient temperature for 1 hr, followed by concentration. Flash chromatography (silica, 25:10:1:1 to 15:10:1:1 EtOAc/EtOH/NH 4 OH/H 2 O) gave 7-3 as a white solid.
TLC RF=0.12 (silica, 10:10:1:1 EtOAc/ethanol/NH 4 OH/H 2 O); 1 H NMR (300 MHz, CD 3 OD) β 7.52 (d, J=7 Hz, 1H), 7.43 (d, J=7 Hz, 1H), 7.30 (d, J=8 Hz, 1H), 7.05 (m, 2H), 6.92 (m, 1H), 6.48 (d, J=7 Hz, 1H), 4.54 (d, J=17 Hz, 1H), 4.27 (m, 1H), 3.50-1.70 (m, 22H). ##STR42## N-(4-Iodo-phenylsulfonylamino)-L-asparagine (8-2)
To a stirred solution of acid 8-1 (4.39 g, 33.2 mmol), NaOH (1.49 g, 37.2 mmol), dioxane (30 ml) and H 2 O (30 ml) at 0° C. was added pipsyl chloride (10.34 g, 34.2 mmol). After ˜5 minutes, NaOH (1.49, 37.2 mmol) dissolved in 15 ml H 2 O, was added followed by the removal of the cooling bath. After 2.0 h, the reaction mixture was concentrated. The residue was dissolved in H 2 O (300 ml) and then washed with EtOAc. The aqueous portion was cooled to 0° C. and then acidified with concentrated HCl. The solid was collected and then washed with Et 2 O to provide acid 8-2 as a white solid.
1 H NMR (300 MHz, D 2 O) δ 7.86 (d, 2H, J=8 Hz), 7.48 (d, 2H, J=8 Hz) 3.70 (m, 1H), 2.39 (m, 2H).
2(S)-(4-Iodo-phenylsulfonylamino)-β-alanine (8-3)
To a stirred solution of NaOH (7.14 g, 181.8 mmol) and H 2 O (40 ml) at 0° C. was added Br 2 (1.30 ml, 24.9 mmol) dropwise over a ten minute period. After ˜5 minutes, acid 8-2 (9.9 g, 24.9 mmol), NaOH (2.00 g, 49.8 mmol) and H 2 O (35 ml) were combined, cooled to 0° C. and then added in a single portion to the reaction. After stirring for 20 minutes at 0° C., the reaction was heated to 90° C. for 30 minutes and then recooled to 0° C. The pH was adjusted to ˜7 by dropwise addition of concentrated HCl. The solid was collected, washed with EtOAc, and then dried in vacuo to provide acid 8-3 as a white solid.
1 H NMR (300 MHz, D 2 O) δ 8.02 (d, 2H, J=8 Hz), 7.63 (d, 2H, J=8 Hz), 4.36 (m, 1H), 3.51 (dd, 1H, J=5 Hz, 13 Hz) 3.21 (m, 1H).
Ethyl 2(S)-(4-iodo-phenylsulfonylamino)-β-alanine-hydrochloride (8-4)
HCl gas was rapidly bubbled through a suspension of acid 8-3 (4.0 g, 10.81 mmol) in EtOH (50 ml) at 0° C. for 10 minutes. The cooling bath was removed and the reaction was heated to 60° C. After 18 h, the reaction was concentrated to provide ester 8-4 as a white solid.
1 H NMR (300 MHz, CD 3 OD) δ 7.98 (d, 2H, J=8 Hz), 7.63 (d, 2H, J=8 Hz), 4.25 (q, 1H, J=5 Hz), 3.92 (m, 2H), 3.33 (m, 1H), 3.06 (m, 1H), 1.01 (t, 3H, J=7 Hz).
Ethyl 4-[2-(2-Aminopyridin-6-yl)ethyl]benzoate (8-5)
A mixture of ester 8-5a (700 mg, 2.63 mmol), (for preparation, see: Scheme 29 of PCT International Application Publication No. WO 95/32710, published Dec. 7, 1995) 10% Pd/C (350 mg) and EtOH were stirred under 1 atm H 2 . After 20 h, the reaction was filtered through a celite pad and then concentrated to provide ester 8-5 as a brown oil.
TLC R f =0.23 (silica, 40% EtOAc/hexanes); 1 H NMR (300 MHz, CDCl 3 ) δ 7.95 (d, 2H, J=8 Hz), 7.26 (m, 3H), 6.43 (d, 1H, J=7 Hz), 6.35 (d, 1H, J=8 Hz), 4.37 (m, 4H), 3.05 (m, 2H), 2.91 (m, 2H), 1.39 (t, 3H, J=7 Hz).
4-[2-(2-Aminopyridin-6-yl)ethyl]benzoic acid hydrochloride (8-6)
A suspension of ester 8-5 (625 mg, 2.31 mmol) in 6N HCl (12 ml) was heated to 60° C. After ˜20 h, the reaction was concentrated to give acid 8-6 as a tan solid.
1 H NMR (300 MHz, CD 3 OD) δ 7.96 (d, 2H, J=8 Hz), 7.80 (m, 1H), 7.33 (d, 2H, J=8 Hz), 6.84 (d, 1H, J=9 Hz), 6.69 (d, 1H, J=7 Hz), 3.09 (m, 4H).
Ethyl 4-[2-(2-Aminopyridin-6-yl)ethyl]benzoyl-2(S)-(4-iodophenylsulfonylamino)-.beta.-alanine (8-7)
A solution of acid 8-6 (400 mg, 1.43 mmol), amine 8-4 (686 mg, 1.57 mmol), EDC (358 mg, 1.86 mmol), HOBT (252 mg, 1.86 mmol), NMM (632 μl, 5.72 mmol) and DMF (10 ml) was stirred for ˜20 h. The reaction was diluted with EtOAc and then washed with sat NaHCO 3 , brine, dried (MgSO 4 ) and concentrated. Flash chromatography (silica, EtOAC→5% isopropanol/EtOAc) provided amide 8-7 as a white solid.
TLC R f =0.4 (silica, 10% isopropanol/EtOAc); 1 H NMR (300 MHz, CD 3 OD) δ 7.79 (d, 2H, J=9 Hz) 7.61 (d, 2H, J=8 Hz), 7.52 (d, 2H, J=9 Hz), 7.29 (m, 1H), 7.27 (d, 2H, J=8 Hz), 4.20 (m, 1H), 3.95 (q, 2H, J=7 Hz), 3.66 (dd, 1H, J=6 Hz, 14 Hz), 3.49 (dd, 1H, J=8 Hz, 13 Hz), 3.01 (m, 2H), 2.86 (m, 2H), 1.08 (t, 3H, J=7 Hz).
4-[2-(2-Aminopyridin-6-yl)ethyl]benzoyl-2(S)-(4-iodophenylsulfonylamino)-.beta.-alanine (8-8)
A solution of ester 8-7 (200 mg, 0.3213 mmol) and 6N HCl (30 ml) was heated to 60° C. After ˜20 h, the reaction mixture was concentrated. Flash chromatography (silica, 20:20:1:1 EtOAc/EtOH/NH 4 OH/H 2 O) provided acid 8-8 as a white solid.
TLC R f =0.45 (silica, 20:20:1:1 EtOAc/EtOH/NH 4 OH/H 2 O); 1 H NMR (400 MHz, DMSO) δ 8.40 (m, 1H), 8.14 (Bs, 1H), 7.81 (d, 2H, J=8 Hz), 7.62 (d, 2H, J=8 Hz), 7.48 (d, 2H, J=8 Hz), 7.27 (m, 3H), 6.34 (d, 1H, J=7 Hz), 6.25 (d, 1H, J=8 Hz), 5.85 (bs, 2H), 3.89 (bs, 1H), 3.35 (m, 2H), 2.97 (m, 2H), 2.79 (m, 2H).
4-[2-(2-Aminopyridin-6-yl)ethyl)benzoyl-2(S)-(4-trimethylstannyl-phenylsulfonylamino-β-alanine (8-9)
A solution of iodide 8-8 (70 mg, 0.1178 mmol), (CH 3 Sn) 2 (49 μl, 0.2356 mmol), Pd(PPh 3 ) 4 (5 mg) and dioxane (7 ml) was heated to 90° C. After 2 h, the reaction was concentrated and then purified by prep HPLC (Delta-Pak C 18 15 μM 100A°, 40×100 mm; 95:5→5:95 H 2 O/CH 3 CN) provided the trifluoroacetate salt. The salt was suspended in H 2 O (10 ml), treated with NH 4 OH (5 drops),and then lyophilized to provide amide 8-9 as a white solid.
1 H NMR (400 MHz, DMSO) δ 8.40 (m, 1H), 8.18 (d, 1H, J=8 Hz), 7.67 (m, 5H), 7.56 (d, 2H, J=8 Hz), 7.29 (d, 2H, J=8 Hz), 6.95-7.52 (m, 2H), 6.45 (bs, 2H), 4.00 (m, 1H), 3.50 (m, 1H), 3.33 (m, 1H), 2.97 (m, 2H), 2.86 (m, 2H).
4-[2-(2-Aminopyridin-6-yl)ethyl]benzoyl-2(S)-4- 125 iodophenylsulfonylamino-β-alanine (8-10)
An iodobead (Pierce) was added to a shipping vial of 5 mCi of Na 125 I (Amersham, IMS30) and stirred for five minutes at room temperature. A solution of 0.1 mg of 8-9 in 0.05 mL of 10% H 2 SO 4 /MeOH was made and immediately added to the Na 125 I/iodobead vial. After stirring for three minutes at room temperature, approximately 0.04-0.05 mL of NH 4 OH was added so the reaction mixture was at pH 6-7. The entire reaction mixture was injected onto the HPLC for purification [Vydac peptide-protein C-18 column, 4.6×250 mm, linear gradient of 10% acetonitrile (0.1% (TFA):H 2 O (0.1% TFA) to 90% acetonitrile (0.1% TFA):H 2 O (0.1% TFA) over 30 minutes, 1 mL/min]. The retention time of 8-10 is 17 minutes under these conditions. Fractions containing the majority of the radioactivity were pooled, lyophilized and diluted with ethanol to give approximately 1 mCi of 8-10, which coeluted on HPLC analysis with an authentic sample of 8-8.
Instrumentation: Analytical and preparative HPLC was carried out using a Waters 600E Powerline Multi Solvent Delivery System with 0.1 mL heads with a Rheodyne 7125 injector and a Waters 990 Photodiode Array Detector with a Gilson FC203 Microfraction collector. For analytical and preparative HPLC a Vydac peptide-protein C-18 column, 4.6×250 mm was used with a C-18 Brownlee modular guard column. The acetonitrile used for the HPLC analyses was Fisher Optima grade. The HPLC radiodetector used was a Beckman 170 Radioisotope detector. A Vydac C-18 protein and peptide column, 3.9×250 mm was used for analytical and preparative HPLC. Solutions of radioactivity were concentrated using a Speedvac vacuum centrifuge. Calibration curves and chemical concentrations were determined using a Hewlett Packard Model 8452A UV/Vis Diode Array Spectrophotometer. Sample radioactivities were determined in a Packard A5530 gamma counter. ##STR43## Methyl (S)-(3-amino-2-oxo-pyrrolidin-1-yl)-acetic acid hydrochloride(9-2)
A solution of 9-1 (0.50 g, 1.84 mmol) (prepared as described by Freidinger, R. M.; Perlow, D. S.; Veber, D. F.; J. Org. Chem., 1982, 26, 104) in anhydrous ethyl acetate (50 mL) was cooled to 0° C. and saturated with HCl gas, then stirred at 0° C. for 2 h. The resulting colorless solution was concentrated at reduced pressure and the residue triturated with anhydrous diethyl ether giving 9-2 as a hygroscopic white solid.
1 H NMR (300 MHz, CD 3 OD) δ 4.16 (d, 2H); 4.2 (m, 1H); 3.68 (s, 3H); 3.53 (m, 2H); 2.58 (m, 1H); 2.09 (m, 1H).
Methyl 2-oxo-3(S)-[1,8]naphthyridin-2-ylmethyl)-amino]-pyrrolidin-1-yl]-acetic acid (9-4)
A solution of 9-2 (232 mg, 1.11 mmol) and 9-3 (176 mg, 1.11 mmol) (prepared as reported by Weissenfels, M.; Ulrici, B.; Z. Chem. 1978, 18, 20.) in anhydrous methanol (10 mL) was treated with NaOAc (91 mg, 1.11 mmol), NaBH 3 CN (70 mg, 1.11 mmol) and powdered 4 Å molecular sieves (450 mg). The resulting mixture was stirred at 0° for 3.5 h, then concentrated and the residue subjected to flash chromatography on silica gel (95:4.5:0.5 CH 2 Cl 2 /MeOH/NH 4 OH) to afford 9-4 as a colorless glass.
FAB MS (315, M +1 ); 1 H NMR (300 MHz, CD 3 OD) δ 9.04 (d, 1H); 8.41 (dd, 1H); 8.38(d, 1H); 7.72 (d, 1H); 7.62 (dd, 1H); 4.31 (d, 2H); 4.21 (m, 2H); 3.68 (s, 3H);3.63 (m, 1H); 3.53 (m, 2H); 2.52 (m, 1H); 1.95 (m, 1H).
Methyl [3(S)-[tert-butoxycarbonyl-[1,8]naphthyridin-2-ylmethyl)-amino]-2-oxo-pyrrolidin-1-yl]-acetic acid (9-5)
A solution of amine 9-4 (69 mg, 0.22 mmol) in THF (5 mL) was treated with Boc 2 O (83 mg, 0.24 mmol) and stirred at room temperature for 18 h. The solvent was removed in vacuo and the resulting residue isolated by chromatography on silica gel (5% MeOH/CH 2 Cl 2 ) to afford 9-5 as a yellow glass. FAB MS (415, M +1 );
1 H NMR (300 MHz, CD 3 OD) δ 9.04 (d, 1H); 8.20 (m, 2H); 7.88 (d, 0.5H (rotamer a)); 7.82 (d, 0.5H (rotamer b)); 7.46(m, 1H); 5.1-4.3 (m, 5H); 3.81 (m, 2H); 3.72 (s, 3H); 3.41 (m, 2H); 2.36 (m, 2H); 1.47 (s, 4.5 H (rotamer a)); 1.30 (s, 4.5 H , (rotamer b)).
Methyl [3(S)-[tert-butoxycarbonyl-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-aminol-]2-oxo-pyrrolidin-1-yl]-acetic acid (9-6)
A solution of 9-5 (40 mg, 0.097mmol) in EtOH (5 mL) was treated with 10% Pd on C (8 mg) and then stirred under a H 2 filled balloon for 16 h. The catalyst was removed by filtration through celite and the filtrate concentrated to afford 9-6 as a colorless glass.
1 H NMR (300 MHz, CD 3 OD) δ 7.10 (d, 1H) 6.78 (d, 0.5H (rotamer a)); 6.62 (d, 0.5H (rotamer b)); 4.8-3.9 (m, 5H); 3.81 (m, 2H); 3.72 (s, 3H); 3.38 (m, 2H); 2.36 (m, 2H); 1.21(s, 4.5 H (rotamer a)); 1.15 (s, 4.5 H. (rotamer b)).
3(S)-[tert-butoxycarbonyl-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-aminol-2-oxo-pyrrolidin-1-yl]-acetic acid (9-7)
A solution of 9-6 (38 mg, 0.091 mmol) in 50% aqueous THF (2 mL) was treated with 1.0 N NaOH (95 mL, 0.095 mmol) and stirred at room temperature for 2 h. The reaction was nuetralized with 1N HCl, evaporated, and the residue dissolved in MeOH (2.5 mL), filtered and evaporated to afford 9-7 as a colorless glass.
1 H NMR (300 MHz, CD 3 OD) δ 7.31 (d, 1H) 6.78 (br, d, 1H); 4.8-3.9 (m, 5H); 3.81 (m, 2H); 3.38 (m, 2H); 2.36 (m, 2H); 1.21(s, 4.5 H (rotamer a)); 1.15 (s, 4.5 H , (rotamer b)).
Ethyl 3-(2-{2-oxo-3(S)-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-pyrrolidin-1-yl}-acetylamino)-3-(S)-pyridin-3-yl-propionic acid (9-8)
9-7 (43 mg, 0.093 mmol), 1-9 (25 mg, 0093 mmol), EDC (18 mg, 0.093 mmol), HOBT (13 mg, 0.093 mmol), and N-methyl morpholine (31 mL, 0.28 mmol) in anhydrous DMF (5 mL) was stirred at room temperature for 18 h, then concentrated in vacuuo and the residue chromatographed on silica gel using 5% MeOH/CH 2 Cl 2 as eluent affording 9-8 as a colorless glass.
1 H NMR (300 MHz, CDCl 3 ) δ 8.61 (s, 1H); 8.45 (d, 1H); 8.00 (m, 1H); 7.68, (d, 1H); 7.21 (m, 1H); 7.17 (d, 1H); 5.56 (m, 1H); 4.75 (s, 2H); 4.45 (m, 2H); 4.05 (q, 2H); 3.95 (m, 1H); 3.5-3.3 (m, 4H); 2.92 (m, 1H); 2.87 (m, 1H); 2.74 (m, 2H); 2.35 (m, 2H); 1.92 (m, 2H); 1.36 (s, 9H); 1.21 (t, 3H).
3-(2-{2-oxo-3(S)-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-pyrrolidin-1-yl }-acetylamino)-3-(S)-pyridin-3-yl-propionic acid (9-9)
9-8 (25 mg, 0.043 mmol) was dissolved in 6 N HCl (2 mL) and stirred at room temperature for 16 h, then evaporated to afford 9--9 as a pale yellow solid.
FAB MS (453, M +1 ); 1 H NMR (300 MHz, CD 3 OD) δ 9.00 (s, 1H); 8.81 (d, 1H); 8.79(m, 1H); 8.10 (m, 1H); 7.71 (d, 1H); 7.01 (m, 1H); 5.56 (m, 1H); 4.75 (s, 2H); 4.61 (m, 1H); 4.50 (m, 1H); 4.35 (m, 1H); 4.10 (s, 2H); 3.62 (m, 4H); 3.4-3.0 (m, 2H); 2.8 (m, 2H); 2.70 (m, 1H); 2.45 (m 1H); 1.98 (m, 2H).
Following the procedure described in Scheme 10, bicyclic compounds such as 10-6 are readily prepared by one of ordinary skill in the art. ##STR44## 3(R)-phenyl-tetrahydro-pyrrolo[1,2(S)-c]oxazol-5-one (11-2)
A mixture of alcohol (S)-5-(hydroxymethyl)-2-pyrrolidinone (11-1, Fluka) (5.0 g, 43.4 mmol), benzaldehyde (5.7 mL, 56.4 mmol), p-TSA (80 mg, 0.4340 mmol) and toluene (125 mL) was heated to reflux with azeotropic removal of water for 18 hours. The solution was concentrated. Flash chromatography (silica, 50% EtOAc/hexanes) gave 11-2 as a yellow oil.
TLC R f =0.21 (silica,50% EtOAc/hexanes); 1 H NMR (300 MHz, CDCl 3 ) δ 7.29→7.46 (m, 5H), 6.34 (s, 1H), 4.24 (m, 1H), 4.16 (t, J=5.8 Hz, 1H), 3.49 ((t, J=7.8 Hz, 1H), 2.82 (m, 1H), 2.55 (m, 1H), 2.39 (m,1H), 1.97 (m,1H).
6(S)-[2-(2-methyl-[1,3]dioxolan-2-yl)-ethyl]-3(R)-phenyl-tetrahydropyrrolo[1,2(S)-c]oxazol-5-one (11-3)
To a stirred solution of 11-2 (7.0 g, 34.4 mmol), HMPA (30.0 mL, 172 mmol) and THF (150 mL) at -78° C. was added LDA (18.9 mL, 37.8 mmol, 2.0M in heptane/THF). After 10 minutes, the reaction was warmed to -15° C. After 20 min, 1-2 (8.3 g, 34.4 mmol), dissolved in 10 mL of THF, was added. After 2 h, the reaction was warmed to ambient temperature for 3.0 hours and then recooled to -15° C. for 18 hours. The reaction was warmed to ambient temperature for 2 hours and then diluted with Et 2 O, washed with H 2 O, dried (MgSO 4 ) and concentrated. Flash chromatography (silica, 40%→60% EtOAc/hexanes) gave 11-3 as an oil.
TLC R f =0.28 (silica, 50% EtOAc/hexanes); 1 H NMR (300 MHz, CDCl 3 ) δ 7.25→7.46 (m, 5H), 6.33 (s,1H), 4.24 (m, 1H), 4.11 (m, 1H), 3.95 (s, 4H), 3.52 (t, J=7.3 Hz, 1H), 2.87 (m, 1H), 2.57 (m, 1H), 2.10 (m,1H) 1.40→1.86 (m, 4H), 1.34 (s,3H).
1-benzyl-5(S)-hydroxymethyl-3(S)-[2-(2-methyl-[1,3]dioxolan-2-yl)ethyl]-pyrrolidin-2-one (11-4)
A mixture of 11-3 (2.0 g, 6.30 mmol) and 10% Pd/carbon (2.0 g) in EtOH (30 mL) was stirred under a balloon of hydrogen for 1.0 h. Following filtration and evaporative removal of the solvent, the residue dissolved in benzene (30 mL), treated with TsOH (10 mg) and ethylene glycol (1.05 mL, 18.9 mmol) and then heated to reflux with azeotropic removal of water for 1 hour. The reaction was concentrated. Flash chromatography (silica, 70:23:7 CHCl 3 /EtOAc/MeOH) gave 11-4 as an oil.
1 H NMR (300 MHz, CDCl 3 ) δ 7.30 (m, 5H), 4.64 (d, J=15 Hz, 1H), 4.25 (d, J=15 Hz, 1H), 3.95 (s, 4H), 3.72 (m, 1H), 3.49 (m, 2H), 2.46 (m, 1H), 2.15 (m, 2H), 1.74 (m,2H), 1.53 (m,2H) 1.35 (s,3H).
1-benzyl-5(S)-iodomethyl-3(S)-[2-(2-methyl-[1,3]dioxolan-2-yl)-ethyl]-pyrrolidin-2-one (11-5)
To a stirred solution of 11-4 (2.0 g, 6.26 mmol), PPh 3 (2.63 g, 10.0 mmol), imidazole (725 mg, 10.6 mmol) and CH 3 CN (30 mL) at 0° C. was added I 2 (2.39 g, 9.39 mmol) in five portions over 15 minutes. After 20 minutes, the reaction was warmed to 50° C. for 30 minutes and then poured into 200 mL 1:1 EtOAc/hexanes. The solution was washed with 10% sodium bisulfite, sat NaHCO 3 , brine, dried (MgSO 4 ) and concentrated. Flash chromatography (silica, 40% EtOAc/hexanes) gave 11-5 as an oil.
TLC R f =0.27 (silica, 50% EtOAc/hexanes); 1 H NMR (300 MHz, CDCl 3 ) δ 7.19→7.35 (m, 5H), 5.04 (d, J=15.1 Hz, 1H), 3.96 (m, 5H), 3.30 (m 1H), 3.19 (m, 2H), 2.50 (m, 1H), 2.32 (m,1H), 2.12 (m,1H), 1.79 (m,2H), 1.58 (m,1H), 1.36 (m,4H).
1-benzyl-5(R)-methyl-3(S)-[2-(2-methyl-[1,3]dioxolan-2-yl)-ethyl]-pyrrolidin-2-one (11-6)
To a stirred solution of 11-5 (900 mg, 6.26 mmol) and HMPA (30 mL) was added NaBH 4 (156 mg, 4.20 mmol). After 45 minutes, the reaction was poured into 50 mL 1:1 Et 2 O/hexanes and then washed with H 2 O, brine, dried (MgSO 4 ) and concentrated to provide 11-6 as an oil.
TLC R f =0.34 (silica, 50% EtOAc/hexanes); 1 H NMR (300 MHz, CDCl 3 ) δ 7.20→7.33 (m, 5H), 4.95 (d, J=15.1 Hz, 1H),4.03 (d, J=14.9 Hz, 1H), 3.95 (s 4H), 3.41 (m, 1H), 2.38 (m, 2H), 2.10 (m,1H), 1.75 (m,2H), 1.48 (m,1H), 1.35 (s,3H), 1.16 (m,4H).
5(R)-methyl-3(S)-[2-(2-methyl-[1,3]dioxolan-2-yl)-ethyl]-pyrrolidin-2-one (11-7)
Into a 3-necked 500 mL flask at -78° C. was condensed 200 mL of ammonia. Lithium (64 mg, 9.25 mmol) was washed with MeOH, then THF and then added to the ammonia. After 20 minutes, 11-6 (560 mg, 1.85 mmol), dissolved in 25 mL of THF, was added. After 30 minutes, the reaction was quenched with NH 4 Cl; 200 mL of THF was added, the cooling bath was removed and the solution purged with argon for 30 minutes to remove the ammonia. The solution was dried (MgSO 4 ) and concentrated. Flash chromatography (silica, EtOAc→5% MeOH/EtOAc) gave 11-7 as an oil.
TLC R f =0.33 (silica, 10% MeOH/EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 5.98 (br s, 1H), 3.94 (s, 4H), 3.67 (m 1H), 2.40 (m, 2H), 2.02 (m, 1H), 1.70 (m,2H), 1.40 (m,1H), 1.33 (s,3H), 1.22 (m,4H).
{5(R)-methyl-3(S)-[2-(2-methyl-[1,3]dioxolan-2-yl)-ethyl]-2-oxo-pyrrolidin-1-yl}-acetic acid ethyl ester (11-8)
To a stirred solution of 11-7 (355 mg, 1.67 mmol) and THF (10 mL) at -78° C. was added NaN(TMS) 2 (1.83 mL, 1.83 mmol, 1.0M in THF). After 20 min, ethyl bromoacetate (0.203 mL, 1.84 mmol) was added and the reaction was warmed to 0° C. After 30 minutes, the reaction mixture was diluted with EtOAc and then washed with H 2 O, brine, dried (MgSO 4 ), and concentrated to give 11-8 as a yellow oil.
TLC R f =0.90 (silica, 10% MeOH/EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 4.35 (d, J=17.6 Hz, 1H), 4.18 (q, J=7.1 Hz, 2H), 3.94 (s, 4H), 3.74 (m, 3H), 2.44 (m, 2H), 2.05 (m, 1H), 1.73 (m, 2H), 1.43 (m, 1H), 1.33 (s,3H), 1.27 (t, J=7.1 Hz, 3H), 1.20 (d, J=6.4 Hz, 3H).
[5(R)-methyl-2-oxo-3(S)-(3-oxo-butyl)-pyrrolidin-1-yl]-acetic acid ethyl ester (11-9)
A solution of 11-10 (360 mg, 1.20 mmol), p-TSA (10 mg) and acetone (20 mL) was heated at reflux for 1 hr. The cooled reaction mixture was diluted with EtOAc and then washed with sat. NaHCO 3 and brine, dried (MgSO 4 ), and concentrated to afford 11-9 as an oil.
TLC R f =0.54 (silica, 75% EtOAc/hexanes); 1 H NMR (300 MHz, CDCl 3 ) δ 4.32 (d, J=17.6 Hz, 1H), 4.18 (q, J=7.1 Hz, 2H), 3.73 (m, 3H), 2.72 (m, 2H), 2.42 (m, 1H), 2.16 (s, 3H), 1.99 (m, 1H), 1.78 (m, 1H), 1.27 (t, J=7.1 Hz, 3H), 1.20 (d, J=6.1 Hz, 3H).
[5(R)-methyl-3(S)-(2-[1,8]naphthyridin-2-yl-ethyl)-2-oxo-pyrrolidin-1-yl]-acetic acid ethyl ester (11-10)
A mixture of 11-9 (220 mg, 0.8619 mmol), 1-4, 2-amino-3-formylpyridine (137 mg, 1.12 mmol) and proline (99 mg, 0.8619 mmol) in absolute ethanol (5 mL) was heated at reflux for 12 h. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:25:5 chloroform/ethyl acetate/MeOH) to give 11-10 as a yellow oil.
TLC Rf=0.37 (70:25:5 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CDCl 3 ) δ 9.08 (m, 1H), 8.16 (dd, J=2 Hz, 6 Hz 1H), 8.12 (d,J=8 Hz, 1H), 7.46 (m, 2H), 4.33 (d, J=17.5 Hz, 1H), 4.17 (m, 2H), 3.71 (m, 3H), 3.21 (t, J=8.0 Hz, 2H), 2.54 (m, 2H), 2.39 (m, 1H), 2.02 (m, 1H), 1.35 (m, 1H), 1.26 (t, J=7.1 Hz, 3H), 1.21 (d, J=6.3 Hz, 3H).
{5(R)-methyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetic acid ethyl ester (11-11)
A mixture of 1-10 (250 mg, 0.7323 mmol) and 10% Pd/carbon (250 mg) in EtOH (5 mL) was stirred under a balloon of hydrogen for 20 h. Following filtration and evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:25:5 chloroform/ethyl acetate/MeOH to give 11-11 as a colorless oil.
TLC Rf=0.25 (70:25:5 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CDCl 3 ) δ 7.05 (d, 1H, J=7.3 Hz), 6.39 (d, 1H, J=7.3 Hz), 4.77 (br s, 1H), 4.17 (d, 1H, J=17.5 Hz), 4.15 (m, 2H), 3.71 (m, 2H), 3.39 (m, 2H), 2.64 (m, 4H), 2.46 (m, 2H), 2.30 (m, 1H), 1.91 (m, 2H), 1.88 (m, 1H), 1.26(t, 3H, J=6.1 Hz) 1.23 (m,1H), 1.19 (d, J=6.4 Hz, 3H).
{5(R)-methyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetic acid hydrochloride (11-12)
A mixture of 11-11 (185 mg, 0.5356 mmol) and 6N HCl (10 mL) was heated at 60° C. for 1 h. Evaporative removal of the solvent gave 11-12 as a yellow solid.
1 H NMR (300 MHz, CD 3 OD) δ 7.59 (d, 1H, J=7.3 Hz), 6.66 (d, 1H, J=7.3 Hz), 4.17 (d, 12H, J=17.8, Hz), 3.90 (d, 1H, J=17.8, Hz), 3.77 (m, 1H), 3.50 (t, J=5.4 Hz, 2H), 3.31 (m, 4H), 2.52 (m, 2H), 2.25 (m, 1H), 1.95 (t, 2H, J=6.6 Hz), 1.80 (m, 1H), 1.34 (m, 1H), 1.25 (d, J=6.3 Hz, 3H)
2-Oxo-5(R)-methyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)-ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine ethyl ester (11-13)
A mixture of 11-12 (350 mg, 0.9892 mmol), 2-9 (193 mg, 1.09 mmol), EDC (378 mg, 1.98 mmol), HOBT (134 mg, 0.9892 mmol) and NMM (1.10 mL, 7.91 mmol) in CH 3 CN (5 mL) was stirred for 20 h. The mixture was diluted with ethyl acetate, washed with sat. NaHCO 3 , brine, and dried over MgSO 4 . Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:25:5 chloroform/ethyl acetate/MeOH to give 11-13 as a colorless foam.
TLC Rf=0.15 (70:25:5 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CDCl 3 ) δ 7.05 (m, 2H), 6.39 (d, 1H, J=7.3 Hz), 5.04 (m, 1H), 4.16 (q, 2H, J=7.1 Hz), 3.90 (s, 2H), 3.64 (m, 1H),3.39 (m, 2H), 2.69 (m, 6H), 2.47 (m, 2H), 2.30 (m, 1H), 1.90 (m, 2H), 1.64 (m, 2H), 1.20 (m, 7H).
2-Oxo-5(R)-methyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine (11-14)
To a solution of 11-13 (70 mg, 0.1589 mmol) in EtOH (1 mL) was added 1N NaOH (0.175 ml, 0.164 mmol). After stirring for 1 h, the solvents were evaporated and the residue was chromatographed (silica gel, 25:10:1:1 to 15:10:1:1 ethyl acetate/EtOH/water/NH 4 OH to give 11-14 as a colorless foam.
TLC Rf=0.21 (10:10:1:1 ethyl acetate/EtOH/water/NH 4 OH). 1 H NMR (300 MHz, CD 3 OD) δ 7.42 (d, 1H, J=7.3 Hz), 6.49 (d, 1H, J=7.3 Hz), 4.35 (d,J=17.1 Hz, 1H), 3.64 (m, 1H,), 3.50 (m, 3H,), 3.18 (m, 2H), 2.77 (t, J=5.6 Hz, 2H), 2.55 (m, 5H), 2.23 (m, 1H), 1.91 (m, 4H), 1.41 (m, 1H) 1.28 (d, J=6.3 Hz, 3H). ##STR45## 1-benzyl-5(S)-methyl-p-toluenesulfonate-3(S)-[2-(2-methyl-[1,3]dioxolan-2-yl)-ethyl]-pyrrolidin-2-one (12-1)
To a stirred solution of 11-4 (1.8 g, 5.63 mmol) and THF (30 mL) at 0° C. was added NaH (248 mg, 6.19 mmol). After 30 minutes, TosCl was added followed by the removal of the cooling bath. After 1.0 hour, the reaction was diluted with EtOAc and then washed with H 2 O, sat NaHCO 3 , brine, dried (MgSO 4 ) and concentrated. Flash chromatography (silica, 40→60% EtOAc/hexanes) gave 12-1 as an oil.
TLC R f =0.75 (silica, EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 7.72 (d, J=8.30 Hz, 2H), 7.35 (d, J=7.3 Hz, 2H), 7.25 (m, 3H), 7.09 (m 2H), 4.94 (d, J=14.9 Hz, 1H), 4.01 (m, 1H), 3.94 (m,5H), 3.83 (d, J=15.1 Hz, 1H), 3.54 (m,1H), 2.46 (s,3H), 2.42 (m,1H), 2.21 (m, 1H), 2.01 (m, 1H), 1.72 (M, 2H), 1.43 (m, 2H), 1.32 (s, 3H).
1-benzyl-5(S)-benzyl-3(S)-[2-(2-methyl-[1,3]dioxolan-2-yl)-ethyl]-pyrrolidin-2-one (12-2)
To a stirred suspension of CuI (2.57 g, 13.5 mmol) and Et 2 O (10 mL) at 0° C. was added PhLi (14.2 mL, 25.6 mmol, 1.8M cyclohexane-ether) dropwise over a 1.0 hour period. After an additional hour, 12-1 (1.4 g, 2.96 mmol), dissolved in 10 mL Et 2 O, was added. The reaction was stirred at -15° C. for 96 hours. The reaction was diluted with EtOAc and then washed with sat NH 4 Cl, sat NaHCO 3 , brine, dried (MgSO 4 ) and concentrated. Flash chromatography (silica, 30→60% EtOAc/hexanes) gave 12-2 as an oil.
TLC R f =0.29 (silica,50% EtOAc/hexanes); 1 H NMR (300 MHz, CDCl 3 ) δ 7.13→7.36 (m, 8H), 7.02 (d, J=7.6 Hz, 2H), 5.06 (d, J=14.9 Hz, 1H), 4.14 (d, J=15.1 Hz, 1H), 3.95 (m, 4H), 3.55 (m, 1H), 3.18 (dd, J=4.2, 17.0 Hz,1H), 2.35 (m,2H), 2.04 (m,2H), 1.66 (m,2H), 1.32 (m,5H).
5(S)-benzyl-3(S)-[2-(2-methyl-[1,3]dioxolan-2-yl)-ethyl]-pyrrolidin-2-one (12-3)
Into a 3-necked 500 mL flask at -78° C. was condensed 100 mL of ammonia. Next, 12-2 (470 mg, 1.24 mmol), dissolved in 20 mL of THF, was added. Lithium (19 mg, 2.48 mmol) was washed with MeOH, then THF and then added to the ammonia. After 20 minutes, the reaction was quenched with NH 4 Cl; 200 mL of THF was added, the cooling bath was removed and the solution purged with argon for 30 minutes to remove the ammonia. The solution was dried (MgSO 4 ) and concentrated. Flash chromatography (silica, EtOAc) gave 12-3 as an oil.
TLC R f =0.22 (silica, EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 7.18→7.35 (m, 5H), 5.43 (br s, 1H), 3.95 (s, 4H), 3.92 (m 1H), 2.88 (dd, J=5.3, 18.6 Hz, 1H), 2.41 (m, 2H), 2.03 (m,1H), 1.71 (m,2H), 1.43 (m,2H), 1.33 (s,3H).
{5(S)-benzyl-3(S)-[2-(2-methyl-[1,3]dioxolan-2-yl)-ethyl]-2-oxo-pyrrolidin-1-yl}-acetic acid ethyl ester (12-4)
To a stirred solution of 12-3 (210 mg, 0.7257 mmol) and THF (5 mL) at -78° C. was added NaN(TMS) 2 (0.943 mL, 0.943 mmol, 1.0M in THF). After 30 min, ethyl bromoacetate (0.104 mL, 0.9434 mmol) was added and the reaction was warmed to 0° C. After 1.0 hour, the reaction mixture was diluted with EtOAc and then washed with sat NaHCO 3 , brine, dried (MgSO 4 ), and concentrated to give 12-4 as a yellow oil.
TLC R f =0.64 (silica, EtOAc); 1 H NMR (300 MHz, CDCl 3 ) δ 7.15→7.33 (m, 5H), 4.40 (d, J=17.8 Hz, 1H), 4.15 (m, 2H), 3.93(m, 5H), 3.77 (d, J=17.8, 1H), 3.07 (dd, J=5.0, 18.6 Hz, 1H), 2.56 (m, 1H), 2.39 (m, 1H), 2.20 (m, 1H), 2.05 (m,1H), 1.69 (m, 2H), 1.23→1.46 (m,8H).
[5(S)-benzyl-2-oxo-3(S)-(3-oxo-butyl)-pyrrolidin-1-yl]-acetic acid ethyl ester (12-5)
A solution of 12-4 (260 mg, 0.6925 mmol), p-TSA (10 mg) and acetone (20 mL) was heated at reflux for 1 hr. NaHCO 3 was added to the cooled reaction mixture and then the mixture was concentrated. The residue was diluted with CHCl 3 and then washed with brine, dried (MgSO 4 ), and concentrated to afford 12-5 as an oil.
TLC R f =0.66 (silica, 75%EtOAc/hexanes); 1 H NMR (300 MHz, CDCl 3 ) δ 7.22→7.36 (m, 3H), 7.15 (d, J=6.5 Hz, 2H), 4.37 (d, J=17.6 Hz, 1H), 4.18 (m, 2H), 3.97 (m, 1H), 3.77 (d, J=17.8 Hz, 1H), 3.06 (dd, J=5, 18 Hz, 1H), 2.60 (m, 3H), 2.42 (m, 1H), 2.17 (m, 1H), 2.14 (s, 3H), 1.96 (m,1H), 1.74 (m, 1H) 1.27 (m, 4H).
[5(S)-benzyl-3(S)-(2-[1,8]naphthyridin-2-yl-ethyl)-2-oxo-pyrrolidin-1-yl]-acetic acid ethyl ester (12-6)
A mixture of 12-5 (230 mg, 0.6940 mmol), 1-4, (2-amino-3-formylpyridine, 110 mg, 0.9022 mmol) and proline (80 mg, 0.6940 mmol) in absolute ethanol (10 mL) was heated at reflux for 18 h. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:28:2 chloroform/ethyl acetate/MeOH) to give 12-6 as a yellow oil.
TLC Rf=0.38 (70:25:5 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CDCl 3 ) δ 9.08 (m, 1H), 8.16 (dd, J=2 Hz, 10 Hz 1H), 8.09 (d,J=8.3 Hz, 1H), 7.44 (m, 2H), 7.28 (m, 2H), 7.16 (d, J=8 Hz, 2H), 4.37 (d, J=17.6 Hz, 1H), 4.16 (m, 2H), 3.96 (m, 1H), 3.80 (d, J=17.6 Hz, 1H), 3.15 (m, 2H), 3.06 (dd, J=5.3, 18.5, 1H), 2.26→2.63 (m, 4H), 1.97 (m, 1H), 1.47 (m, 1H), 1.25 (t, J=7.1 Hz, 3H).
{5(S)-benzyl-2-oxo-3 (S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetic acid ethyl ester (12-7)
A mixture of 12-6 (220 mg, 0.5270 mmol) and 10% Pd/carbon (100 mg) in EtOH (4 mL) was stirred under a balloon of hydrogen for 2 h. Following filtration and evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:25:5 chloroform/ethyl acetate/MeOH to give 12-7 as a colorless oil.
TLC Rf=0.25 (70:25:5 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CDCl 3 ) δ 7.26 (m, 3H), 7.16 (d, J=8.1 Hz, 2H), 7.04 (d, J=7.3 Hz, 1H), 6.36 (d, J=7.3 Hz, 1H), 4.74 (br s, 1H), 4.39 (d, J=17.8 Hz, 1H), 4.15 (m, 2H), 3.90 (m, 1H), 3.77 (d, J=17.5 Hz, 1H), 3.38 (m, 2H), 3.06 (dd, J=2.4, 18.8 Hz, 1H), 2.65 (m, 5H), 2.43 (m, 1H), 2.22 (m, 3H), 1.89 (m, 1H) 1.36 (m,1H), 1.26 (t, J=7.1 Hz, 3H).
{5(s)-benzyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetic acid hydrochloride (12-8)
A mixture of 12-7 (150 mg, 0.3559 mmol) and 6N HCl (10 mL) was heated at 60° C. for 1 h. Evaporative removal of the solvent gave 12-8 as a yellow solid.
1 H NMR (300 MHz, CD 3 OD) δ 7.57 (d, J=7.3 Hz, 1H), 7.24 (m, 5H), 6.60 (d, J=7.3 Hz, 1H), 4.24 (d, J17.8, Hz, 1H), 4.03 (m, 2H), 3.49 (t, J=5.6 Hz, 2H), 3.15 (dd, J=4.4, 17.6 Hz, 1H), 2.71 (m, SH), 2.46 (m, 1H), 2.21 (m, 1H), 1.97 (m,3H), 1.64 (m, 1H), 1.45 (m,1H)
2-Oxo-5(S)-benzyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)-ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine ethyl ester (12-9)
A mixture of 12-8 (150 mg, 0.3559 mmol), 2-10 (60 mg, 0.2135 mmol), EDC (132 mg, 0.7118 mmol), HOBT (48 mg, 0.3559mmol) and NMM (0.4 mL, 2.85 mmol) in DMF (4 mL) was stirred for 20 h. The mixture was diluted with ethyl acetate, washed with sat. NaHCO 3 , brine, and dried over MgSO 4 . Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:20:10 chloroform/ethyl acetate/MeOH to give 12-9 as a colorless foam.
TLC Rf=0.15 (70:25:5 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CD 3 OD) δ 8.55 (s, 1H), 8.44 (m, 1H), 7.82 (m, 1H), 7.6-7.1 (m, 7H), 6.33 (d, J=7.5 Hz, 1H), 5.40 (t, J=8 Hz, 1H), 4.2-3.8 (m, 6H), 3.38 (m, 1H), 3.17 (m, 2H), 2.90 (m, 2H), 2.67 (m, 2H), 2.54 (m, 2H), 2.12 (m, 2H),1.84 (m, 2H), 1.43 (m, 2H) 1.18 (m, 3H).
2-Oxo-5(S)-benzyl-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-yl)ethyl]pyrrolidin-1-yl)acetyl-3(S)-pyridin-3-yl-β-alanine (12-13)
To a solution of 12-9 (70 mg, 0.1229 mmol) in EtOH (1 mL) was added 1N NaOH (0.150 ml, 0.150 mmol). After stirring for 1.5 h, the solvents were evaporated and the residue was chromatographed (silica gel, 25:10:1:1 to 15:10:1:1 ethyl acetate/EtOH/water/NH 4 OH to give 12-10 as a colorless foam.
TLC Rf=0.21 (10: 10:1:1 ethyl acetate/EtOH/water/NH 4 OH). 1 H NMR (300 MHz, CD 3 OD) δ 8.62 (s, 1H), 8.36 (m, 1H), 7.92 (m, 1H), 7.45-7.2 (m, 7H), 6.49 (d, J=7.1 Hz, 1H), 5.27 (m, 1H), 4.31 (d, J=17.3 Hz, 1H), 3.93 (m, 1H), 3.72 (d, J=17.5 Hz, 1H), 3.30 (m, 3H), 2.92-2.52 (m, 8H), 2.36 (m, 2H), 1.90 (m, 3H), 1.57 (m, 1H). ##STR46## 1-benzyl-5(S)-hydroxymethyl-pyrrolidin-2-one (13-1)
A mixture of 11-2 (5.0 g, 24.6 mmol), 10% Pd/C (2.5 g), and ethanol (80 mL) was stirred at ambient temperature under a hydrogen atmosphere (1 atm) for 5 hr. The catalyst was removed by filtration through a celite pad and the filtrate concentrated to give 13-1 as a colorless oil.
TLC RF=0.55 (silica, 70:20:10 CHCl 3 /EtOAc/CH 3 OH); 1 H NMR (300 MHz, CDCl 3 ) δ 7.29 (m, 5H), 4.83 (d, 2H, J=15H), 4.25 (d, 1H, J=15 Hz), 3.77 (m, 1H), 3.51 (m, 2H), 2.54 (m, 1H), 2.40 (m, 1H), 1.92 (m, 2H).
1-benzyl-5(S)-iodomethyl-pyrrolidin-2-one (13-2)
To a solution of 13-1 (18.5 g, 90.1 mmol), triphenylphosphine (40.1 g, 153 mmol), and imidazole (11.03 g, 162 mmol) in 225 mnL of acetonitrile and 150 mL of ether at 0° C. was added iodine (34.3 g, 135 mmol) in 5 portions over 5 minutes. After 10 minutes, the reaction was heated to 50° C., and a stream of argon passed over the reaction to purge the evaporating ether. After an additional 30 minutes, the mixture was diluted with ether, the organic layer washed with NaHCO 3 (sat.) and brine, dried over K 2 CO 3 , and the solvent evaporated. Flash chromatography of the residue (silica, 7-15% EtOAc/CHCl 3 ) gave 13-2 as a yellow oil.
TLC R f =0.53 (silica, 30% EtOAc/CHCl 3 ); 1 H NMR (300 MHz, CDCl 3 ) δ 7.31 (m,5H), 5.05 (d, 1H, J=15 Hz), 3.92 (d, 1H, J=15 Hz), 3.41 (m, 1H), 3.26 (m, 2H), 2.62 (m, 1H), 2.43 (m, 1H), 2.16 (m, 1H), 1.81 (m, 1H).
1-benzyl-5(R)-methyl-pyrrolidin-2-one (13-3)
To a solution of 13-2 (22.1 g, 70 mmol) in 200 mL of hexamethylphosphorous triamide at 0° C. was added NaBH 4 (5.25 g, 140 mmol) in 5 portions over 5 minutes. After 10 minutes, the reaction was allowed to warm to ambient temperature and stirred for 2 h. The mixture was diluted with 1:1 ether/hexanes, quenched by the careful addition of 300 mL 10% KHSO 4 (aq), separated, the organics dried over K 2 CO 3 , and the solvent evaporated to give 13-2 as a yellow oil
TLC R f =0.45 (silica, 30% EtOAc/CHCl 3 ); 1 H NMR (300 MHz, CDCl 3 ) δ 7.32 (m, 5H), 4.95 (d, 1H, J=15 Hz), 4.00 (d, 1H, J=15 Hz), 3.52 (m, 1H), 2.46 (m, 2H), 2.15 (m, 1H), 1.60 (m, 1H), 1.16 (d, 3H, J=6.0 Hz)).
3(R)-azido-1-benzyl-5(R)-methyl-pyrrolidin-2-one (13-4)
To a solution of 13-3 (2.2 g, 11.6 mmol) in THF (45 mL) at -78° C. was added a solution of LDA (6.39 mL, 12.8 mmol; 2M/THF, ethylbenzene). The mixture was warmed to -15° C. for 20 minutes, then recooled to -78° C., and 2,4,6-triisopropylbenzenesulfonyl azide (4.31 g, 13.9 mmol, prepared as described in Harmon, et al, J. Org. Chem. 1973, 38, 11-16. ) was added rapidly as a solution in 40 mL THF at -78° C. After 10 minutes, glacial acetic acid (2.67 mL, 47 mmol) was added, and the resultant viscous liquid mixture allowed to warm to ambient temperature and stir for 1 hour. The solvent was then evaporated, the residue dissolved in CHCl 3 , washed with NaHCO 3 (sat.), and dried over magnesium sulfate. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 25% ethyl acetate/hexanes) to give 13-4 as a colorless oil.
TLC Rf=0.38 (25% ethyl acetate/hexanes). 1 H NMR (300 MHz, CHCl 3 ) δ 7.32 (m, 5H), 5.00 (d, 1H, J=15 Hz), 4.27 (t, 1H, J=7.5 Hz), 3.98 (d, 1H, J=15 Hz), 3.54 (m, 1H), 1.97 (m, 2H), 1.16 (d, 3H, J=6.0 Hz).
3(S)-azido-1-benzyl-5(R)-methyl-pyrrolidin-2-one
To a solution of 13-4 (2.17 g, 9.42 mmol) in EtOH (50 mL) was added a solution of NaOEt (3.52 mL, 9.42 mmol; 2.68 M/EtOH). The mixture was stirred for 90 minutes, then quenched by the addition of glacial acetic acid (3 mL). The solvent was then evaporated, the residue slurried in EtOAc, washed with NaHCO 3 (sat.), and dried over K 2 CO 3 . Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 17% ethyl acetate/hexanes) to give 13-5 as a colorless oil and 13-4 as a colorless oil.
TLC Rf=0.44 (25% ethyl acetate/hexanes). 1 H NMR (300 MHz, CHCl 3 ) δ 7.32 (m, 5H), 4.97 (d,1H, J=15 Hz), 4.17 (t, 1H, J=7.5 Hz), 4.05 (d, 1H, J=15 Hz), 3.44 (m, 1H), 2.48 (m, 2H), 1.50 (m, 1H), 1.22 (d, 3H, J=6.6 Hz).
(1-benzyl-5(R)-methyl-2-oxo-pyrrolidin-3(S)-yl)-carbamic acid tert-butyl ester (13-6)
A mixture of 13-5 (2.38 g, 10.3 mmol), 10% Pd/C (1.0 g), TFA (10 mL), THF (80 mL) and methanol (100 mL) was stirred at ambient temperature under a hydrogen atmosphere (1 atm) for 3 hr. The catalyst was removed by filtration through a celite pad and the filtrate concentrated to give the intermediate amine salt as a colorless oil. To a solution of the crude amine salt in THF (50 mL) at 0° C. was added NEt 3 (2.88 mL, 20.7 mmol) and di-tert-butyl dicarbonate (2.59 g, 11.9 mmol). The mixture was allowed to warm to ambient temperature and stir for 4 hours. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 40% ethyl acetate/hexanes) to give 13-6 as a colorless oil.
TLC RF=0.44 (silica, 40% ethyl acetate/hexanes); 1 H NMR (300 MHz, CHCl 3 ) δ 7.31 (m, 5H), 5.17 (br s, 1H), 4.94 (d, 1H, J=15 Hz), 4.20 (m, 1H), 4.07 (d, 1H, J=15 Hz), 3.44 (m, 1H), 2.77 (m, 1H), 1.45 (s, 9H), 1.20 (d, 3H, J=7 Hz).
(5(R)-methyl-2-oxo-pyrrolidin-3(S)-yl)-carbamic acid tert-butyl ester (13-7)
To a blue solution of lithium metal (0.237 g, 34.2 mmol) in NH 3 (1) (200 mL) at -78° C. was added a solution of 13-6 (2.60 g,8.54 mmol) in THF (15 mL). The mixture was stirred for 15 minutes, then quenched by the addition of ammonium chloride until the blue color dispersed. An additional 30 mL of THF was added, and the mixture warmed to 35° C. to evaporate the ammonia. MgSO 4 was added,the mixture was filtered through a celite pad. Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:20:10 chloroform/ethyl acetate/MeOH) to give 13-7 as a colorless oil
TLC Rf=0.45 (70:20:10 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CHCl 3 ) δ 6.97 (br s, 1H), 5.24 (d,1H, J=7.6 Hz), 4.32 (br s, 1H), 3.66 (m, 1H), 2.79 (m, 1H), 1.45 (s, 9H), 1.25 (d, 3H, J=6.0 Hz).
(3(S)-tert-butoxycarbonylamino-5(R)-methyl-2-oxo-pyrrolidin-1-yl)-acetic acid ethyl ester (13-8)
To a solution of 13-7 (1.83 g, 8.4 mmol) in THF (22 mL) at -78° C. was added sodium bis(trimethylsilyl)amide (9.4 mL, 9.4 mmol; 1M/THF) dropwise. After an additional 20 min, ethyl bromoacetate (1.13 mL, 10.3 mmol) was added dropwise. After an additional 20 minutes, the mixture was allowed to warm to 0° C., and 20 mL sat. aqueous NH 4 Cl was added. The layers were separated, the aqueous layer washed with EtOAc, and the combined organic extracts were dried over K 2 CO 3 . Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 40% ethyl acetate/hexanes) to give 13-8 as a colorless oil.
TLC Rf=0.39 (40% ethyl acetate/hexanes). 1 H NMR (300 MHz, CHCl 3 ) δ 5.20 (br s, 1H), 4.38 (d,1H, J=18 Hz), 4.21 (m, 3H), 3.77 (m, 2H), 2.83 (m, 1H), 1.44 (s, 9H), 1.23 (m, 6H).
(3(S)-tert-butoxycarbonylamino-5(R)-methyl-2-oxo-pyrrolidin-1-yl)-acetic acid (13-9)
To a solution 13-8 (527 mg, 1.75 mmol) in EtOH was added 1N NaOH (1.93 mL, 1.925 mmol). After stirring for 1 h, the solvents were evaporated, the mixture was diluted with EtOAc, acidified with 10% KHSO 4 , washed with brine, dried over MgSO 4 , and evaporated to give 13-9 as a white solid.
TLC R f =0.48 (silica, 9.5/0.5/0.5 CH 2 Cl 2 /MeOH/AcOH); 1 H NMR (300 MHz, CD 3 OD) δ 4.21 (m, 2H), 3.85 (d, 1H, J=18 Hz), 3.74 (m, 1H), 2.58 (m, 1H), 1.52 (m, 1H), 1.44 (s, 9H), 1.25 (d, J=6.3 Hz, 3H).
(3(S)-tert-butoxycarbonylamino-5(R)-methyl-2-oxo-pyrrolidin-1-yl)-acetyl-3(S)-ethynyl-β-alanine ethyl ester (13-10)
A mixture of 13-9 (440 mg, 1.62 mmol), 2-9 (290 mg, 1.62 mmol), EDC (373 mg, 1.94 mmol), HOBT (262 mg, 1.94 mmol) and NMM (1.20 mL, 11.34 mmol) in CH 3 CN (5 mL) was stirred for 20 h. The mixture was diluted with EtOAc, washed with sat. NaHCO 3 , brine, and dried over MgSO 4 . Following evaporative removal of the solvent, the residue was chromatographed (silica gel, EtOAc) to give 13-10 as a colorless foam.
TLC Rf=0.20 (silica, EtOAc). 1 H NMR (300 MHz, CDCl 3 ) δ 7.31 (bd, 1H), 5.33 (bd, 1H), 5.21 (m, 1H), 4.16 (m, SH), 3.64 (m, 2H), 2.72 (m, 2H), 2.45 (d, J=2.2 Hz, 1H), 1.52 (m, 1H), 1.46 (s, 9H), 1.27 (m, 6H).
(3(S)-amino-5(R)-methyl-2-oxo-pyrrolidin-1-yl)-acetyl-3(S)-ethynyl-β-alanine ethyl ester hydrochloride (13-11)
To a solution of 13-10 (550 mg, 1.39 mmol) in EtOAc at 0° C. was bubbled HCl gas for 5 minutes. The reaction was stirred an additional 5 minutes, followed by removal of the cooling bath and then purged with Argon for 20 minutes. Evaporative removal of the solvent gave 13-11 as a white solid.
1 H NMR (300 MHz, CD 3 OD) δ 5.02 (m, 1H), 4.12 (m, 4H), 3.83 (m, 2H), 2.77 (m, 2H), 1.59 (m,1H), 1.25 (m, 6H).
5(R)-methyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine ethyl ester (13-12)
To a solution of 13-11 (450 mg, 1.39 mmol) and 5,6,7,8-tetrahydro-[1,8]naphthyridine-2-carbaldehyde (225 mg, 1.39 mmol) in dichloroethane at 0° C. was added Na(OAc) 3 BH. After 1.5 h the reaction was quenched with sat. NaHCO 3 , diluted with EtOAc, washed with sat. NaHCO 3 , brine and dried over MgSO 4 . Following evaporative removal of the solvent, the residue was chromatographed (silica gel, 70:20:10 chloroform/ethyl acetate/MeOH to give 13-12 as a colorless foam.
TLC Rf=0.17 (70:15:15 chloroform/ethyl acetate/MeOH). 1 H NMR (300 MHz, CDCl 3 ) δ 7.09 (d, J=6.8 Hz, 1H), 7.03 (d, J=8.5 Hz, 1H), 6.48 (d, J=7.3 Hz, 1H), 5.05 (m, 1H), 4.83 (bs, 1H), 4.17 (q, J=6.4, 1H), 3.92 (m, 2H), 3.74 (m, 2H), 3.58 (m, 4H), 3.40 (m, 2H), 2.70 (m, 4H), 2.54 (m, 1H), 2.26 (s, 1H), 1.90 (m, 2H), 1.55 (m, 2H), 1.25 (m, 6H).
5(R)-methyl-2-oxo-3(S)-[2-(5,6,7,8-tetrahydro[1,8]-naphthyridin-2-ylmethyl)-amino]pyrrolidin-1-yl)acetyl-3(S)-ethynyl-β-alanine (13-13)
To a solution of 13-12 (108 mg, 0.24 mmol) in EtOH (2 mL) was added 1N NaOH (0.270 ml, 0.264 mmol). After stirring for 1 h, the solvents were evaporated and the residue was chromatographed (silica gel, 25:10:1:1 to 15:10:1:1 ethyl acetate/EtOH/water/NH 4 OH) to give 13-13 as a colorless foam.
TLC Rf=0.23 (12:10:1:1 ethyl acetate/EtOH/water/NH 4 OH). 1 H NMR (300 MHz, D 2 O) δ 7.53 (d, 1H, J=7.3 Hz), 6.69 (d, 1H, J=7.3 Hz), 4.41 (m, 2H), 3.71 (m, 2H), 3.45 (t, J=5.8 Hz, 2H), 2.79 (t, J=5.8 Hz, 2H), 2.6 (m, 4H), 1.92 (m, 3H), 1.50 (m, 1H), 1.19 (m, 3H). ##STR47## 2-Dimethoxymethyl-[1,8]naphthyridine (14-1)
A mixture containing 1-4 (30 g, 0.245 mol), pyruvaldehyde dimethylacetal (87 g, 0.737 mol), and L-proline (7.0 g, 0.062 mol) in MeOH (300 mL) was refluxed under argon for 16 h. The cooled solution was filtered, evaporated and the residue dissolved in CH 2 Cl 2 (500 mL) and washed with water and brine then dried and concentrated to a volumn of ca. 100 mL. Hexane (300 mL) was added and the mixture was kept at 0° C. for 3 h, then filtered affording 14-1 as an off-white crystalline solid.
1 H NMR (300 MHz, CDCl 3 ) δ 9.14 (d, J=2.2 Hz, 1H); 8.26 (d, J=8.7 Hz, 1H); 8.21 (dd, J=8.7, 2.2 Hz, 1H); 7.8 (d, J=8.3 Hz, 1H); 7.5 (m, 1H); 5.48 (s, 1H); 3.53 (s, 6H).
2-Dimethoxymethyl-5,6,7,8-tetrahydro-[1,8]naphthyridine (14-2)
A solution 14-1 (10 g, 0.049 mol) in MeOH, (100 ml) was treated with 10% Pd on C (1.5 g) and the resulting mixture stirred under a H 2 filled balloon for 12.5 h. The catalyst was removed by filtration through celite and the solution concentrated to afford 14-2 as a yellow crystalline solid.
1 H NMR (300 MHz, CDCl 3 ) δ 7.18 (d, J=7.12 Hz, 1H); 6.71 (d, J=7.12 Hz, 1H); 5.18 (s, 1H); 4.96 (br, s, 1H); 3.43 (s, 6H); 3.4 (m, 2H); 2.65 (m, 2H); 1.91 (m, 2H).
5,6,7,8-tetrahydro-[1,8]naphthyridine-2-carboxaldehyde (14-3)
14-2 (10 g, 0.048 mol) was trifluoroacetic acid (50 mL) and the resulting solution stirred under argon for 12.5 h. The TFA was removed at reduced pressure and the residue partitioned between sat. NaHCO 3 and CH 2 Cl 2 . The organic layer was dried, concentrated and passed through a 3 in. pad of silica gel (10% acetone/CH 2 Cl 2 ) and concentrated to afford 14-3 as a yellow crystalline solid.
1 H NMR (300 MHz, CDCl 3 ) δ 9.80 (s, 1H); 7.31 (d, J=7.32 Hz, 1H); 7.16 (d, J=7.32 Hz, 1H); 5.31 (br, s, 1H); 3.48 (m, 2H); 2.81 (m, 2H); 1.94 (m, 2H). ##STR48## 1-Bromo-3-(2,2-diethoxy-ethoxy)-benzene (15-2)
To a suspension of NaH (2.77 g, 115.6 mmol) in DMF (100 mL) at 0° C. was added a solution of 3-bromophenol 15-1 in DMF (40 mL) over 40 min. After the addition was complete, the solution was stirred for an additional 30 min. The solution was then treated with neat bromoacetaldehyde diethyl acetal (17.36 g, 115.6 mmol). The solution was heated at 100° C. for 8 h, cooled to room temperature, and extracted with Et 2 O (3×200 mL). The combined organic extracts were washed with 10% aq NaOH (100 mL) and brine (100 mL), dried over MgSO 4 , filtered and concentrated to give 15-2 as a yellow oil.
TLC Rf=0.4 (10% ethyl acetate/hexanes). 1 H NMR (300 MHz, CHCl 3 ) δ 7.19-7.05 (m, 3H), 6.85 (d, 1H), 4.81 (t, 1H, J=6.8 Hz), 3.99 (d, 2H, J=6.8 Hz), 3.71 (m, 4H), 1.22 (t, 6H, J=7.1 Hz) ppm.
6-Bromo-benzofuran (15-3)
To a solution of the acetal 15-2 in toluene (200 mL) was added polyphosphoric acid (20 g). The biphasic mixture was heated to 100° C. and stirred at this temperature for 4 h. The mixture was cooled to room temperature, poured onto ice, and extracted with Et 2 O (2×200 mL). The combined organic extracts were washed with saturated aq NaHCO 3 and brine. The solution was dried over MgSO 4 , filtered, and concentrated. The residue was purified by flash chromatography (100% hexanes) to give the product 15-3 as a yellow oil.
TLC Rf=0.3 (100% hexanes). 1 H NMR (300 MHz, CHCl 3 ) δ 7.68 (s, 1H), 7.60 (d, 1H, J=2.1 Hz), 7.46 (d, 1H, J=8.4 Hz), 7.36 (dd, 1H, J=8.1, 1.5 Hz), 6.75 (dd, 1H, J=7.1, 0.9 Hz) ppm.
3-Benzofuran-6-yl-acrylic acid ethyl ester (15-4)
A mixture of the 6-bromobenzofuran 15-3 (1.74 g, 8.79 mmol), ethyl acrylate (1.09 g, 10.98 mmol), Pd(OAc) 2 (0.099 g, 0.44 mmol), tri-o-tolylphosphine (0.268 g, 0.880 mmol), and sodium acetate (3.60 g, 43.9 mmol) in DMF (10 mL) was heated to 100° C. in a sealed tube for 4 h. The mixture was cooled to room temperature, diluted with water, and extracted with Et 2 O (2×40 mL). The combined organic extracts were washed with brine (30 mL), dried over MgSO 4 , filtered, and concentrated. The residue was purified by flash chromatography (10% ethyl acetate/hexanes) to give the ester 15-4 as an off-white solid.
TLC Rf=0.3 (10% ethyl acetate/hexanes). 1 H NMR (300 MHz, CHCl 3 ) δ 7.78 (d, 1H, J=15.9 Hz), 7.68 (d, 1H, J=2.4 Hz), 7.66 (s, 1H), 7.59 (d, 1H, J=8.4 Hz), 7.43 (dd, 1H, J=9.0, 1.5 Hz), 6.78 (m, 1H), 6.47 (d, 1H, J=15.9 Hz), 4.27 (q, 2H, J=7.2 Hz), 1.34 (t, 3H, J=7.2 Hz) ppm.
3-(S)-Benzofuran-6-yl-3-[benzyl-(1(R)-phenyl-ethyl)-amino]-propionic acid ethyl ester (15-5)
A solution of benzyl-α-(R)-methylbenzylamine (1.32 g, 6.30 mmol) in THF (25 mL) at 0° C. was treated with n-BuLi (2.52 mL of a 2.5 M soln in hexanes). The resulting solution was stirred at 0° C. for 30 min and then cooled to -78° C. A solution of acrylate 15-4 (0.681 g, 3.15 mmol) in THF (5 mL) was added. After stirring for 15 min at -78° C., satd aq NH 4 Cl soln (5 nmL) was added and the cold bath removed. The mixture was warmed to room temperature, and extracted with Et 2 O (2×40 mL). The combined organic extracts were washed with brine (30 mL), dried over MgSO 4 , filtered, and concentrated. The residue was purified by flash chromatography (10% ethyl acetate/hexanes) to give the β-aminoester 15-5 as a yellow oil.
TLC Rf=0.8 (10% ethanol/dichloromethane). 1 H NMR (300 MHz, CHCl 3 ) δ 7.58 (m, 3H), 7.41 (m, 2H), 7.22 (m, 9H), 7.59 (s, 1H), 4.58 (m, 1H), 4.05 (m, 1H), 3.91 (q, 2H, J=7.1 Hz), 3.72 (m, 2H), 2.62 (m, 2H), 1.21 (d, 3H, J=7.2 Hz), 1.03 (t, 3H, J=7.1 Hz) ppm.
3(S)-Amino-3-(2,3-dihydro-benzofuran-6-yl)-propionic acid ethyl ester (15-6)
A mixture of the dibenzylamine 15-5 (1.19 g, 2.78 mmol) in EtOH/H 2 O/AcOH (26 mL/3 mL/1.0 mL) was degassed with argon and treated with Pd(OH)2 (1.19 g). The mixture was placed under 1 atm of H 2 . After stirring for 18 h, the mixture was diluted with EtOAc, and filtered through celite. The filtrate was concentrated and the residue purified by flash chromatography (10% ethyl acetate/dichloromethane) to give the ester 15-6 as a white solid.
TLC Rf=0.25 (10% ethanol/dichloromethane). 1 H NMR (300 MHz, CD 3 OD) as the trifluoroacetate salt: δ 7.25 (d, 1H, J=8.1 Hz), 6.88 (m, 1H), 7.66 (s, 1H), 6.82 (s, 1H), 4.58 (m, 3H), 4.12 (m, 2H), 3.30 (m, 1H), 3.19 (m, 2H), 2.98 (m, 2H), 1.11 (t, 3H, J=7.2 Hz) ppm.
3(S)-(2,3-Dihydro-benzofuran-6-yl)-3-(2-{2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetylamino)-propionic acid ethyl ester (15-7)
A solution of the amine 15-6 (0.100 g, 0.425 mmol), acid 3-11 (0.155 g, 0.511 mmol), EDC (0.098 g, 0.511 mmol), NMM (0.103 g, 1.02 mmol), and HOAT (0.069 g, 0.511 mmol) in DMF (6 mL) was stirred at room temperature for 48 h. The solution was diluted with satd aq NaHCO 3 (3 mL) and extracted with EtOAc (2×10 mL). The combined organic extracts were washed with brine (10 mL), dried over MgSO 4 , filtered, and concentrated. The residue was purified by flash chromatography (8% ethanol/dichloromethane) to give the ester 15-7 as an yellow oil.
TLC Rf=0.3 (10% ethanol/dichloromethane). 1 H NMR (300 MHz, CHCl 3 ) δ 7.12 (m, 2H), 6.78 (m, 1H), 6.65 (s, 1H), 6.39 (m, 1H), 5.36 (m,1H), 4.99 (br s, 1H), 4.55 (t, J=7.2 Hz, 2H), 4.11 (m, 2H), 3.91 (m, 2H), 3.39 (m, 2H), 3.19 (m, 2H), 2.79 (m, 2H), 2.70 (m, 2H), 2.51 (m, 1H), 2.28 (m, 2H), 1.85 (m, 3H), 1.18 (m, 3H) ppm.
3(S)-(2,3-Dihydro-benzofuran-6-yl)-3-(2-{2-oxo-3(S)-[2-(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-yl)-ethyl]-pyrrolidin-1-yl}-acetylamino)-propionic acid (15-8)
A solution of the ester 15-7 (0.038 g, 0.073 mmol) in EtOH/H 2 O (4.5 mL/0.5 mL) was treated with LiOH (0.009 g, 0.365 mmol) and the homogeneous solution stirred at room temperature for 4 h. The solution was concentrated to a solid residue which was dissolved in H 2 O and purified by preparative HPLC (gradient conditions: 95:05 to 50:50 H 2 O/MeCN with 0.1% TFA) to give the acid 15-8 as a white solid (as the bis-trifluoroacetate salt).
MS (LR, FAB) M+1 calcd 493, found 493.39. 1 H NMR (300 MHz, CHCl 3 ) δ 7.91 (m, 1H), 7.35 (m, 1H), 7.09 (m, 1H), 6.76 (m, 1H), 6.68 (s, 1H), 6.43 (m, 2H), 5.28 (m, 1H), 4.53 (m, 2H), 4.41 (m, 1H), 3.38 (m, 7H), 3.14 (m, 3H), 2.81 (m, 5H), 2.60 (m, 1H), 2.28 (m, 1H), 2.05 (m, 3H) ppm. ##STR49## 3-Benzyloxycarbonylamino-6-methyl-2-pyridinone (16-2). ##STR50## DPPA (35.6 ml, 165 mmol) was added to a stirred solution of 2-hydroxy-6-methylpyridine-3-carboxylic acid (16-1; Aldrich; 22.97 g, 165 mmol) and triethylamine (23.0 ml, 165 mmol) in dry dioxane (300 ml) and the resulting solution was-heated to reflux. After 16 h more triethylamine (23.0 ml, 165 mmol) and benzyl alcohol (17.1 ml, 165 mmol) were added and the solution was refluxed for a further 24 h. The reaction was concentrated in vacuo to remove most of the volatiles. The residue was partitioned between methylene chloride (500 ml) and brine (500 ml), acidified to pH 1 with 1 M HCl (165 ml). The aqueous layer was extracted methylene chloride (two times) and the combined organic layers were washed with sodium hydrogen carbonate solution and brine, dried (Na 2 SO 4 ) and evaporated in vacuo to a brown solid. This was recrystallized from methanol, to give the title compound 16-2 as a tan solid: 1 H NMR (300 MHz, CDCl 3 ) δ 2.29 (s, 3H, CH 3 ), 5.20 (s, 2H, PhCH 2 ), 6.06 (d, J=7.6 Hz, pyridinone-5-H), 7.32-7.43 (m, 5H, Ph), 7.67 (br s, 1H, CbzNH), 8.03 (br d, pyridinone-4-H).
2-[6-methyl-2-oxo-3-(benzyloxycarbonylamino)-2H-pyridin-1-yl]acetic acid t-butyl ester (16-3). ##STR51## Sodium hydride (5.3 g, 0.22 mol) was added to a stirred slurry of 3-benzyloxycarbonylamino-6-methyl-2-pyridinone (16-2; 53.2 g, 0.20 mol) in THF at 0° C. t-Butylbromoacetate (45 ml, 0.27 mol) was added to the resulting solution and a precipitate rapidly forms. The reaction was warmed to rt over 1 h and after 2 h the solvent was evaporated in vacuo and the residue was partitioned between 1:1 water/brine (200 ml) and 6:1 THF/methylene chloride (700 ml). The organic layer was dried (Na 2 SO 4 ) and evaporated in vacuo to a solid which was triturated with hexane to give the title compound 16-3 as a crystalline solid:
1 H NMR (400 Mz, CDCl 3 ) δ 1.47 (s, 9H), 2.25 (s, 3H), 4.75 (s, 2 H), 5.19 (s, 2H), 6.09 (d, J=7.8 Hz), 7.30-7.40 (m, 5H), 7.75 (br s, 1H), 7.94 (br d, 1H).
2-[6-methyl-2-oxo-3-(benzyloxycarbonylamino)-2H-pyridin-1-yl]acetic acid (16-4). ##STR52## HCl gas was bubbled through a stirred suspension of 2-[6-methyl-2-oxo-3-(benzyloxycarbonylamino)-2H-pyridin-1-yl]acetic acid t-butyl ester (16-3; 12.3 g, 33 mmol) in ethyl acetate (250 ml) at -15° C. for 20 min. The resulting solution was allowed to warm to room temperature and was then stirred there for 3 h. After purging with argon, the bulk of the solvent was rotavapped off and ether added to the residue. The solid which precipitated was filtered off and washed with ether. The title compound 16-4 was thus obtained as a white fluffy powder: 1 H NMR (CD 3 OD) δ 2.32 (s, 3 H), 4.86 (s, 2 H), 5.18 (s, 2 H), 6.24 (d, J=7.9 Hz, 1 H), 7.31-7.41 (m, 6 H), 7.94 (br s, 1 H).
3-(2-{6-methyl-2-oxo-3-(benzyloxycarbonylamino)-2H-pyridin-1-yl}-acetylamino)-3(S)-pyridin-3-yl-propionic acid ethyl ester (16-5). ##STR53## To a solution of the acid 2-4 (150 mg, 0.47 mmol) and the amine 1-9 (Rico et al; J. Org. Chem., 1993, 58, 7948; 139 mg, 0.52 mmol) in DMF (3 mL) was added HOBT (77 mg, 0.57 mmol) then Et 3 N (200 μL, 1.42 mmol). After 15 minutes, EDC (136 mg, 0.71 mmol) was added and the mixture was stirred for 16 hours. The solution was poured into EtOAc, washed with saturated NaHCO 3 then brine, dried (MgSO 4 ), and evaporated to give the title compound 16-5 as a white solid which was used as such in the next step. 1 H NMR (CDCl 3 ) δ 1.14 (3H, t), 2.40 (3H, s), 2.8-2.9 (2H, m), 4.05 (2H, q), 4.78 (2H, m), 5.22 (2H, s), 5.4 (1H, q), 6.17 (1H, d), 7.22 (1H, m), 7.3-7.45 (4H, m), 7.59 (1H, m), 7.7-7.8 (2H, m), 8.0 (1H, m), 8.52 (2H, m).
3-(2-{6-methyl-2-oxo-3-amino-2H-pyridin-1-yl}-acetylamino)-3(S)-pyridin-3-yl-propionic acid ethyl ester (16-6). ##STR54## To a degassed solution of the pyridone 16-5 (243 mg; 0.49 mmol) in EtOH (20 mL) was added 10% Pd on carbon (25 mg) and this was then stirred under an atmosphere of hydrogen gas (balloon) for 3 hours. The mixture was filtered through a pad of celite and the solvent removed to give the title compound (16-6) as a viscous oil which was used as such in the next step.
3-(2-{6-methyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-2H-pyridin-1-yl}-acetylamino)-3(S)-pyridin-3-yl-propionic acid ethyl ester (16-7). ##STR55## To a solution of the amine 16-6 (155 mg, 0.433 mmol), the aldehyde 14-3 (70 mg, 0.433 mmol) in CH 2 ClCH 2 Cl was added crushed 4A seives, AcOH (20 μL) and then NaB(OAc) 3 H (184 mg, 0.866 mmol). After stirring for 48 hours, the mixture was filtered through celite, poured into EtOAc and washed with saturated NaHCO 3 then brine. The dried (MgSO 4 ) solution was concentrated in vacuo to give a foam type solid. Column chromatography (5%MeOH in CHCl 3 ) afforded the title compound 16-7 as a foam type solid.
Analysis calculated for C 27 H 32 N 6 O 4 .0.25CHCl 3 C, 61.24; H, 6.08; N, 15.73 found C, 61.33; H, 6.09; N, 15.85. FAB mass spectrum. m/z=505.34 (M+H)
3-(2-{6-methyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-2H-pyridin-1-yl}-acetylamino)-3(S)-pyridin-3-yl-propionic acid bis trifluoroacetate (16-8). ##STR56## The ester 16-7 (120 mg, 0.238 mmol) was dissloved in H 2 O (1 mL) and THF (1 mL) and then 1N LiOH (1 mL, 1 mmol) was added. After 2 hours, the mixture was purified by reverse phase HPLC (Waters PrepPak C18 column eluting with H 2 O/acetonitrile gradient) to give, after lyophilization, the title compound 16-8 as a powder.
Analysis calculated for C 25 H 28 N 6 O 4 .2.5TFA.0.55H 2 O C, 46.70; H, 4.13; N, 10.89 found C, 46.70; H, 4.14; N, 11.04. FAB mass spectrum. m/z=477.2 (M+H) ##STR57## β-N,N-Dimethylaminoethenylcyclopropyl ketone (17-2). ##STR58##
A mixture of cyclopropyl methyl ketone (5.88 ml, 59 mmol) and N,N-dimethylformaldehyde dimethyl acetal (7.83 ml, 59 mmol) was heated in the presence of a catalytic quantity of p-toluenesuffonic acid for 48 hours. The resulting crude sample of the title compound (17-2, a pale yellow oil) was used in subsequent reactions without further purification: 1 H NMR (CDCl 3 ) δ 0.74 (m, 2 H), 1.00 (m, 2 H), 1.75 (m, 1 H), 3.48 (s, 3 H), 3.50 (s, 3 H), 5.20 (d, 1 H), 7.55 (d, 1 H).
6-Cyclopropyl-3-nitro-2-(1H)-pyridinone (17-3). ##STR59##
A mixture of crude β-N,N-dimethylaminoethenylcyclopropyl ketone (17-2; 12 g, <86 mmol), nitroacetamide (9 g, 86 mmol) and aqueous piperidinium acetate (10 ml) [prepared from glacial acetic acid (42 ml), water (100 ml) and piperidine (72 ml)] was stirred at room temperature overnight. Following dilution with water (20 ml), the yellow precipitate was isolated via filtration and drying in vacuo to yield the title compound 17-3: 1 H NMR (CDCl 3 ) δ 1.15 (m, 2 H), 1.36 (m, 2 H), 2.10 (m, 1 H), 6.02 (br d, J=8.0 Hz, 1 H), 8.41 (d, J=8.0 Hz, 1 H).
3-Nitro-6-cyclopropyl-1-(t-butyl-carboxymethylene)-2-pyridinone (17-4) ##STR60##
Solid 6-cyclopropyl-3-nitro-2-(1H)-pyridinone (17-3; 1.4 g, 7.78 mmol) was added in small portions to a suspension of sodium hydride (260 mg, 10.8 mmol) in THF (30 ml) at room temperature. After stirring the resulting solution for 20 min, tert-butylbromoacetate (4 ml, 27 mmol) was added. The mixture was stirred for an additional 30 min. then heated at 55° C. for 15 hrs. After cooling to room temperature the THF was evaporated in vacuo and ice carefully added to tile residue to destroy any excess sodium hydride. The resulting miture was extracted with 2:1:1 ethyl acetate:ether:chloroform and the extracts dried over magnesium sulfate. Filtration and evaporation of the filtrate gave a yellow oil as a 3:1 mixture of N and O-alkylated products respectively. Flash column chromatography eluting with 1:1 hexane/ethyl acetate gave the title compound 17-4 as a yellow crystalline solid: 1 H NMR (CDCl 3 ) δ 0.94 (m, 2 H), 1.18 (m, 2 H), 1.49 (s, 9 H), 1.79 (m, 1 H), 5.04 (s, 2 H), 6.10 (d, J=8.1 Hz, 1 H), 8.33 (d; J=8.1 Hz, 1 H).
3-Amino-6-cyclopropyl-1-(t-butyl-carboxymethylene)-2-pyridinone (17-5) ##STR61##
A mixture of 3-nitro-6-cyclopropyl-1-(t-butyl-methylenecarboxy)-2-pyridinone (17-4; 760 mg, 2.58 mmol) and platinum oxide (250 mg) in ethanol (30 ml) was stirred at 0° C. under an atmosphere of hydrogen for 3 hours. Following removal of most of the catalyst by filtration through a bed of Celite, the filtrate was concentrated and the residue purified by flash column chromatography eluting with 2:1 hexane/ethyl acetate. This yielded the title product 17-5 as a viscous orange gum: 1 H NMR (CDCl 3 ) δ 0.67 (m, 2 H), 0.89 (m, 2 H), 1.49 (s, 9 H), 1.63 (m, 1 H), 4.07 (br s, 2 H), 4.99 (s, 2 H), 5.91 (dd, J=1.2 and 7.4 Hz, 1 H), 6.47 (d, J=7.4 Hz, 1 H).
{6-Cyclopropyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-2H-pyridin-1-yl}-acetic acid tert-butyl ester (17-6) ##STR62## Following the procedure described for the synthesis of 16-7, the amine 17-5 was coupled with 14-3 to yield the title compound 17-6 as an oil. R f (silica gel; 5% MeOH in CHCl 3 )=0.39
{6-Cyclopropyl-2-oxo-3-[(5,6,7 ,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-2H-pyridin-1-yl}-acetic acid (17-7). ##STR63## Following the procedure described for the preparation of 16-8, the ester 17-6 was hydrolysed to give the title compound 17-7. 1 H NMR (CD 3 OD) δ 0.66 (m, 2 H), 0.9 (m, 2 H), 1.78 (m, 1 H), 1.9 (m, 2H), 2.75 (m, 2H), 3.4 (m, 2H), 4.6 (br s, 2 H), 6.02 (d, 1H), 6.19 (d, 1H), 6.58 (m, 1 H), 7.27 (m, 1H).
Ethyl 3-amino-3(S)-(3-fluorophenyl)propionate hydrochloride (17-8) ##STR64## The title compound was prepared starting from 3-fluorobenzaldehyde (Aldrich) by conversion to ethyl 3-fluorocinnamate and employing the asymmetric addition/hydrogenolysis methodology described by Rico et al; J. Org. Chem., 1993, 58, 7948.
1 H NMR (CD 3 OD) δ 1.21 (t, 3H), 3.03 (dd, 1H), 3.13 (dd, 1H), 4.15 (q, 2H), 4.77 (t, 1H), 7.19 (m, 1H), 7.3 (m, 2H), 7.5 (m, 1H).
3-(2-{6-Cyclopropyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]2H-pyridin-1-yl}-acetylamino)-3(S)-(3-fluorophenyl)propionic acid ethyl ester (17-9) ##STR65## Following the procedure described for the preparation of 16-5, the acid 17-7 was coupled with the amine 17-8 to yield the title compound 17-9.
Analysis calculated for C 30 H 34 N 5 O 4 F 1 .0.25H 2 O C, 65.26; H, 6.30; N, 12.69 found C, 65.20; H, 6.04; N, 13.00. FAB mass spectrum. m/z=548.12 (M+H)
3-(2-{6-Cyclopropyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]2H-pyridin-1-yl}-acetylamino)-3(S)-(3-fluorophenyl)propionic acid ditrifluoroacetate (17-10) ##STR66## Following the procedure described for the preparation of 16-8, the ester 17-9 was hydrolysed to give the title compound 17-10.
Analysis calculated for C 28 H 30 N 5 O 4 F 1 .2.15TFA.0.5H 2 O C, 55.16; H, 4.91; N, 10.62 found C, 55.19; H, 4.91; N, 10.89. FAB mass spectrum. m/z=520.05 (M+H)
3-(2-{6-Cyclopropyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]2H-pyridin-1-yl}-acetylamino)-3(S)-(3-pyridyl)-propionic acid ditrifluoroacetate (17-11). ##STR67## Following the procedures described for Scheme 16, the acid 17-7 was coupled with the amine 1-9 followed by saponification of the ester to afford the title compound 17-11.
Analysis calculated for C 27 H 30 N 6 O 4 .2.5TFA.0.6H 2 O C, 48.13; H, 4.25; N, 10.53 found C, 48.11; H, 4.23; N, 10.64. FAB mass spectrum. m/z=503.25 (M+H)
3-(2-{6-Cyclopropyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-2H-pyridin-1-yl}-acetylamino)-3(S)-(ethynyl)-propionic acid ethyl ester (17-12) ##STR68## Following the procedures described for Scheme 16, the acid 17-7 was coupled with 3-amino-3(S)-(ethynl)-propionic acid ethyl ester 2-9 (Zablokie et al, J. Med. Chem., 1995, 38, 2378) to afford the title compound 17-12.
Analysis calculated for C 26 H 31 N 5 O 4 .0.35H 2 O C, 64.53; H, 6.60; N, 14.47 found C, 64.52; H, 6.71; N, 14.54. FAB mass spectrum. m/z=478.35 (M+H)
3-(2-{6-Cyclopropyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]2H-pyridin-1-yl}-acetylamino)-3(S)-(ethynl)-propionic acid (17-13) ##STR69## Following the procedure described for the preparation of 16-8, the ester 17-12 was hydrolysed to give the title compound 17-13. FAB mass spectrum. m/z=450.23 (M+H) ##STR70## Benzyl-N-(1-cyanoethyl)glycine hydrochloride (18-2) ##STR71## TMSCN (18.8 mL, 141 mmol) was added cautiously to a stirred solution of benzylglycine free base (23.3 g 141 mmol--from the HCl salt by partition between EtOAc and brine basified with saturated Na 2 CO 3 solution) and acetaldehyde (7.88 mL, 141 mmol) in CH 2 Cl 2 (50 mL). After 4 h the volatiles were removed in vacuo and the residue was taken up in EtOAc and washed with brine, dried (Na 2 SO 4 ) and evaporated in vacuo to an oil. The oil was redissolved in EtOAc and 9.9 M HCl in EtOH (15.25 mL, 151 mmol) was added to give a crystalline precipitate which was isolated by filtration, washing with EtOAc and Et 2 O to give the title compound (18-2):
1 H NMR (CD 3 OD) δ 1.70 (d, 3H), 4.16 (d, 1H), 4.21 (d, 1H), 4.64 (q, 1H), 5.31 (s, 2H), 7.35-7.44 (m, 5H).
1-Benzyloxycarbonylmethyl-3,5-dichloro-6-methylpyrazinone (18-3) ##STR72## A stirred mixture of oxalyl chloride (40.4 mL, 463 mmol) and 18-2 (29.51 g, 116 mmol) in 1,2-dichlorobenzene (110 mL) was heated to 100° C. for 15 h. The volatiles were removed in vacuo and the residue was purified by chromatography (silica gel; hexanes followed by 30% EtOAc in hexanes) to give a solid which was heated in EtOAC/hexanes 2:5 (140 mL), cooled and collected by filtration to give the title compound 18-3 as a pale green solid:
1 H NMR (CDC1 3 ) δ 2.35 (s, 3H), 4.88 (s, 2H), 5.24 (s, 2H), 7.38 (m, 5H).
3-(4-Methoxybenzylamino)-5-chloro-6-methyl-1-benzyloxycarbonylmethyl -pyrazinone (18-4) ##STR73## A solution of the pyrazinone 18-3 (5 g, 15.3 mmol) and 4 methoxybenzylamine (6.0 mL, 45.9 mmol) in EtOAc (60 mL) was heated at 80° C. for 2 h. The solution was cooled and filtered. The filtrate was concentrated in vacuo, the residue swished with MeOH and filtered to afford the title compound as a solid:
1 H NMR (CDCl 3 ) δ 2.23 (s, 3H), 3.82 (s, 3H), 4.5 (d, 2H), 4.81 (s, 2H), 5.22 (s, 2H), 6.25 (t, 1H), 6.85 (m, 2H), 7.27 (m, 2H), 7.38 (m, 5H).
3-(4-Methoxybenzylamino)-5-chloro-6-methyl-1-carboxymethyl pyrazinone (18-5) ##STR74## A solution of the benzyl ester 18-4 (1.06 g, 2.48 mmol) in toluene (60 mL) was degassed with argon and then 150 mg 10% palladium on carbon was added. The mixture was stirred under an atmosphere of hydrogen gas for 16 h. The solution was filtered through celite and the solvent evaporated to give the title compound 18-5 as a white solid:
1 H NMR (CD 3 OD) δ 2.25 (s, 3H), 3.78 (s, 3H), 4.45 (s, 2H), 4.81 (s, 2H), 4.90 (s, 2H), 6.85 (d, 2H), 7.28 (d, 2H).
3-(4-Methoxybenzylamino)-6-methyl-1-carboxymethyl pyrazinone (18-6) ##STR75## The acid 18-5 (810 mg) was dissolved in 40 mL 1 N NaOH and 40 mL MeOH at room temperature and was treated with Raney nickel suspension (˜5 g). A second charge of Raney nickel (˜5 g) and 1 N NaOH (20 mL) was added after 3 h. After 6 h, the suspension was filtered through celite washing with water and MeOH. The volatiles were removed in vacuo and the residue then taken up 1 N HCl (˜5 mL). Saturated NaHCO 3 solution was added until pH˜7-8 and the solution was extracted exhaustively with EtOAc/THF. After drying (MgSO 4 ), the solvent was removed to give the title compound 18-6 as a solid which was used as such:
1 H NMR (CD 3 OD) δ 2.16 (s, 3H), 3.76 (s, 3H), 4.46 (s, 2H), 4.64 (s, 2H), 4.86 (s, 2H), 6.65 (s, 1H), 6.85 (d, 2H), 7.25 (d, 2H).
3-Amino-6-methyl-1-carboxymethylpyrazinone (18-7) ##STR76## The pyrazinone 18-6 (900 mg) was heated at reflux in trifluoroacetic acid (20 mL) for 7 h. The volatiles were removed in vacuo and the residue was azeotroped with CH 2 Cl 2 , then EtOAc then MeOH. MeOH was added to the residue and the solution filtered to remove impurities. Removal of the methanol then afforded the title compound 18-7 which was used as such:
1 H NMR (CD 3 OD) δ 2.22 (s, 3H), 4.82 (s, 2H), 6.58 (s, 1H).
3-(3-Fluorophenyl)-3-(2-{6-methyl-2-oxo-3-amino]2H-pyrazin-1-yl}-acetylamino)propionic acid ethyl ester (18-8) ##STR77## Following the procedure described for the preparation of 16-6, the acid 18-7 was coupled with the amine 17-8 to yield the title compound 18-8.
1 H NMR (CDCl 3 ) δ 1.15 (t, 3H), 2.23 (s, 3H), 2.78 (dd, 1H), 2.84 (dd, 1H), 4.05 (q, 2H), 4.68 (ABq, 2H), 5.30 (br s, 2H), 5.35 (m, 1H), 6.68 (s, 1H), 6.9-7.1 (m, 3H), 7.27 (m, 1H), 7.57 (d, 2H).
3-(3-Fluorophenyl)-3-(2-{6-methyl-2-oxo-3-[(5,6,7,8-tetrahydro-[1,8]naphthyridin-2-ylmethyl)-amino]-2H-pyrazin-1-yl}-acetylamino)propionic acid ditrifluoroacetate (18-9) ##STR78## Following the procedure described for the synthesis of 16-9, the amine 18-8 was coupled with 14-3 and the product hydrolyzed to yield the title compound 18-9.
Analysis calculated for C 25 H 27 N 6 O 4 F.2.25TFA.0.85H 2 O C, 46.23; H, 4.07; N, 10.97 found C, 46.22; H, 4.00; N, 11.12. FAB mass spectrum. m/z=495.26 (M+H) ##STR79##
The test procedures employed to measure ανβ3 binding and the bone resorption inhibiting activity of the compounds of the present invention are described below.
Bone Resorption-Pit Assay
When osteoclasts engage in bone resorption, they will literally cause the formation of pits in the surface of bone that they are acting upon. Therefore, when testing compounds for their ability to inhibit osteoclasts, it is useful to measure the ability of osteoclasts to excavate these resorption pits when the inhibiting compound is present.
Consecutive 200 micron thick cross sections from a six mm cylinder of bovine femur diaphysis were cut with a low speed diamond saw (Isomet, Beuler, Ltd., Lake Bluff, Ill.). Bone slices were pooled, placed in a 10% ethanol solution and refrigerated until further use.
Prior to experimentation, bone slices were ultrasonicated twice, 20 minutes each in H 2 O. Cleaned slices were placed in 96 well plates such that two control lanes and one lane for each drug dosage are available. Each lane represents either triplicate or quadruplicate cultures. The bone slices in 96 well plates were sterilized by UV irradiation. Prior to incubation with osteoclasts, the bone slices were hydrated by the addition of 0.1 ml Medium 199, pH 6.9 containing 15% fetal bovine serum and 1% penicillin/streptomycin.
Osteoclasts were isolated from the long bones of 1 to 3 day old rat pups (Sprague-Dawley) by modifications of Chambers et al., (J. Cell. Science, 66:383-399). The resulting suspension (0.75 ml/bone) was gently triturated 90-120 times using a wide bore transfer pipet. The cellular population was separated from bone fragments by a cell strainer with a 100 micron nylon mesh. 100 μl of the cell suspension was placed onto each bone slice. Test compounds were then added at the desired experimental concentrations.
Bone slices exposed to osteoclasts for 20-24 hrs were processed for staining. Tissue culture media was removed from each bone slice. Each well was washed with 200 μl of H 2 O, and the bone slices were then fixed for 20 minutes in 2.5% glutaraldehyde, 0.1 M cacodylate, pH 7.4. After fixation, any remaining cellular debris was removed by 2 min. ultrasonication in the presence of 0.25 M NH 4 OH followed by 2×15 min ultrasonication in H 2 O. The bone slices were immediately stained for 6-8 min with filtered 1% toluidine blue and 1% borax.
After the bone slices have dried, resorption pits were counted in test and control slices. Resorption pits were viewed in a Microphot Fx (Nikon) fluorescence microscope using a polarizing Nikon IGS filter cube. Test dosage results were compared with controls and resulting IC 50 values were determined for each compound tested.
The appropriateness of extrapolating data from this assay to utility and use in mammalian (including human) disease states is supported by the teaching found in Sato, M., et al., Journal of Bone and Mineral Research, Vol. 5, No. 1, 1990. That article teaches that certain bisphosphonates have been used clinically and appear to be effective in the treatment of Paget's disease, hypercalcemia of malignancy, osteolytic lesions produced by bone metastases, and bone loss due to immobilization or sex hormone deficiency. These same bisphosphonates are then tested in the resorption pit assay described above to confirm a correlation between their known utility and positive performance in the assay.
EIB Assay
Duong et al., J. Bone Miner. Res., 8:S 378, describe a system for expressing the human integrin αvβ3. It has been suggested that the integrin stimulates attachment of osteoclasts to bone matrix, since antibodies against the integrin, or RGD-containing molecules, such as echistatin (European Publication 382 451), can effectively block bone resorption.
Reaction Mixture:
1. 175 μl TBS buffer (50 mM Tris·HCl pH 7.2, 150 mM NaCl, 1% BSA, 1 mM CaCl 2 , 1 mM MgCl 2 ).
2. 25 μl cell extract (dilute with 100 mM octylglucoside buffer to give 2000 cpm/25 μl).
3. 125 I-echistatin (25 μl/50,000 cpm) (see EP 382 451).
4. 25 μl buffer (total binding) or unlabeled echistatin (non-specific binding).
The reaction mixture was then incubated for 1 h at room temp. The unbound and the bound αvβ3 were separated by filtration using a Skatron Cell Harvester. The filters (prewet in 1.5% poly-ethyleneimine for 10 mins) were then washed with the wash buffer (50 mM Tris HCl, 1 mM CaCl 2 /MgCl 2 , pH 7.2). The filter was then counted in a gamma counter.
SPA Assay
Materials:
1. Wheatgerm agglutinin Scintillation Proximity Beads (SPA): Amersham
2. Octylglucopyranoside: Calbiochem
3. HEPES: Calbiochem
4. NaCl: Fisher
5. CaCl 2 : Fisher
6. MgCl 2 : SIGMA
7. Phenylmethylsulfonylfluoride (PMSF): SIGMA
8. Optiplate: PACKARD
9. Compound 8-10 (specific activity 500-1000 Ci/mmole)
10. test compound
11. Purified integrin receptor: α.sub.ν β3 was purified from 293 cells overexpressing α.sub.ν β3 (Duong et al., J. Bone Min. Res., 8:S378, 1993) according to Pytela (Methods in Enzymology, 144:475, 1987)
12. Binding buffer: 50 mM HEPES, pH 7.8, 100 mM NaCl, 1 mM Ca 2+ /Mg 2+ , 0.5 mM PMSF
13. 50 mM octylglucoside in binding buffer: 50-OG buffer
Procedure
1. Pretreatment of SPA beads:
500 mg of lyophilized SPA beads were first washed four times with 200 ml of 50-OG buffer and once with 100 ml of binding buffer, and then resuspended in 12.5 ml of binding buffer.
2. Preparation of SPA beads and receptor mixture
In each assay tube, 2.5 μl (40 mg/ml) of pretreated beads were suspended in 97.5 μl of binding buffer and 20 μl of 50-OG buffer. 5 μl (˜30 ng/μl) of purified receptor was added to the beads in suspension with stirring at room temperature for 30 minutes. The mixture was then centrifuged at 2,500 rpm in a Beckman GPR Benchtop centrifuge for 10 minutes at 4° C. The pellets were then resuspended in 50 μl of binding buffer and 25 μl of 50-OG buffer.
3. Reaction
The following were sequentially added into Optiplate in corresponding wells:
(i) Receptor/beads mixture (75 μl)
(ii) 25 μl of each of the following: compound to be tested, binding buffer for total binding or 8-8 for non-specific binding (final concentration 1 μM)
(iii) 8-10 in binding buffer (25 μl, final concentration 40 μM)
(iv) Binding buffer (125 μl)
(v) Each plate was sealed with plate sealer from PACKARD and incubated overnight with rocking at 4° C.
4. Plates were counted using PACKARD TOPCOUNT
5. % inhibition was calculated as follows:
A=total counts
B=nonspecific counts
C=sample counts
% inhibition=[{(A-B)-(C-B)}/(A-B)]/(A-B)×100
Ocform Assay
Osteoblast-like cells (1.8 cells), originally derived from mouse calvaria, were plated in CORNING 24 well tissue culture plates in α MEM medium containing ribo- and deoxyribonucleosides, 10% fetal bovine serum and penicillin-streptomycin. Cells were seeded at 40,000/well in the morning. In the afternoon, bone marrow cells were prepared from six week old male Balb/C mice as follows:
Mice were sacrificed, tibiae removed and placed in the above medium. The ends were cut off and the marrow was flushed out of the cavity into a tube with a 1 mL syringe with a 27.5 gauge needle. The marrow was suspended by pipetting up and down. The suspension was passed through >100 μm nylon cell strainer. The resulting suspension was centrifuged at 350×g for seven minutes. The pellet was resuspended, and a sample was diluted in 2% acetic acid to lyse the red cells. The remaining cells were counted in a hemacytometer. The cells were pelleted and resuspended at 1×10 6 cells/mL. 50 μL was added to each well of 1.8 cells to yield 50,000 cells/well and 1,25-dihydroxy-vitamin D 3 (D 3 ) was added to each well to a final concentration of 10 nM. The cultures were incubated at 37° C. in a humidified, 5% CO 2 atmosphere. After 48 h, the medium was changed. 72 h after the addition of bone marrow, test compounds were added with fresh medium containing D 3 to quadruplicate wells. Compounds were added again after 48 h with fresh medium containing D 3 . After an additional 48 h the medium was removed, cells were fixed with 10% formaldehyde in phosphate buffered saline for 10 minutes at room temperature, followed by a 1-2 minute treatment with ethanol:acetone (1:1) and air dried. The cells were then stained for tartrate resistant acid phosphatase as follows:
The cells were stained for 10-15 minutes at room temperature with 50 mM acetate buffer, pH 5.0 containing 30 mM sodium tartrate, 0.3 mg/mL Fast Red Violet LB Salt and 0.1 mg/mL Naphthol AS-MX phosphate. After staining, the plates were washed extensively with deionized water and air dried. The number of multinucleated, positive staining cells were counted in each well.
αvβ5 Attachment Assay
Duong et al., J. Bone Miner. Res., 11:S 290, describe a system for expressing the human αvμ5.
Materials:
1. Media and solutions used in this assay are purchased from BRL/Gibco, except BSA and the chemicals are from Sigma.
2. Attachment medium: HBSS with 1 mg/ml heat-inactivated fatty acid free BSA and 2 mM CaCl 2 .
3. Glucosaminidase substrate solution: 3.75 mM p-nitrophenyl-N-acetyl-beta-D-glucosaminide, 0.1 M sodium citrate, 0.25% Triton, pH 5.0.
4. Glycine-EDTA developing solution: 50 mM glycine, 5 mM EDTA, pH 10.5.
Methods:
1. Plates (96 well, Nunc Maxi Sorp) were coated overnight at 4° C. with human vitronectin (3 ug/ml) in 50 mM carbonate buffer (pH 9/.6), using 100 μl/well. Plates were then washed 2× with DPBS and blocked with 2% BSA in DPBS for 2h at room temperature. After additional washes (2×) with DPBS, plates were used for cell attachment assay.
2. 293 (alpha v beta 5) cells were grown in MEM media in presence of 10% fetal calf serum to 90% confluence. Cells were then lifted from dishes with 1× Trypsin/EDTA and washed 3× with serum free MEM. Cells were resuspended in attachment medium (3×10 5 cells/ml).
3. Test compounds were prepared as a series of dilutions at 2× concentrations and added as 50 μl/well. Cell suspension was then added as 50 ml/well. Plates were incubated at 37° C. with 55 CO 2 for 1 hour to allow attachment.
4. Non-adherent cells were removed by gently washing the plates (3×) with DPBS and then incubated with glucosaminidase substrate solution (100 μl/well), overnight at room temperature in the dark. To quantitate cell numbers, standard curve of glucosaminidase activity was determined for each experiment by adding samples of cell suspension directly to wells containing the enzyme substrate solution.
5. The next day, the reaction was developed by addition of 185 μl/well of gylcine/EDTA solution and reading absorbance at 405 nm using a Molecular Devices V-Max plate reader. Average test absorbance values (4 wells per test samples) were calculated. Then, the number of attached cells at each drug concentration was quantitated versus the standard curve of cells using the Softmax program.
EXAMPLE OF A PHARMACEUTICAL FORMULATION
As a specific embodiment of an oral composition, 100 mg of compound 3-13 is formulated with sufficient fmely divided lactose to provide a total amount of 580 to 590 mg to fill a size O hard gel capsule.
Representative compounds of the present invention were tested and found to bind to human αvμ3 integrin. These compounds were found to have IC 50 values in the range of 0.1 to 100 nM in the SPA assay.
Representative compounds of the present invention were tested and found to inhibit ≧50% the attachment of αvβ5 expressing cells to plates coated with vitronectin at concentrations of 1 μM.
While the invention has been described and illustrated in reference to certain preferred embodiments thereof, those skilled in the art will appreciate that various changes, modifications and substitutions can be made therein without departing from the spirit and scope of the invention. For example, effective dosages other than the preferred doses as set forth hereinabove may be applicable as a consequence of variations in the responsiveness of the mammal being treated for severity of bone disorders caused by resorption, or for other indications for the compounds of the invention indicated above. Likewise, the specific pharmacological responses observed may vary according to and depending upon the particular active compound selected or whether there are present pharmaceutical carriers, as well as the type of formulation and mode of administration employed, and such expected variations or differences in the results are contemplated in accordance with the objects and practices of the present invention. It is intended, therefore, that the invention be limited only by the scope of the claims which follow and that such claims be interpreted as broadly as is reasonable. | This invention relates to certain novel compounds and derivatives thereof, their synthesis, and their use as vitronectin receptor antagonists. The vitronectin receptor antagonist compounds of the present invention are αvβ3 antagonists, αvβ5 antagonists or dual αvβ3/αvβ5 antagonists useful for inhibiting bone resorption, treating and preventing osteoporosis, and inhibiting restenosis, diabetic retinopathy, macular degeneration, angiogenesis, atherosclerosis, inflammation and tumor growth. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dilators or dilator assemblies for compressing fatty substances deposited in or on the walls and lumen of major arteries.
2. Description of the Prior Art
In our society and in other developed societies, the aging process is accompanied by the deposition of fatty substances in the walls and lumen of the major arteries. The precise causes of this buildup are unknown but are in all likelihood related to diet. The fatty substances are not deposited uniformly throughout the arterial system but, for reasons that are not well understood, are concentrated at various sites within the arteries. These deposits may take the form of hard crystalline masses within the wall of the artery, soft gelatinous masses within the lumen, or various combinations of these conditions. In some instances, these deposits build to such an extent that they severely restrict blood flow to body sites such as the lower extremeties, the brain and the heart.
In cases wherein the deposits have restricted blood flow to such an extent that the individual develops clinical symptoms which indicate that the normal course of life is threatened, the sections of artery which are obstructed by the deposits are removed and replaced with artificial arterial segments or the sections are bypassed using vein segments taken from another site in the body. In either case, the procedure requires a traumatic invasion of the individual's body which is both costly and of high risk.
It has recently been shown by Grunzig that an inelastic sack inserted into the blocked artery can, when properly positioned, be inflated and compress the deposit in the artery. Upon removal of the sack, the deposit remains compressed and the blood flow in the artery is substantially increased.
Since the sack is inserted into the arterial system through a simple incision, for instance, in the groin to reach the femoral artery, the surgical trauma is greatly reduced. Likewise, the risk of the procedure, although still significant, is greatly reduced.
Current methods of fabrication of sacks consist of the joining of a cylindrically shaped sack to the end of a tube which serves as an insertion guide and additionally for transfer of the inflating medium from outside the body to the sack. This device requires two joints, one at each end of the sack. These joints represent potential failure sites, whereby the sack may rupture or separate making the expansion of the sack ineffective and releasing the expansion medium to the bloodstream with increased risk to the individual undergoing the procedure.
Also, indwelling catheters and self-retaining catheters are known that are held in a desired position in a urethra for withdrawal of urine from a bladder. One such catheter is known as the de Pezzer catheter. Such a catheter has a bulbous extremity for holding the catheter in a desired position. Similarly, winged catheters are known that have projections on distal ends of the catheters for retaining them in desired positions.
Further, cannulas, such as Trendelenburg's cannula, are known that have a dilatable rubber bag covering the cannula. Such cannulas are used for closing the trachea to prevent entrance of blood after a tracheotomy.
U.S. patents representative of the aforementioned devices include U.S. Pat. Nos. 2,919,697, 3,834,394, 3,889,685, 3,991,767, 4,130,119, 4,147,169, and Re. 27,910.
SUMMARY OF THE INVENTION
The present invention provides both improved dilators and methods of fabricating and using such dilators. The improved dilators are intended to overcome the problems encountered with use of previously known dilators and similar surgical devices.
One dilator of the present invention eliminates the aforementioned possibility of leakage through joints or rupture of joints connecting a cylindrically shaped sack to an end of a tube by eliminating the joints. In accordance with this embodiment of the invention, an inelastic sack of thermoplastic material is fabricated as an integral part of a longitudinally-extending tube. First, a distal end portion of plastics tubular material is mechanically expanded to form a longitudinally-extending expanded portion. Next, a main body or supporting tube is positioned inside the tubular material. The supporting tube, preferably, has a main body formed from a spring guide and a leading or distal end formed from a fusible, relatively rigid, material. Finally, the distal end of the supporting tube and the end of the expanded portion of the tubular material are heated to shrink and fuse the tip of the tubular material to the supporting tube. A portion of the expanded material is not heated, and forms an inelastic sack or balloon. Since the sack is an integral part of the tubular material, there are no joints connecting the expanded portion to the tubular material.
In a modification of this embodiment, a heatshrinkable elongate tube of material, such as TEFLON (TFE) material, is used to form the dilator. First a longitudinally-extending guide wire is positioned inside the expanded tube. Second, spaced-apart portions, for instance, proximal and distal ends of the tube are heat-shrunk to the guide wire. A portion of the tube intermediate the ends is not heated and remains expanded to form a "balloon" or inelastic sack. Third, a plug of inert material, such as TEFLON (FEP or PFA) is inserted into the distal end of the guide. Finally, the plug or tip is heated to effect a bond between the tube and the plug and to seal the distal end of the tube.
Another dilator according to the present invention utilizes mechanical, instead of pneumatic, action to compress the deposits of fatty substances. With this embodiment, a dilator is used having a plurality of longitudinally-extending wires that are buckled radially when a compressive stress or force is imposed on the wires after they have been inserted into an artery. The compressive stress is applied by applying a tensile force to an internal "pull" wire surrounded by the buckling wires and having a distal end attached to distal ends of the wires to be buckled. A spring guide coil has a first portion wrapped around a first or distal end of the buckling wires and a second portion spaced from the first portion. When the tensile force is applied by pulling on the internal pull wire, the wires buckle in the region between the portions encircled by the spring guide coil. Preferably, the wires are pre-buckled or pre-formed so that the buckling occurs in a predetermined region. In a modification of this embodiment, a part or all of the buckling portion of the wires is covered with an elastic membrane. A significant advantage of this embodiment is that blood flow through an artery is not occluded during dilation of the artery.
A third embodiment of the present invention combines the first two embodiments, that is, a thin elastic membrane and wires that can be buckled by a compressive stress. The membrane, which may be made of a material such as silastic, prevents or minimizes possible damage to the intima portion of an artery being dilated. Further, the membrane can be expanded by pneumatic pressure, in conjunction with the mechanical expansion or buckling of the wires, so that more uniform distribution of pressure and radial dilation is obtained.
A fourth embodiment of the present invention utilizes a dilator that has a cannula with a plurality of longitudinally-extending slots formed in its distal end. During insertion of the cannula into an artery, a sleeve encompasses the distal end to prevent its expansion. After the cannula is positioned in a desired location, a translatable member, such as a spherical ball, positioned in front of the distal end of the cannula is pulled rearwardly by a wire, either simultaneously with or after rearward movement of the sleeve. Rearward movement of the ball expands the split distal end portion of the cannula and rearward movement of the dilator dilates the artery. When the split distal end is formed of a relatively rigid material, the degree of dilation can be controlled by the amount of rearward movement of the spherical member.
The invention, and its objects and advantages, will become more apparent in the detailed description of the preferred embodiments hereinafter presented.
BRIEF DESCRIPTION OF THE DRAWINGS
In the detailed description of the preferred embodiments of the invention hereinafter presented, reference is made to the accompanying drawings, in which:
FIG. 1 is a schematic, partial longitudinal cross section of one embodiment of the present invention;
FIG. 2 is a schematic view of the embodiment of FIG. 1 in a compressed position;
FIG. 3 is a schematic, partial longitudinal cross section of another embodiment of the present invention;
FIG. 4 is a view of the embodiment of FIG. 3 in a dilating position;
FIG. 5 is a view taken along line 5--5 of FIG. 3;
FIG. 6 is a schematic view of a modification of the embodiment of FIG. 4 taken along line 6--6 of FIG. 4;
FIG. 7 is a schematic, partial longitudinal cross section of another embodiment of the present invention; and
FIG. 8 is a view of the embodiment of FIG. 7 in a dilating position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Because surgical dilators are well-known, the present description will be directed in particular to elements forming part of, or cooperating more directly with, the present invention. Elements not specifically shown or described herein are understood to be selectable from those known in the art.
Referring now to the drawings, and to FIGS. 1 and 2 in particular, one embodiment of the present invention is illustrated and will be described in connection with a dilator, generally designated 10. For the purposes of clarity, the portion of the artery encompassing the dilator or dilator assembly of the present invention has been omitted from all of the figures.
The dilator 10 has a longitudinally-extending support member, generally designated 12, positioned inside and encompassed by a longitudinally-extending tubular member, generally designated 13. During a dilation procedure, the components of the support member 12 provide guide means for guiding insertion of the dilator into an artery. The support member 12 has a bipartite distal end portion, generally designated 14, and a proximal end portion that extends outside an artery to be dilated (not shown) when the distal portion 14 is positioned in a desired location in an artery. The end portion 14 includes a relatively rigid end portion 16, formed of Teflon or other fusible suitable material, and a spring wire guide 18 forming a flexible guide member extending from the end portion 16 towards the proximal end of the support means or member. Preferably, the spring wire guide 18 partially encompasses the end portion 16, as illustrated in FIGS. 1 and 2. An annular member 20 is positioned between the end of portion 16 and wire guide 18 in order to form a blocking surface to limit forward movement of the spring wire guide. The annular member, when heated together with a portion of the tubular member 13, melts to fuse tubular members 13 and end portion 16 to each other.
The aforementioned tubular member 13 has an enlarged distal end portion, generally designated 24, and a proximal end portion. The enlarged end portion 24 is formed by expanding the tube mechanically, for instance, by forcing the tube over a heated mandrel. The enlarged end portion 24, after assembly of the dilator 10, has a first part 26 of the side wall of the tube forming an integral, radially protruding, enlarged balloon or inelastic sack, and a second part that is heat shrunk and sealed to annular member 20 and/or end portion 16. During a dilation procedure, the sack portion 26 is expanded into contact with walls of an artery to provide means for dilating the artery.
The dilator 10 is manufactured as follows:
(a) first, a distal end portion of a longitudinally-extending tubular member is mechanically enlarged;
(b) second, a support member having a relatively rigid end portion made of fusible material and a spring wire guide extending rearwardly from the end portion is positioned inside the tubular member with a part of the end portion surrounded by the distal end of the tubular member;
(c) third, the end of the tubular member and at least a part of the end portion of the support member are heated so that the tubular member is heat shrunk and fused to the end portion. The non-heated portion of the tubular member retains the enlarged shape thereby forming an inelastic sack.
The dilator 10 can also be manufactured from an expanded longitudinally-extending tube of heat-shrinkable material. With this method, which is the presently preferred method, the following steps are used:
(a) first, the spring wire guide 18 is positioned inside or enveloped by the expanded tube;
(b) second, distal and proximal end portions of the tube spaced from each other are heated so that the tube shrinks about the wire guide, the non-heated portion between the heated portions maintains its original shape to form an inelastic sack;
(c) third, a plug of material is inserted into the distal end of the wire guide and at least a portion of the plug is enveloped or encompassed by the heat-shrunk tube; and
(d) fourth, the plug is heated, for instance to a temperature between approximately 621° and 627° F. to fuse and bond the plug and tube to each other so that the plug seals the distal end of the tube.
In a modification of this method, the plug is positioned inside the wire guide prior to initial heat shrinking of the tube. A problem sometimes arises with this method in that positioning of the plug inside the wire guide can be difficult.
The previously described methods of fabrication eliminate the possibility of leakage from joints or rupture of the joints connecting the inelastic sack to the tubular member by eliminating the joints. The inelastic sack is fabricated as an integral part of the tubular member by expanding the member during manufacture or by expanding the member mechanically. Since the tube is composed of a thermoplastic material, it will revert to, or nearly to, its original shape when sufficient heat is applied (commonly known as "shrink tubing"). To form the balloon or inelastic sack, a portion of the tube where the sack is to be located is not heated.
When it is desired to use dilator 10 to compress fatty substances in an artery, the dilator is inserted into the artery with its distal end located in a desired position using a conventional method. For instance, an incision is made to give access to an artery to be dilated. A guide wire is then inserted through the incision into the artery. Next, a hollow catheter guided on the guide wire is inserted into the artery. The guide wire is then removed and the dilator 10 is inserted through the hollow catheter. Alternatively, if the artery to be dilated has already been cut, for instance during open-heart or bypass surgery, the dilator 10 can be inserted directly into the artery. In the latter case, a shorter dilator 10 is normally used. In either case, the proximal end of the dilator normally remains outside the body. To minimize trauma during insertion, and to minimize the possibility that build-up materials might be broken away from the artery during insertion of the dilator, the interior of the dilator is preferably subjected to reduced pressure, in a known manner, so that the sack portion 26 is contracted towards the axis of tubular member 13. In this manner, the maximum diameter of the tubular member is reduced. Once the dilator is located in a desired position, the reduced pressure is replaced with either atmospheric or a pressure of up to five atmospheres, so that the sack portion 26 expands into contact with the walls of the artery thereby dilating the artery and compressing fatty substances deposited thereon.
As an aid to better understanding this embodiment of the present invention, some representative dimensions will be set forth. It is to be realized that these dimensions are merely illustrative of one embodiment of the present invention. The dilator has an overall length of approximately 145 cm, with an end portion of approximately 3 cm. An annular member of approximately 1.5 cm encompasses the end portion. The distal end of a tubular member is heat shrunk and sealed to the annular member for a distance of approximately 0.5 cm. The heat shrunk portion of the tubular member gradually extends or expands for a distance of between 1 to 2 mm to an enlarged portion having a diameter of between approximately 0.18 cm and 0.32 cm. A spring guide wire fabricated from 0.008 inch diameter wire having an 0.038 inch outside diameter is positioned inside the tubular member. The end portion, which is preferably a Teflon bead, has an outside diameter of approximately 0.020 inch. The annular member is preferably formed of FEP light wall tubing that melts to seal a chamber formed within the sack portion 26 when expanded PTFE tubing forming the tubular member is shrunk at the tip.
Referring now to FIGS. 3 to 5 of the drawings, a dilator according to the present invention, generally designated 40, is illustrated.
The dilator 40 has a longitudinally-extending center, first or pull wire 42 with a distal end 44 connected to a first securing or bulbous member 46 located at the distal end of the dilator, which is generally designated 48. Preferably, member 46 is shaped to facilitate insertion of the dilator 40 into an artery. The proximal end 50 of the wire 42 passes through and extends beyond a second securing, or housing member, generally designated 52. The housing member has a longitudinally-extending and preferably axially-extending, bore 53 for guiding longitudinal movement of the wire 42. A plurality of second longitudinally-extending, or dilating wires, for instance six as illustrated, encompass the pull wire 42. Distal ends 56 of the wires are connected to the first bulbous member 46, and proximal ends 58 are securely held by the second, or housing member 52.
A blocking member 60 is welded or otherwise affixed to the center wire 42 and to the dilating wires 54 a predetermined distance, for instance 1.0 cm, from bulbous member 46. It will be appreciated that the dilating wires 54 can terminate at the member 60 rather than at the member 46. Also, member 60 can be eliminated. A first spring wire guide 62 fabricated from, for instance, 0.004 inch diameter wire, is wrapped around the center wire and dilating wires between the members 46 and 60 thereby forming first encompassing means. A second spring wire guide 64 forming second encompassing means has a distal end 66 positioned a predetermined distance, for instance, between approximately 0.5 and 0.65 cm, from the blocking member 60. If the blocking member is eliminated, the end will be spaced from a facing end of the first spring wire guide. A proximal end 68 of the second spring wire guide 64 extends inside the housing 52 and is secured with the dilating wires by heat shrinking of the housing member 52, or other suitable means.
Considering now the housing member 52, it has an insert 70 positioned inside and held by a tubular member 72. Preferably, the insert 70 has a plurality of longitudinally-extending grooves 74 for receiving the proximal ends 58 of the dilating wires 54. The length of the grooves is sufficiently long, for instance approximately 1.0 cm, to ensure that the proximal ends 58 are frictionally held between facing surfaces of the insert 70 and the tubular member 72. Such contact can be enhanced by engagement of an innermost end 76 of insert 70 with curved portions 78 of the wires 54. It will be appreciated that the grooves 74 can be replaced with or cooperate with corresponding grooves formed in inner surfaces of tubular member 72. As illustrated in phantom lines in FIG. 4, a compressive sleeve 82 can be applied to tubular member 72 to clamp together the components of housing 52.
As previously mentioned, the length of the grooves 74 in one embodiment is approximately 1.0 cm. With this embodiment, the overall length of the insert 70 is approximately 1.5 cm, and the overall length of the housing member 52 is approximately 4.0 cm. Other representative dimensions include a bore diameter 53 between approximately 0.02 and 0.036 cm; and an insert 70 having a maximum outer diameter of between approximately 0.8 and 0.12 cm and a minimum diameter (between the bottoms of two radially aligned grooves) of between approximately 0.06 and 0.092 cm. A suitable spring guide 64 is fabricated from 0.004 inch diameter wire and has an outer diameter between approximately 0.038 and 0.045 inches (0.096 and 0.114 cm). Suitable dilating wires 54 are fabricated from 304 stainless or beryllium copper having a diameter of between approximately 0.008 and 0.012 inches (0.020 to 0.030 cm). It will be appreciated that the diameter of the dilating wires 54 determines the depth of the grooves 74. Also, the buckling strength of wires 54, taken as a group, must be less than the tensile strength of pull wire 42, so that the wires 54 buckle instead of wire 42 breaking.
Referring now to FIG. 6, a modification of the embodiment of FIGS. 4 and 5 is illustrated. Since this embodiment is similar to the embodiment of FIGS. 4 and 5, the same reference numerals, with primes attached, have been used to identify the same or similar components.
FIG. 6 illustrates a dilator, generally designated 40' having a plurality of dilating wires 54' surrounding a pull wire 42'. A first spring guide (not shown) encompasses a distal end portion of the dilating wires and the pull wire. A second spring guide (not shown) is spaced from the first spring guide and extends to the proximal end of the dilator. The region between the two spring guides forms a buckling region for the dilating wires 54'. In the embodiment of the present invention illustrated in FIG. 6, the dilating wires are encompassed by a thin elastic membrane 80, formed of a material such as silastic, that stretches when the wires 54' are buckled. The membrane 80 prevents or minimizes possible damage to the intima of an artery being dilated. Since the membrane encompasses only a portion of the wires 54', the membrane does not interfere with flow of blood through the dilator 40'.
In another embodiment of the present invention (not illustrated), a membrane similar to membrane 80 is shaped like the tubular member 13 illustrated in FIGS. 1 and 2. With this embodiment, the membrane or tubular member is pneumatically expanded, while the dilating wires are mechanically buckled. The combination of pneumatic and mechanical expansion provides a more uniform distribution of pressure and radial dilation.
In the embodiment illustrated in FIG. 6, the peripheral surfaces of adjacent dilating wires contact each other to form a generally tubular member encompassing the pull wire.
However, it is within the scope of the present invention to space adjacent peripheral surfaces apart from each other, or to have some surfaces contacting and some spaced apart from each other.
Since the embodiments illustrated in FIGS. 3 to 6 all function in generally the same manner, only the functioning or use of the embodiment of FIG. 3 will be explained.
In use, the dilator 40 is inserted into an artery to be dilated by a standard surgical procedure, for instance, one of the procedures previously described in connection with use of dilator 10. The buckling region of the dilator 40, i.e., the region between facing ends of the two spring wire guides 62 and 64, is positioned in or just past the portion of the artery to be dilated. Next, the housing 52 is grasped to prevent its movement, and the proximal end 50 of wire 42 is moved rearwardly (to the right as illustrated). Since the proximal ends of the pull wire and dilating wires are interconnected, and since rearward movement of the dilating wires is prevented by housing 52, rearward movement or a tensile force on pull wire 42 places a compressive force on the dilating wires 54. Since longitudinal movement of the wires is prevented by housing 52, the wires buckle in the region between the two spring guides. This buckling results in lateral expansion and radial protrusion of the wires and dilation of the artery. Thus, movement of the first wire 42 radially outwardly deforms portions of the second wires 54. Preferably, to better control the buckling of the wires, the wires are prebuckled in the region between the two spring guides.
Referring now to FIGS. 7 and 8, another embodiment of a dilator according to the present invention, which is generally designated 90, is illustrated.
The dilator 90 has a longitudinally-extending tubular member 92 with a distal end portion 94 formed with at least two slits 95 that extend from the distal end to one or more openings or apertures 96 formed in side walls of the tubular member. The openings 96 are provided to minimize stress concentration at the end of the slits 95. The length of the slits 95 is preferably approximately twice the diameter of the tubular member. An expansion member, such as a spherical ball 97, is located at the distal end of the tubular member. Preferably, the diameter of the ball is equal to or slightly larger than the diameter of the tube so that the ball is not forced into the tube when the dilator 90 is inserted into an artery. A wire 98 has a distal end rigidly connected to the ball, for instance by welding, and a proximal end (not shown) extending from the proximal end (not shown) of the tubular member 92. A longitudinally-extending sheath 99 encompasses the tubular member 92 to prevent inadvertent opening of the slit end during insertion of the dilator. Preferably, at least the distal end portion of the tubular member 92 is relatively rigid, so that movement of the ball expands the slit end, as illustrated in FIG. 8.
In use, the dilator of this embodiment of the present invention is inserted in a conventional manner into an artery to be dilated. The distal end 94 of the dilator 90 is positioned past the portion of the artery to be dilated. The proximal end of the dilator remains outside of the artery or body with the proximal end of the wire 98 extending beyond the ends of the tubular member 92 and sheath 99. In order to start a dilation, the sheath and wire are moved to the right, as illustrated in FIG. 8, so that the ball 97 enters the split end and forces it open. Subsequent rearward movement of the dilator assembly 90 dilates the occluded portion of the artery.
In one embodiment of the present invention, the proximal ends of the sheath and wire are interconnected so that the movement is conjoint. In another embodiment, the proximal ends are separated from each other, so that the sheath must be moved before the wire is pulled. It will be appreciated that the radial distance between the radially protruding split ends of the tubular member is a function of the amount of movement of ball 97 by wire 98.
The embodiment illustrated in FIGS. 7 and 8 is formed with two longitudinally-extending slits 95. It will be appreciated that more than two such slits can be formed to obtain more uniform compression of the occluded portion of the artery. Also, although not illustrated in FIGS. 7 and 8, it will be appreciated that a spring wire guide can be positioned at the distal end of the ball 97 to facilitate insertion of the dilator 90 into an artery. Also, when the tubular member 92 is formed of relatively rigid material, the sheath can be eliminated.
Previously, specific embodiments of the present invention have been described. It should be appreciated, however, that these embodiments have been described for the purposes of illustration only, without any intention of limiting the scope of the present invention. Rather, it is the intention that the present invention be limited only by the appended claims. | A dilator, a method of making the dilator, and a method of using the dilator to compress fatty substances deposited in or on the walls and lumen of the major arteries. The dilator includes a tubular member that has a distal end portion that can be expanded to compress the fatty substances. One embodiment of the dilator has a balloon or inelastic sack formed integrally with side walls of the tubular member and spaced from its distal end. A second embodiment of the dilator utilizes a tubular member formed by first and second spring wire guides encompassing a plurality of dilating wires surrounding a center pull wire. Near the distal end of the dilator, the spring wire guides are spaced from each other to define a buckling region for the dilating wires. When the center wire is pulled, a compressive force is applied on the dilating wires, so that the wires buckle, or expand, in the buckling region. In one modification of this embodiment, a thin elastic membrane encompasses the dilating wires and the buckling region. In another modification, the thin elastic membrane covers substantially the entire length of the dilating wires so that both pneumatic and mechanical compressive forces can be exerted on the fatty substances. The elastic membrane is positioned inside or on the outside of the spring wire guides. A further embodiment of the dilator utilizes a tubular member having a distal end split by longitudinally-extending slits. Rearward movement of a ball member positioned in front of the leading or distal end of the tubular member, after or simultaneously with rearward movement of a sheath encompassing the split end, forces apart the split end thereby dilating the artery and exerting a compressive force on the fatty substances. | 0 |
BACKGROUND OF THE INVENTION
In petroleum refining operations in which crude oil is processed to produce gasoline, diesel fuel, lubricants and so forth, there always remains a residue that is referred to in the trade as "coke". This residue is heated in a furnace to cause destructive distillation of the hydrocarbon feed stock in which substantially all of the remaining useable hydrocarbon products are driven from the residue, leaving the coke product which is conveyed into a coke drum. The typical coke drum is a large, upright, cylindrical, steel walled vessel that may, for example, be in the order of approximately 90-100 feet in height and 20-30 feet in diameter, although the actual structural size and shape of the coke drum can vary considerably from one installation to another. Typically, a refinery has a plurality of coke drums, the production of coke being a batch process, that is, wherein coke is deposited in a very hot state in a drum, is cooled using a process that is the subject of this invention, and after cooling, the coke is removed, the drum then being ready for reuse. While coke is being cooled in one or more drums and while the cooled coke is being extracted, other drums are being employed to receive the continuous production of coke as a part of the operation of a refining process.
Typically, the residue feed stock from a refinery operation is fed through a furnace where distillation occurs. The output of the furnace is a residue that is substantially free of all higher order hydrocarbons. The residue is in the form of a hot vicious liquid product that is fed into a coke drum at a temperature of about 900° F. The hot liquid material fills the drum to approximately 80% of its capacity. Due to the high temperature (about 900° as an example) of the liquid product entering the coke drum, the drum thermally expands both longitudinally and circumferentially to thereby have a larger volume than when the drum is cold. The hot liquid coke enters the drum, typically flowing into the bottom of the drum and lays down layers of coke that solidifies as the temperature drops. Eventually the coke drum becomes a solid mass with flow channels kept molten by the hot product entering the drum.
When a coke drum is filled to the desired capacity, or during the process of filling, steam is typically introduced into the drum to drive off any remaining hydrocarbon vapors. The drum remains substantially full of coke that, as it cools, hardens into a solid material.
Since the coke, as it transforms from a liquid to a solid, is exceedingly hot and since the coke cannot be discharged from the coke drum as a solid product until it is cooled to substantially ambient temperature, some means must be provided for cooling the coke in the drum otherwise it would take an inordinate length of time for the coke to cool as a result of ambient temperature alone. Consequentially it is a standard procedure to cool coke in a drum by the admission of quench water.
In the coke drum, the drum sidewalls shrink both longitudinally and circumferentially due to thermal contraction of the metal of which the sidewalls are formed. As the coke cools, it is transformed from a liquid to a solid phase and the coke drum thermally constricts around the solidified coke tending to crush and compact the coke. This thermal contraction of the coke drum sidewall, both circumferentially and longitudinally, which shrinkage is counteracted by the resistance to shrinkage of the solidified coke, introduces substantial stress in the coke drum metal sidewalls. This thermal stress results in deterioration of the coke drum sidewalls and unless the rate of stress is controlled to keep the stress below a preselected maximum level, failure of the coke drum sidewall will result. More specifically, if the program of quenching is carried out in such a way that the quenching operation repeatably introduces excessive stress in the coke drum sidewalls as repeated batches of cokes are quenched, the life expectancy of a coke drum is substantially reduced.
It is an object of the present disclosure to provide an improved means of controlling the rate of quench of coke in a coke drum to reduce the rate of deterioration of the coke drum sidewall.
Others have suggested methods of controlling the quenching rate in coke drums and for background information, reference may be had to U.S. Pat. No. 4,634,500 issued Jan. 6, 1987 and entitled "Method of Quenching Heated Coke To Limit Coke Drum Stress". This patent discloses a method of controlling the quenching of coke in a coke drum in which the longitudinal thermal temperature gradient along the coke drum wall is measured. This longitudinal temperature measurement is compared with a predetermined gradient parameter for the coke drum and the rate of flow of quenching water into the drum is controlled as a result of such comparison. Measuring a longitudinal thermal temperature gradient along the coke sidewall does not provide a direct indication of thermal stress taking place within the coke drum sidewall and requires that the stress actually taking place be implied from the thermal gradient temperature measurements. In contrast, the present disclosure employs a unique system of direct stress measurement that more rapidly and more accurately indicates the actual conditions of a coke drum sidewall to more rapidly and accurately control the quenching operation to permit the quenching operation to be conducted in such a way as to minimize deterioration of the coke drum sidewall.
U.S. Pat. No. 3,936,358 issued Feb. 3, 1976, entitled "Method of Controlling The Feed Rate of Quenched Water To A Coking Drum In Response To The Internal Pressure Therein" teaches, as the title of the patent implies, a method of controlling a quenching operation of a coke drum in response to the internal pressure measured within the drum. Measuring the internal pressure requires that the stress be implied. Further, the actual pressure within a coke drum does not accurately reflect the stress caused by the resistance to thermal contraction imposed by solidified coke within a drum.
For further background information relating to quenching of coke, reference may be had to the following additional United States patents:
______________________________________PATENT NO. INVENTOR TITLE______________________________________1065081 Reubold Apparatus For Quenching Coke3611787 D'Annessa et al Apparatus For Minimizing Thermal Gradient In Test Specimens3780888 Hoffman Material Transfer Apparatus For A Rotary Drum3917516 Waldmann et al Coke-Cooling Apparatus3936358 Little Method of Controlling The Feed Rate of Quench Water To A Coking Drum In Response To The Internal Pressure Therein4135986 Cain et al Qne-Spot Rotary Coke Quenching Car4147594 Cain et al One-Spot Cylindrical Coke Quenching Car and Quenching Method4282068 Flockenhaus et al Apparatus For The Transfer and Quenching of Coke4284478 Brommel Apparatus For Quenching Hot Coke4285772 Kress Method and Apparatus For Handling and Dry Quenching Coke4289585 Wagener et al Method and Apparatus For The Wet Quenching of Coke4294663 Tennyson Method For Operating A Coke Quench Tower Scrubber System4312711 Brown et al Fluid Cooled Quenching Cars4344822 Schwartz et al One-Spot Car Coke Quenching Method4358343 Goedde et al Method For Quenching Coke4396461 Neubaum et al One-Spot Car Coke Quenching Process4409067 Smith Quenching Method and Apparatus4437936 Jung Process For Utilizing Waste Heat and For Obtaining Water Gas During The Cooling of Incandescent Coke4469557 Schweer et al Process For Calcining and Carbonizing Petroleum Coke4512850 Mosebach Process For Wet Quenching Of Coal-Coke4557804 Baumgartner et al Coke Cooler4588479 Weber et al Device For Cooling Incandescent Coke4614567 Stahlherm et al Method and Apparatus For Selective After-Quenching Of Coke On A Coke Bench4634500 Elliott et al Method of Quenching Heated Coke To Limit Coke Drum Stress4664750 Biesheuvel et al Method For Coke Quenching Control4726465 Kwasnik et al Coke Quenching Car4743342 Pollert et al Coke Quenching Apparatus4747913 Gerstenkorn et al Cooling Apparatus For Granular Coke Material4772360 Beckmann et al Thin Wall Coke Quenching Container4802573 Holter et al Process For Wet Quenching Of Coke4832795 Lorenz et al Coke Dry Cooling Chamber4886580 Kress et al Dry Quenching Coke Box4997527 Kress et al Coke Handling and Dry Quenching Method5024730 Colvert Control System For Delayed Coker______________________________________
BRIEF SUMMARY OF THE INVENTION
This invention provides a method of controlling the rate of quench of coke in a coke drum to reduce the rate of deterioration of the coke drum sidewall. The method includes the steps of admitting water into a hot coke drum to cool the coke therein. The stress imposed on the coke drum sidewall as a consequence of the cooling effect of the water entering the coke drum is directly measured by means of at least one strain gauge (but more preferably, a plurality of strain gauges) affixed to the coke drum sidewall. The rate of admission of water into the coke drum is then controlled in response to the determined stress of the coke drum sidewall to a rate that results in the determined stress remains below a preselected maximum level.
In a preferred method of practicing the invention, a plurality of strain gauges are affixed to the exterior surface of a coke drum sidewall in a predetermined pattern that may include placement of the strain gauges either in a vertically aligned pattern or in a horizontally aligned pattern or in a pattern wherein the axis of the individual strain gauges are at an angle with relative to the vertical axis of the drum.
An actual strain measurement from at least one but preferably measurements from a plurality of strain gauges are fed to a computer wherein the stress detected by the strain gauge is or gauges are analyzed employing appropriate software to determine the level of stress actually being experienced by a coke drum as quench water is introduced. Employing the information derived from strain gauge or gauges, the program then provides appropriate electrical signals for controlling a valve that governs the rate of quench water flow into the coke drum to thereby maintain a rate of water flowage into the coke drum to a level that results in the drum sidewall stress being kept below a preselected maximum level to thereby insure a rate of stress deterioration of the vessel sidewall that is within acceptable limits. In one embodiment, the computer program determines the rate of stress increase and calculates the rate of quench water flow consonant with the rate of stress increase so that the stress in the vessel sidewall remaining below a predetermined level.
A better understanding of the invention will be obtained from the following description of the preferred embodiments and the claims, taken in conjunction with the attached drawings.
DESCRIPTION OF THE DRAWINGS
The drawing is a schematic diagram of the system of this invention illustrating, in broken away segments, a coke drum and the sidewall thereof having diagrammatically illustrated strain gauges secured thereto and showing schematically the use of information collected by a plurality of strain gauges for producing an electrical signal to control a valve that determines the rate of quenching water flow into the coke drum.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawing, a coke drum is indicated generally by the numeral 10, the drum being illustrated diagrammatically rather than pictorially. Coke drums 10 are commonly employed in refinery operations for receiving the residue after substantially all useable higher hydrocarbons have been extracted from crude oil. The useful and valuable higher hydrocarbons obtained from crude oil include gasoline, diesel fuel and lubricants, as well as a host of other products utilized by the transportation and chemical manufacturing industry. After all of these valuable and highly useful products are removed from the crude oil in the refinery process there remains a residue product that is in the form, after it has solidified, commonly referred to as "coke". This product, which is essentially carbon, must be dealt with in a refinery operation. It has some commercial value, although the value per volume is much lower than other products derived from crude oil.
The residue from the refinery operation in the form of the coking feed stock is supplied through piping 12. This liquid material is fed to a furnace 14 where destructive distillation takes place with gases generated by the destructive distillation passing off at 16, which gases are collected and useful components thereof extracted. The output from furnace 14 passes by conduit 18 into a bottom section 20 of coke drum 10. The liquid product flowing into drum 10 through conduit 18 is typically at a temperature of about 900° F. This liquid material is fed into drum 10 until it is typically about 80% filled. When the drum is filled to this level, further flow of feed stock from conduit 18 is terminated and the flow of feed stock is then routed to another coke drum and the process is repeated. Thus, in a refinery operation, there are sufficient coke drums of the type identified by the numeral 10 to permit liquidified coke to be fed into the drum, the coke cooled and removed as a solid and the drum then continuously reused in batch processes.
After the liquid coke at typically 900° F. fills the drum 10 and further flow is terminated, the coke must be cooled to a temperature of near ambient before the material is removed as a solid and the drum then prepared to receive a new batch of coke. Since it would be exceedingly time consuming to permit the coke in drum 10 to cool by dissipating heat into the ambient environment, that is, the air surrounding the coke drum, the usual process in refining operations is to quench the coke in drum 10 by the introduction of quenching water. However, before quenching water is introduced, a common procedure is to introduce steam into drum 10, the steam flowing through conduit 22 into the bottom of vessel 10. Steam passes upwardly through the coke, either as the coke is being conveyed into the drum or after the drum is substantially filled, the steam serving to begin the cooling process and, in addition, to drive off any entrained hydrocarbon vapors. The steam and commingled vapors pass out through vapor outlet 24 in the top end portion 26 of the drum, any entrained hydrocarbons being recovered.
Vessel 10 has a cylindrical wall 28 extending between bottom 20 and top 26. Vessel 10 may have a cylindrical sidewall of a height such as about 90-100 feet and a diameter of about 20 feet, although these dimensions can vary considerably and the exact dimensions are not related to the essence of the invention. The coke drum illustrated in the drawing is, as has been previously stated, schematic only and the details of construction of the coke drum are not part of the invention. Instead, the invention is concerned with controlling the quenching of coke within vessel 10 in a way to limit deterioration of the coke drum sidewall 28.
Vessel 10 is preferably made of metal and most preferably steel because of its strength and economy compared to other comparable metal. Steel, like all metals, has a thermal expansion characteristic so that as the hot coke enters drum 10, the sidewall 28 thereof expands both longitudinally and circumferentially, meaning that the height of the drum increases as the temperature of the sidewall increases to reflect the temperature of the coke and that the diameter of the drum increases. The longitudinal and circumferential change of dimension of the drum does not take place uniformly but instead takes place in a highly localized manner, that is, as the hot coke enters the drum from the bottom and builds in layers, portions of the drum sidewall 28 contacted by the hot coke increase in dimension both laterally and circumferentially while other portions that have not yet been contacted by the hot coke remain relatively unaffected. Thus, stress levels within the vessel sidewall 28 are highly localized, at least in an elevational manner. The increase in the vessel sidewall and temperature as the coke enters the vessel however is not the factor that causes the greatest stress and, therefore, the greatest rate of deterioration of the vessel sidewall. Instead, after the drum is substantially filled with liquid coke, that builds up in solidified layers, the maximum stress on the sidewall occurs as the quenching process begins. To cool the coke within the drum to near ambient temperature so that it can be extracted as a solid material for subsequent disposal and use, the standard technique is to quench the coke by introduction of water which is available through conduit 30. The water passes through a controlled valve 32 to conduit 34 by which the water enters into the lower end 20 of vessel 10. The system of this invention is concerned with controlling valve 32 so that the rate and timing of water entry into coke drum 10 is controlled in such a way that stresses are managed in a way to result in decreased rate of deterioration of vessel sidewall 28.
To accomplish this result, the system of this invention measures the stress in vessel sidewall 28 directly by the use of at least one but preferably a plurality of strain gauges. In the diagrammatic illustration of the drawing, three different patterns of strain gauge orientations are illustrated by way of example. In the lower most example, vessel sidewall has strain gauges 36 that are vertically oriented, that is longitudinally oriented, in a spaced apart pattern. A strain gauge, as is well known to those experienced in the art of stress measurement, functions to respond to change in dimension of a physical object to which it is attached by creating a measurable electrical signal. This electrical signal can be created, such as by the strain gauge changing in resistance in response to a change of dimension or by the generation of an electric voltage potential. This electrical signal is derived from a pair of conductors connected to each strain gauge 36. For instance, at the right hand of the lowermost portion of the vessel sidewall 28 a representative strain gauge 36 has a first electrical contact point 36A and a second electrical contact point 36B. By means of conductors 38A and 38B, an electrical signal is provided that is fed to a computer 40. The term "computer" is utilized in its broadest sense, that is, the term includes all of the electrical circuitry utilized in practicing the invention to employ a measurement obtained from conductors 38A and 38B of a transistor 36 to ultimately provide a control signal for valve 32.
Strain gauge 36 each has a contact point 36B that is elevationally positioned above a contact point 36A and, thus, the strain gauges 36 are oriented to respond to longitudinal stresses in the vessel sidewall 28.
An intermediate section 28B of vessel sidewall has strain gauges 42 that are oriented horizontally in a pattern. In the right hand portion of the drawing, strain gauge 42 as an example of the other strain gauges 42, has contact points 42A and 42B to which are connected conductors 44A and 44B by which signals are supplied to computer 40. Strain gauges 42 in the illustrated pattern respond primarily to stress in the vessel sidewall that is circumferential.
Vessel sidewall section 28C has strain gauges 46 oriented at an angle relative to the vertical and also at an angle relative to the circumferential. The right hand most strain gauge 46 is shown with contact points 46A and 46B with contact point 46A mounted longitudinally above and circumferentially displaced relative to contact point 46B. Thus the orientation of strain gauge 46 will respond to both longitudinal stress and circumferential stress. By means of conductors 48A and 48B, a signal produced by representative strain gauge 46 is supplied to computer 40.
As the level of quench water rises within vessel 10, the stress on the vessel sidewall 28 is detected by strain gauges, whether a gauge is oriented as illustrated by the numerals 36, 42 and 46 or by some other orientation or pattern of orientations.
Computer 40, as has been previously stated, is representative of the total circuitry by which signals from strain gauges at various levels of the vessel are processed to provide an output signal on conductor 50 to control valve 32. Valve 32 can be controlled by turning the valve on or off to start and stop the flow of quench water into coke drum 10 or valve 32 can be controlled to regulate the rate of flow, that is, to change the flow from a faster rate to a slower rate and vice versa.
Computer 40 includes software designed to utilize the information provided by one or more strain gauges to control the quenching rate so that the stress within the vessel sidewall 28 remains below a preselected maximum that would cause excessive or accelerated deterioration of the vessel sidewall. This can be achieved basically in two ways. In a simplified arrangement, computer 40 can be made to function to shut off flow of water, that is, close valve 32 when a detected stress level reaches a certain maximum level and to maintain the water shut off until the stress level falls below the preselected maximum allowable stress, at which time valve 32 can be reopened to admit additional quenching water. This process is repeated until vessel 10 is filled and, thus, all of the coke therein cooled. Another method employs computer 40 to determine a rate of increase of stress in vessel wall 28 and, based on the rate of increase, to project a level of stress that would be beyond an accepted level and to thereby control valve 32. In a sense, this system employs a signal derived as a first differential of the equation representing the detected increase in stress in the vessel sidewall. A third program can combine both systems, that is, a program to control valve 32 in response both to the maximum detected level of stress in conjunction with the computed rate of increase of stress. Irrespective of the system employed, the program in computer 40 is that which achieves the most rapid quenching of coke while, at the same time, preventing stress in the vessel sidewall that is beyond an acceptable level.
Strain gauges of the type identified by numerals 36, 42 and 46 are commercially available. Experiments verifying the efficacy of the invention have been completed utilizing strain gauges manufactured by Tokyo Sokki Kenkyujo Co., Ltd. whose address is 8-2, Minami-Ohi 6-Chome, Shinagawa-Ku, Tokyo 140 Japan. Model AWH-8/-16 strain gauges manufactured by this company have been used on coke drums in accordance with this invention. The strain gauges were used in accordance with the specification for use provided by this company. The model AWH-8/-16 is of the type previously referred to in the literature as an "Eaton (Ailtech) Weldable Strain Gauge, Model SG-425 ". The Tokyo Sokki Kenkyujo Company model AWH-8/-16 strain gauge is more or less a modern version of the Ailtech Model SG-425 strain gauge.
The listing of this particular strain gauge is by example only as other manufacturers market strain gauges that can be used to accomplish the purpose of this invention.
It is well known that in utilizing a signal from or generated by a strain gauge that temperature compensation is necessary. It is understood that each of the strain gauges herein is accompanied by temperature compensation employing techniques well known in the industry. One method of temperature compensation employs a thermocouple 52 affixed to the drum sidewall adjacent the pattern of strain gauges 36. A temperature indicating signal is fed to computer 40 by conductor 54. Computer 40 employs the detected temperature to compensate the signals received from the pattern of strain gauges.
The claims and the specification describe the invention presented and the terms that are employed in the claims draw their meaning from the use of such terms in the specification. The same terms employed in the prior art may be broader in meaning than specifically employed herein. Whenever there is a question between the broader definition of such terms used in the prior art and the more specific use of the terms herein, the more specific meaning is meant.
While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled. | A method of controlling the rate of quench of coke in a coke drum to reduce deterioration of the coke drum sidewall in which water is admitted into the coke drum filled with hot coke to cool the coke includes the steps of determining the stress imposed on the coke drum sidewall by means of at least one strain gauge affixed to the sidewall and controlling the rate of admission of water into the coke drum in response to the determined stress so that the rate of water admission keeps the stress below a preselected maximum level. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to the insertion of clips or advertising sequences into a sequence of video pictures.
BACKGROUND OF THE INVENTION
[0002] With the arrival of the distribution of video content over the Internet, advertising is considered by the players of the domain such as Yahoo™, Google™ or Microsoft™ as a key element of growth. Different tools have been developed for this purpose to increase the visual impact of the inserted advertising in the video, while avoiding inconveniencing the spectators.
[0003] In particular, Microsoft™ has developed a tool called VideoSense described in the document entitled “VideoSense: a contextual video advertising system”, Proceedings of the 15th international conference on Multimedia, pp 463-464, 2007. This tool was created to insert advertising clips into a video sequence, the objective being to select a clip that is relevant to the video sequence and insert it at key moments in the video, not only at the start and end of the video sequence. To select the clip to insert, low-level parameters of the colour, movement or sound rhythm type are extracted form the clip and the sequence, then compared with each other, the clip selected then being the one having the low-level parameters closest to those of the video sequence. Additional information, such as a title associated with the clip or with the sequence and supplied by the advertisers or the broadcaster of video content or text information contained in the clip or the sequence, are also used to select the clip to insert into the sequence. Once selected, the clip is inserted at particular points of the sequence, and more specifically at points of the sequence for which the discontinuity is high and at which the attractiveness is low, for example at the end of a scene or a shot not comprising any movement.
[0004] The selected clip is therefore generally placed after a shot change. Although the video content of the selected clip is related to the content of the sequence in which it is inserted, the impact of this shot change on the perception of the clip by the spectator is neglected. Indeed, a phenomenon observed by several studies, particularly in the document entitled “Predicting visual fixations on video based on low-level visual features” by O. Le Meur, P. Le Callet and D. Barba, Vision Research, Vol. 47/19 pp 2483-2498, September 2007, on the temporal extension of the fixated zone after a shot change is not taken into account. The result of these studies is that the spectator continues to fixate, for an approximate time of 200 to 300 ms after the shot change, the area that he was fixating before the shot change. Hence, the area looked at by the spectator depends, not on the pictures displayed at the current time, but on pictures displayed previously. This phenomenon is illustrated by FIG. 1 . The line of pictures in the upper part of the figure represented by a video sequence comprising 7 pictures separated from each other by a time interval of 100 ms. A shot change occurs between the third and fourth picture of the sequence. The line of pictures in the is lower part of the figure shows, by white dots, the picture areas fixated by the spectator. It is noted that the spectator only shifts his fixation at the end of the sixth picture, namely 2 pictures after the shot change. This temporal extension is due to different factors, particularly to the temporal masking, to the surprise effect and to the time biologically necessary to reinitialise the action of perception. In the case of a 50 Hz video, this temporal extension lasts for about 15 pictures after the shot change.
[0005] If the interesting regions of the advertising are not positioned at the same points as those of the video sequence before the shot change, the content of the advertising is therefore not immediately perceived by the spectator and the visual impact of the advertising on the spectator is therefore reduced. There is no direct perception of the message carried by the advertising.
SUMMARY OF THE INVENTION
[0006] One purpose of the present invention is to optimise the visual impact of an advertising clip inserted into a video sequence.
[0007] For this purpose, it is proposed according to the invention to account for, in the selection process of the advertising clip to insert, the regions of interest of the video sequence and of the advertising clip in such a manner that there is a continuity between the regions of interest of the pictures of the video sequence and the regions of interest of the advertising clip. The content of the clip will be more rapidly perceived by the spectator.
[0008] The present invention therefore relates to a method for processing pictures intended to insert an advertising clip at a point, called insertion point, between two pictures of a sequence of video pictures, called video sequence, comprising the following steps:
generating a salience map representing the salience of the video sequence before said insertion point, generating, for each advertising clip of a set of advertising clips, a salience map, determining, for each advertising clip of said set of advertising clips, a degree of similarity between the salience map of the video sequence and the salience map of said advertising clip; said degree of similarity being representative of the comparison between the location of the salience zones on both said maps, selecting, among said set of advertising clips, the advertising clip having the highest degree of similarity, and inserting the advertising clip selected into the video sequence at the insertion point.
[0014] Hence, the inserted advertising clip is the one providing, at the level of the insertion point, the best continuity in terms of salience between the video sequence and the advertising clip.
[0015] According to particular embodiment, the insertion point is a point of the video sequence corresponding to a shot change in the video sequence.
[0016] According to a particular embodiment, the salience map representative of the salience of the video sequence before the insertion point is generated from the salience maps of the last n pictures of the video sequence that precede the insertion point, n being comprised between 1 and 50. For example, the average is made of the salience maps of the last 15 pictures of the video sequence before the insertion point in the case of a 50 Hz video.
[0017] According to one embodiment, the salience map of the advertising clip is generated from the salience maps of the first p pictures of the advertising clip, p being comprised between 1 and 50. For example, the average is made of the salience maps of the first 15 of the clip in the case of a 50 Hz video.
[0018] A clip is therefore selected providing a continuity in terms of salience between the last pictures of the video sequence before the insertion point and the start of the advertising clip.
[0019] According to a particular embodiment, the degree of similarity of an advertising clip is determined by calculating the correlation coefficient between the salience map of the video sequence and the salience map of said advertising clip, the degree of similarity thus being proportional to the correlation coefficient calculated.
[0020] According to another particular embodiment of the method of the invention, the degree of similarity for an advertising clip is determined by calculating the Kullback-Leibler divergence between the salience map of the video sequence and the salience map of said advertising clip, the degree of similarity thus being inversely proportional to the divergence calculated.
[0021] According to another particular embodiment, to determine the degree of similarity of an advertising clip, the following steps are carried out:
selecting, from the salience map of the video picture and from the salience map of the advertising clip, the N most salient points of the map, called maximum salience points, said points being separated from each other by at least m points and ordered from the most salient to the least salient, N being greater than or equal to 1, determining, for each of the N maximum salience points of the salience map of the picture, the Euclidean distance between said point and the maximum salience point of the same order of the salience map of the advertising clip, and calculating the average of the N Euclidean distances determined, the degree of similarity thus being inversely proportional to the calculated average.
[0025] In this embodiment, the Euclidean distance being determined between the maximum salience points of the same order, the salience value of the points is, to a certain extent, taken into account in determining the degree of similarity.
[0026] According to a variant embodiment, the N maximum salience points are not ordered. In this embodiment, the determination of the degree of similarity of an advertising clip comprises the following steps:
selecting, from the salience map of the video picture and from the salience map of the advertising clip, the N most salient points of the map, called maximum salience points, said points being separated from each other by at least m points, N being greater than or equal to 1, determining, for each of the N maximum salience points of the salience map of the video picture, the Euclidean distance between said point and the closest maximum salience point in the salience map of the advertising clip, and calculating the average of the N Euclidean distances determined, the degree of similarity thus being inversely proportional to the calculated average.
[0030] In these last two embodiments, the selection of N maximum salience points separated by at least m points in a salience map is carried out in the following manner:
[0031] a) the point having the maximum salience is selected from said salience map,
[0032] b) all the points belonging to a zone of radius R around said detected point are inhibited, R being equal to m points, and
[0033] c) the steps a) and b) are repeated for the non-inhibited points of the salience map until the N maximum salience points are obtained.
[0034] The present invention also relates to device for processing pictures intended to insert an advertising clip at a point, called insertion, of a sequence of video pictures, called video sequence, comprising:
means for generating a salience map representative of the salience of the video sequence before the insertion point and a salience map for each advertising clip of a set of advertising clips, means for determining, for each advertising clip of said set of advertising clips, a degree of similarity between the salience map of the video sequence and the salience map of said advertising clip. means for selecting, among said set of advertising clips, the advertising clip having the highest degree of similarity, and means for inserting the advertising clip selected into the video sequence at said insertion point.
[0039] According to a particular embodiment, the device further comprises means for detecting a shot change in the video sequence, the selected advertising clip thus being inserted at the point of the video sequence corresponding to this shot change.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] The invention will be better understood, and other purposes, details, characteristics and advantages will appear more clearly during the following detailed explanatory description of several currently preferred particular embodiments of the invention, with reference to the annexed diagrammatic drawings, wherein:
[0041] FIG. 1 , already described, illustrates the phenomenon of temporal extension after a shot change in a video sequence,
[0042] FIG. 2 shows a functional diagram of the method of the invention,
[0043] FIG. 3 is a flowchart showing the steps of the method of the invention,
[0044] FIG. 4 illustrates the determination of a degree of similarity between the salience map of an advertising clip and the salience map of the video sequence according to a first embodiment,
[0045] FIG. 5 illustrates the determination of a degree of similarity between the salience map of an advertising clip and the salience map of the video sequence according to another embodiment, and
[0046] FIG. 6 diagrammatically shows a device capable of implementing the method of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0047] In the rest of the description, advertising clip is understood to mean a series of fixed or animated pictures displaying an advert or a logo and insertion point is understood to mean the point between two pictures of the video sequence into which the advertising clip is inserted.
[0048] According to the invention, the regions of interest of the last pictures of the video sequence before the insertion point and the regions of interest of the advertising clips of a predefined set of advertising clips are determined and the advertising clip having the regions of interest spatially closest to those of the last pictures of the video sequence before the insertion point are selected. This insertion point can be predefined or be manually defined at the start of the method by an operator or be defined automatically at the start of the method.
[0049] The insertion point is advantageously a point of the video sequence corresponding to a shot change so that the spectator is not inconvenienced or disturbed by the sudden appearance of an advertising clip in the video sequence.
[0050] FIG. 2 is a functional diagram of the method of the invention in which the insertion point (point of the video sequence in which the advertising clip is inserted) corresponds to a shot change. According to the invention, the regions of interest of the last pictures of the video sequence before the shot change and the regions of interest of the advertising clips of a predefined set of advertising clips are determined and the advertising clip having the regions of interest spatially closest to those of the last pictures of the video sequence before the shot change are selected. The location of this shot change can be contained in metadata associated with the video sequence or defined at the start of the method. The shot change can be detected automatically, for example by an algorithm such as the one described in the document “Information Theory-Based Shot Cut/Fade Detection and Video Summarization” by Z. Cerneková, I. Pitas and C. Nikou, IEEE transactions on circuits and systems for video technology, Vol. 16, no. 1, January 2006) or selected manually by an operator.
[0051] FIG. 3 more particularly illustrates the steps of the method of the invention. According to a first step E 1 , a salience map is generated representing the salience of the video sequence before the said insertion point. This salience map is for example the salience map of the last picture of the sequence before the insertion point or then the average of the salience maps of the last n pictures of the sequence before the insertion point. The methods for generating the salience maps are fully known by those skilled in the art. Such a method is for example described in the patent application EP 1 544 792. Such a map associates each pixel of the video picture with a point having a given salience value. The higher the salience value of the point, the greater the interest of the associated pixel and the more this pixel attracts the attention of the spectator. The salience value of the points is for example comprised between 0 and 255 (8 bits).
[0052] According to a step E 2 , a salience map is then generated for each of the advertising clips of the set of clips. This salience map is advantageously defined from the first pictures of the advertising clip, for example from the p first pictures. The salience map of a clip is for example the average of the salience maps of the p first pictures of this clip.
[0053] According to the next step, referenced E 3 , for each advertising clip, a degree of similarity is determined between the salience map of the video sequence and the salience map of the advertising clip.
[0054] This degree of similarity can be determined in different manners.
[0055] According to a first embodiment, the step E 3 consists in calculating, for each advertising clip, the correlation coefficient between the salience map of the video sequence and the salience map of the advertising clip, the degree of similarity thus being proportional to the correlation coefficient calculated.
[0056] According to a second embodiment, the step E 3 consists in calculating, for each advertising clip, the Kullback-Leibler divergence between the salience map of the video sequence and the salience map of the advertising clip, the degree of similarity thus being proportional to the divergence calculated.
[0057] According to a third particular embodiment, the step E 3 consists in carrying out, for each advertising clip, the following sub-steps:
[0058] (a) in the salience map of the video sequence and in the salience map of the advertising clip, a selection is made of the N most salient points of the map, called maximum salience points, the points being separated from each other by at least m points and ordered from the most salient to the least salient; to achieve this, a selection is first made of the point having the maximum salience in the salience map; then, a zone of m points surrounding the detected point is inhibited; among the non-inhibited points of the salience map, the point having the maximum salience is then detected and all the points belonging to a radius R equal to m points around this maximum salience point are inhibited; the operation is repeated until the N maximum salience points are obtained; N points are thus obtained in the salience map of the video sequence and N points in the salience map of the advertising clip,
[0059] (b) for each of the N maximum salience points of the salience map of the video picture, the Euclidean distance is then determined between said point and the maximum salience point of the same order of the salience map of the advertising clip,
[0060] (c) the average of the N previously calculated Euclidean distances is calculated, the degree of similarity for the considered advertising clip thus being inversely proportional to the calculated average.
[0061] This embodiment of the step E 3 is illustrated by FIG. 4 for three advertising clips. In this figure, three maximum salience points (N=3) have been identified in the video sequence V and are noted P V1 , P V2 and P V3 , with S(P V1 )>S(P V2 )>S(P V3 ) where S(P) designates the salience value of the point P. Moreover, P A1 , P A2 and P A3 designate the three maximum salience points of an advertising clip A, with S(P A1 )>S(P A2 )>S(P A3 ). Likewise, P B1 , P B2 and P A3 designate the three maximum salience points of an advertising clip B, with S(P B1 )>S(P B2 )>S(P B3 ). Finally, P C1 , P C2 and P C3 designate the three maximum salience points of an advertising clip C, with S(P C1 )>S(P C2 )>S(P C3 )
[0062] According to this figure, the step E 3 consists in calculating, for each clip, the Euclidean distance d between the points of the same order, namely d(P Vi ,P Ai ), d(P Vi ,P Bi ) and d(P Vi ,P Ci ) with iε[1 . . . 3], then in calculating, for each clip, the average of the 3 calculated distances and in deducing a degree of similarity for each of them, this degree being inversely proportional to the calculated average. The degree of similarity is for example the inverse of the calculated average.
[0063] According to an embodiment that is a variant of the third embodiment, the maximum salience points selected are not ordered. Step E 3 thus consists in carrying out, for each advertising clip, the following sub-steps:
[0064] (a) in the salience map of the video sequence and in the salience map of the advertising clip, a selection is made of the N most salient points of the map, the points being separated from each other by at least m; as for the previous embodiment, a selection is first made of the point having the maximum salience in the salience map; then, a zone of m points surrounding the detected point is inhibited; among the non-inhibited points of the salience map, the point having the maximum salience is then detected and all the points belonging to a radius R equal to m points around this maximum salience point are inhibited; the operation is repeated until the N maximum salience points are obtained; N points are thus obtained in the salience map of the video sequence and N points in the salience map of the advertising clip,
[0065] (b) for each of the N maximum salience points of the salience map of the video picture, the Euclidean distance is then determined between said point and the closest maximum salience point of the salience map of the advertising clip,
[0066] (c) the average of the N previously calculated Euclidean distances is calculated, the degree of similarity for the considered advertising clip thus being inversely proportional to the calculated average.
[0067] This variant embodiment is illustrated by FIG. 5 for three advertising clips. This figure uses the maximum salience points defined for FIG. 4 . According to this embodiment, for each point P Vi of the video sequence, a calculation is made of its Euclidean distance d with each of the maximum salience points of each clip and only the smallest distance is kept. For example, in FIG. 5 , for the clip A, the point P A2 is closest to the point P V1 , the point P A2 is closest to the point P V2 and the point P A1 is closest to the point P V3 . Hence, for clip A, the average of the distances d(P V1 ,P A2 ), d(P V2 ,P A2 ) and d(P V3 ,P A1 ) is calculated. In the same manner, by referring again to FIG. 5 , a calculation is made, for the clip B, of the average of the distances d(P V1 ,P B3 ), d(P V2 ,P B3 ) and d(P V3 ,P B3 ) and, for the clip C, of the average of the distances d(P V1 ,P C1 ), d(P V2 ,P C2 ) and d(P V3 ,P C3 ). From these, a degree of similarity is thus deduced for each of the three clips that is inversely proportional to the calculated average. The degree of similarity is for example the inverse of the calculated average.
[0068] Naturally, any other method making it possible to calculate the similarity between the salience map of the video sequence and the salience map of the advertising clip can be used to implement the step E 3 .
[0069] By referring again to FIG. 3 , the next step, referenced E 4 , consists in selecting, from all the advertising clips, the clip having the highest degree of similarity.
[0070] Finally, the advertising clip selected is inserted at a step E 5 into the video sequence at the insertion point of the video sequence. At the end of the method, an enhanced video sequence is obtained in which an advertising clip has been inserted.
[0071] Naturally, the selection of the advertising clip to insert can be more complex and combined with other selection processes. The clips contained in the set of advertising clips can already have been preselected according to their semantic content with respect to that of the video sequence into which it has been inserted. For example, a first preselection of clips can have been made according to the theme of the video sequence or of the text and/or objects contained in the video sequence or also according to the profile of the spectator.
[0072] The present invention also relates to a device for processing pictures referenced 100 in FIG. 6 that implements the method described above. In this figure, the modules shown are functional units that may or may not correspond to physically distinguishable units. For example, these modules or some of them can be grouped together in a single component, or constitute functions of the same software. On the contrary, some modules may be composed of separate physical entities. Only the essential elements of the device are shown in FIG. 6 . The device 100 notably comprises: a random access memory 110 (RAM or similar component), a read-only memory 120 (hard disk or similar component), a processing unit 130 such as a microprocessor or a similar component, an input/output interface 140 and possibly a man-machine interface 150 . These elements are connected to each other by an address and data bus 160 . The read-only memory contains the algorithms implementing the steps E 1 to E 5 of the method according to the invention. If the device is responsible for detecting a change in the video to sequence to insert an advertising clip into it, the memory also contains an algorithm for detecting shot changes. When powered up, the processing unit 130 loads and runs the instructions of these algorithms. The random access memory 110 notably comprises the operating programs of the processing unit 130 that are responsible for powering up the device, as well as the video sequence to process and the advertising clips to insert into this video sequence. The function of the input/output interface 140 is to receive the input signal (the video sequence and the advertising clips), and output the enhanced video sequence into which the advertising clips was inserted. Possibly, the operator selects the shot change into which the advertising clip is to be inserted by means of the man-machine interface 160 . The enhanced video sequence is stored in random access memory then transferred to read only memory to be archived with a view to possible future processing.
[0073] Although the invention has been described in relation to different particular embodiments, it is obvious that it is in no way restricted and that it comprises all the technical equivalents of the means described together with their combinations if the latter fall within the scope of the invention. Notably, the advertising clip can be inserted at points of the videos sequence that are not shot changes. The clip can for example be inserted at a specific point of the sequence defined in the metadata accompanying the video sequence. It can also possibly be inserted at regular intervals of time into the sequence. | The present invention relates to a method for processing pictures intended to insert an advertising clip at a point, called insertion, between two pictures of a sequence of video pictures, called video sequence, comprising the following steps:
generating a salience map representing the salience of the video sequence preceding the insertion point, generating, for each advertising clip of a set of advertising clips, a salience map, determining, for each advertising clip of said set of advertising clips, a degree of similarity between the salience map of the video sequence and the salience map of said advertising clip, said degree of similarity being representative of the comparison between the location of the salience zones on both said maps, selecting, among said set of advertising clips, the advertising clip having the highest degree of similarity, and inserting the advertising clip selected into the video sequence at the insertion point. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims all benefits accruing under 35 U.S.C. §119 from China Patent Application No. 201410423957.7, filed on Aug. 26, 2014, in the China Intellectual Property Office, disclosure of which is incorporated herein by reference.
FIELD
[0002] The subject matter herein generally relates to light emitting devices and display devices, in particular, to light emitting devices and display devices based on metamaterial.
BACKGROUND
[0003] Currently, liquid crystal displays (LCDs) are widely used.
[0004] Polarizer is used in the LCD to polarize the inputting light. The polarizer is a usually a film polarizer and will waste half of the incident light intensity. Thus, it not only reduces the brightness of the LCD but also waste the electric energy. Although an additional liquid crystal layer is used to replace the polarizer to polarize the incident light. However, the polarizations of the incident light are all based on far field operation.
[0005] What is needed, therefore, is to provide a light emitting device and a display device for solving the problem discussed above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Implementations of the present technology will now be described, by way of example only, with reference to the attached figures, wherein:
[0007] FIG. 1 is a schematic view of one embodiment of a light emitting device.
[0008] FIG. 2 is a cross-sectional view along line II-II of FIG. 1 .
[0009] FIG. 3 shows a plurality of metamaterial units in different shapes.
[0010] FIG. 4 is a Scanning Electron Microscope (SEM) image of one embodiment of a metamaterial unit.
[0011] FIG. 5 shows how the light emitting device of FIG. 1 works by irradiating from the front surface and outputting light from the back surface.
[0012] FIG. 6 is a polarization testing result of the light emitting device of FIG. 1 on the work mode of FIG. 5 .
[0013] FIG. 7 shows how the light emitting device of FIG. 1 works by irradiating from the back surface and outputting light from the front surface.
[0014] FIG. 8 is a polarization testing result of the light emitting device of FIG. 1 on the work mode of FIG. 7 .
[0015] FIG. 9 shows how a light emitting device of a compare embodiment works.
[0016] FIG. 10 is a polarization testing result of the light emitting device of FIG. 9 .
[0017] FIG. 11 shows testing results of transmission, reflection and absorption of a metamaterial layer in a far field of another compare embodiment.
[0018] FIG. 12 is a schematic view of one embodiment of a display device.
[0019] FIG. 13 is a schematic view of another one embodiment of a light emitting device.
[0020] FIG. 14 is a schematic view of another one embodiment of a light emitting device.
[0021] FIG. 15 is an SEM image of one embodiment of a metamaterial unit.
[0022] FIG. 16 is a schematic view of another one embodiment of a light emitting device.
[0023] FIG. 17 is a schematic view of another one embodiment of a light emitting device.
[0024] FIG. 18 is a schematic view of another one embodiment of a light emitting device.
[0025] FIG. 19 is a schematic view of another one embodiment of a light emitting device.
[0026] FIG. 20 is a schematic view of another one embodiment of a light emitting device.
DETAILED DESCRIPTION
[0027] It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures and components have not been described in detail so as not to obscure the related relevant feature being described. The drawings are not necessarily to scale and the proportions of certain parts may be exaggerated to better illustrate details and features. The description is not to be considered as limiting the scope of the embodiments described herein.
[0028] Several definitions that apply throughout this disclosure will now be presented.
[0029] The term “coupled” is defined as connected, whether directly or indirectly through intervening components, and is not necessarily limited to physical connections. The connection can be such that the objects are permanently connected or releasably connected. The term “outside” refers to a region that is beyond the outermost confines of a physical object. The term “inside” indicates that at least a portion of a region is partially contained within a boundary formed by the object. The term “substantially” is defined to be essentially conforming to the particular dimension, shape or other word that substantially modifies, such that the component need not be exact. For example, substantially cylindrical means that the object resembles a cylinder, but can have one or more deviations from a true cylinder. The term “comprising” means “including, but not necessarily limited to”; it specifically indicates open-ended inclusion or membership in a so-described combination, group, series and the like. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
[0030] References will now be made to the drawings to describe, in detail, various embodiments of the present light emitting devices and display devices based on metamaterial.
[0031] Referring to FIGS. 1-2 , a light emitting device 100 of one embodiment includes an insulative transparent substrate 110 , a metamaterial layer 120 and a light emitting layer 130 . The insulative transparent substrate 110 , the metamaterial layer 120 and the light emitting layer 130 are stacked with each other.
[0032] The metamaterial layer 120 is located on a surface of the insulative transparent substrate 110 . The light emitting layer 130 is located on a surface of the metamaterial layer 120 so that the metamaterial layer 120 is sandwiched between the insulative transparent substrate 110 and the light emitting layer 130 . The light emitting layer 130 covers the metamaterial layer 120 . Furthermore, an optional transparent protective layer (not shown) can be located on a surface of the light emitting layer 130 that is spaced from the metamaterial layer 120 .
[0033] The insulative transparent substrate 110 can be flat or curved and configured to support other elements. The insulative transparent substrate 110 can be made of rigid materials such as silicon oxide, silicon nitride, ceramic, glass, quartz, diamond, plastic or any other suitable material. The insulative transparent substrate 110 can also be made of flexible materials such as polycarbonate (PC), polymethyl methacrylate acrylic (PMMA), polyimide (PI), polyethylene terephthalate (PET), polyethylene (PE), polyether polysulfones (PES), polyvinyl polychloride (PVC), benzocyclobutenes (BCB), polyesters, or acrylic resin. The size and shape of the insulative transparent substrate 110 can be selected according to need. For example, the thickness of the insulative transparent substrate 110 is in a range from about 100 micrometers to about 500 micrometers. In one embodiment, the insulative transparent substrate 110 is a silicon dioxide layer with a thickness of 200 micrometers. If the metamaterial layer 120 and the light emitting layer 130 is free standing, the insulative transparent substrate 110 is optional.
[0034] The metamaterial layer 120 includes metamaterial which is artificial material engineered to have properties that have not yet been found in nature, such as negative refractive index. The metamaterial layer 120 includes a plurality of metamaterial units 122 arranged to form a periodic array. The plurality of metamaterial units 122 can be a plurality of bulges protruded from a surface of the insulative transparent substrate 110 or a plurality of apertures/holes defined by and extending through the insulative transparent substrate 110 . The plurality of bulges are spaced from each other so that the metamaterial layer 120 allows light to pass through. The shapes of the plurality of metamaterial units 122 can be the patterns as shown in FIG. 3 , or mirror image of the patterns of FIG. 3 , or the patterns of FIG. 3 being rotated. The patterns of the metamaterial units 122 of FIG. 3 can be , , , , , and .
[0035] The thickness h of the metamaterial units 122 can be in a range from about 30 nanometers to about 100 nanometers, the period of the metamaterial units 122 can be in a range from about 300 nanometers to about 500 nanometers, and the line width of the metamaterial unit 122 can be in a range from about 30 nanometers to about 40 nanometers. The size of the metamaterial unit 122 can be less than or equal to wavelength of the light emitted from the light emitting layer 130 . In one embodiment, the size of the metamaterial unit 122 in each direction is less than 100 nanometers. The material of the metamaterial layer 120 is metal which can generate surface plasmons (SPS). The metal can be gold, silver, copper, iron, aluminum, nickel or alloys thereof. The metamaterial layer 120 can be fabricated by treating a metal layer by focusing ion beam etching or electron beam lithography. In one embodiment, the metamaterial layer 120 is made by depositing a gold film on the surface of the silicon dioxide layer and focusing ion beam etching the gold film to obtain a plurality of strip-shaped apertures arranged to form a periodic array. The plurality of strip-shaped aperture are used as the metamaterial units 122 . The thickness of the gold film is 50 nanometers. The period of the strip-shaped apertures is 250 nanometers. As shown in FIG. 4 , the length of the strip-shaped aperture is 90.38 nanometers. The width of the strip-shaped aperture is 26.53 nanometers. As shown in Table 1 below, the metamaterial unit 122 can be classified into four categories according to the properties of chirality symmetry, isotropy and polarized light. The metamaterial units 122 of strip-shaped apertures are belong to category 4 of the Table 1.
[0000]
TABLE 1
Chirality
Categories
Symmetry
Isotropy
Classification of polarized light
1
Yes
Yes
Circularly polarized light
2
Yes
No
Elliptically polarized light
3
No
Yes
Non-polarized light
4
No
No
Linearly polarized light
[0036] The light emitting layer 130 includes photoluminescent material, such as semiconductor quantum dots, dye molecules or fluorescent powder. The semiconductor quantum dots can be PbS quantum dots, CdSe quantum dots or GaAs quantum dots. The diameter of the semiconductor quantum dot can be in a range from about 10 nanometers to about 200 nanometers. The dye molecules can be rhodamine 6G. The light emitting layer 130 is located on a surface of the metamaterial layer 120 and extends through the metamaterial layer 120 to be in direct contact with the insulative transparent substrate 110 . The surface of the light emitting layer 130 that is spaced from the metamaterial layer 120 can be flat or curved. The thickness H of the light emitting layer 130 can be in a range from about 50 nanometers to about 500 nanometers, such as from about 100 nanometers to about 200 nanometers. The light emitting layer 130 can be fabricated by spinning coating, spraying, printing, or depositing. In one embodiment, the light emitting layer 130 includes a polymer matrix 132 and a plurality of CdSe quantum dots 134 dispersed in the polymer matrix 132 . The thickness of the light emitting layer 130 is 100 nanometers. The light emitting layer 130 is made by dispersing the CdSe quantum dots 134 in photoresist to form a mixture solution, and then spinning coating the mixture solution on the metamaterial layer 120 .
[0037] The surface of the light emitting layer 130 that is spaced from the insulative transparent substrate 110 is defined as a front surface 102 . The surface of the insulative transparent substrate 110 that is spaced from the light emitting layer 130 is defined as back surface 104 . As shown in FIG. 5 , when the incident light 140 irradiate the light emitting device 100 from the front surface 102 , light emitted from the light emitting layer 130 will pass through the metamaterial layer 120 to output from the back surface 104 to form the emitted light 150 . Usually, the incident light 140 is laser light. As shown in FIG. 6 , the degree of linear polarization of the emitted light 150 from the back surface 104 is 95%. As shown in FIG. 7 , when the incident light 140 irradiate the light emitting device 100 from the back surface 104 , light emitted from the light emitting layer 130 will output from the front surface 102 directly to form the emitted light 150 . As shown in FIG. 8 , the linear polarization of the emitted light 150 from the front surface 102 is 10%. The linear polarization of the emitted light 150 of FIG. 5 is much greater than the linear polarization of the emitted light 150 of FIG. 7 . When the emitted light 150 pass through the metamaterial layer 120 , the linear polarization of the emitted light 150 is enhanced.
[0038] Usually, a light source with a distance far than a wavelength can be seen as a far field light source, and a light source with a distance close to 1/10 wavelength can be seen as a near field light source. The wavelength of visible light is in a range from about 390 nanometers to about 770 nanometers. Usually, the electromagnetic field is localized in the subwavelength scale near the surface of the metamaterials. Therefore, the light emitting layer 130 of visible light with a thickness less than 100 nanometers is within the near field domain of the metamaterial layer 120 , which guarantees the strong interaction between the metamaterial layer 120 and the light emitting layer 130 .
[0039] The metamaterial layer 120 can be regarded as a nano antenna array for the electromagnetic waves and will cause scattering to the electromagnetic waves nearby. According to the classical electromagnetic theory the electromagnetic waves that were previously emitted by the dipole sources undergo a series of scattering events on the antenna elements, which would rebound back and, in turn, work as the driving field for the dipole moments. Secondary emission would be induced, which influences the total emission fields through superimposing on the previously emitted fields. Notably, the secondary emitted field is polarized identically to the scattering driving fields. In one embodiment, the metamaterial layer 120 of FIG. 1 show different scattering strengths for orthogonally polarizations, the scattering along Y-direction could be enhanced, whereas the scattering fields along the X-direction is overwhelmed. As a result, the linearly Y-polarized emission in the far-field happens. According to the Fresnel rule and the boundary conditions of electromagnetic fields, the emitted light 150 on the back surface 104 has higher polarization.
[0040] Furthermore, as shown in FIGS. 9-10 , in one compare embodiment, the light emitting layer 130 is directly located on a surface of the insulative transparent substrate 110 without any metamaterial layer therebetween. When the incident light 140 irradiate the light emitting layer 130 from the front surface 102 , the emitted light 150 from the back surface 104 is non-linearly polarized light. Thus, the polarization property of the light emitting device 100 is caused by the metamaterial layer 120 .
[0041] In another compare embodiment, the transmission, reflection and absorption of the metamaterial layer 120 are tested when a far field plane wave light source is used to irradiate the light emitting device 100 . The far field plane wave light source emits white light, which would not activate the light emitting layer 130 to emit light, to irradiate the light emitting device 100 from front side 102 . As shown in FIG. 11 , Ty/Tx is about 5, where the Ty represents the transmission of the Y polarized light of the emitted light 150 and Tx represents the transmission of the X polarized light of the emitted light 150 . The linear polarization of the transmission light can be calculated by (I max −I min )/(I max +I min )=(5−1)/(5+1)˜67%. Therefore, the polarization of the metamaterial layer 120 for far field light source is about 67%, but for near field light source is about 95%. Therefore, the polarization of the emitted light 150 of the light emitting device 100 is not caused simply by the transmission of the metamaterial layer 120 , but caused by that the metamaterial layer 120 adjust the radiation rate of the light emitting layer 130 which is a near field light source.
[0042] The light emitting device 100 has following advantages. First, the brightness of the emitted light 150 can be enhanced because the plasmon resonance of the metamaterial layer 120 . Second, the light emitted from the light emitting layer 130 are polarized in nano-scale by the polarization of plasmon resonance of the metamaterial layer 120 so that the light emitting device 100 can emit polarized light directly.
[0043] Referring to FIG. 12 , a display device 10 is provided. The display device 10 includes the light emitting device 100 , a light guide plate 160 and a liquid crystal panel 170 . The light emitting device 100 , the light guide plate 160 and the liquid crystal panel 170 are stacked with each other in that order. The light guide plate 160 is located on the back surface 104 of the insulative transparent substrate 110 and sandwiched between the light emitting device 100 and the liquid crystal panel 170 . The light emitting device 100 is used as a light source of the display device 10 . Because the light emitting device 100 can emit polarized light directly, the display device 10 is simple and does not need other polarizer. The display device 10 can also include the light emitting devices 200 , 300 , 400 of embodiments below.
[0044] Referring to FIG. 13 , a light emitting device 200 of one embodiment includes the insulative transparent substrate 110 , the metamaterial layer 120 , the light emitting layer 130 and a reflection layer 180 . The insulative transparent substrate 110 , the metamaterial layer 120 , the light emitting layer 130 and the reflection layer 180 are stacked with each other.
[0045] The light emitting device 200 is similar with the light emitting device 100 except that the reflection layer 180 is located on and covers the light emitting layer 130 so that the light emitting layer 130 is sandwiched between the insulative transparent substrate 110 and the reflection layer 180 . The reflection layer 180 can be a metal film such as a gold film. Because part of the light that is emitted from the light emitting layer 130 and travel to the reflection layer 180 will be reflected by the reflection layer 180 to pass through the metamaterial layer 120 to output from the back surface 104 , the light emitting efficiency of the light emitting device 200 is enhanced.
[0046] In work of the light emitting device 200 , the incident light 140 can irradiate the light emitting device 200 from the back surface 104 or side surface 106 . The emitted light 150 output from the back surface 104 . In one embodiment, the incident light 140 irradiate the light emitting device 200 from entire side surface 106 so that more emitted light 150 can output from the back surface 104 .
[0047] Referring to FIG. 14 , a light emitting device 300 of one embodiment includes the insulative transparent substrate 110 , the metamaterial layer 120 , and the light emitting layer 130 . The insulative transparent substrate 110 , the metamaterial layer 120 , and the light emitting layer 130 are stacked with each other.
[0048] The light emitting device 300 is similar with the light emitting device 100 except that the metamaterial layer 120 includes a plurality of strip-shaped bulges arranged to form a periodic array and used as a plurality of metamaterial units 122 . The metamaterial layer 120 defined a plurality of spaces 124 between adjacent metamaterial units 122 . The light emitting layer 130 is wave-shaped and has a uniform thickness. The light emitting layer 130 has a plurality of first surfaces and a plurality of second surface depressed from the plurality of first surfaces. As shown in FIG. 15 , the plurality of metamaterial units 122 are arranged to form a two dimensional array. In one embodiment, the thickness of the strip-shaped bulges is 50 nanometers, the period of the strip-shaped bulges is 300 nanometers, the length of the strip-shaped bulge is 152 nanometers, and the width of the strip-shaped bulge is 116 nanometers.
[0049] Referring to FIG. 16 , a light emitting device 400 of one embodiment includes the insulative transparent substrate 110 , the metamaterial layer 120 , and the light emitting layer 130 . The insulative transparent substrate 110 , the metamaterial layer 120 , and the light emitting layer 130 are stacked with each other.
[0050] The light emitting device 400 is similar with the light emitting device 100 except that the plurality of metamaterial units 122 are a plurality of shaped apertures arranged to form a periodic two dimensional array. The plurality of shaped apertures is fabricated by etching a gold film. In one embodiment, the thickness of the gold film is 50 nanometers, the period of the shaped apertures is 400 nanometers, and the line width of the shaped aperture is 40 nanometers.
[0051] The light emitting devices 100 , 200 , 300 , 400 are all optical pumping light emitting devices and work by light irradiating. The light emitting devices 500 , 600 , 700 , 800 below are electric pumping light emitting devices and work by supplying a voltage or current.
[0052] Referring to FIG. 17 , a light emitting device 500 of one embodiment is a vertical structure light emitting diode (LED) and includes a first electrode 510 , a first semiconductor layer 520 , an active layer 530 , a second semiconductor layer 540 and a second electrode 550 .
[0053] The first electrode 510 , the first semiconductor layer 520 , the active layer 530 , the second semiconductor layer 540 and the second electrode 550 are stacked with each other in that order. The first electrode 510 is electrically connected to the first semiconductor layer 520 . The second electrode 550 is electrically connected to the second semiconductor layer 540 . At least one of the first electrode 510 and the second electrode 550 is a metal metamaterial layer, and the distance between the metal metamaterial layer and the active layer 530 is less than or equal to 100 nanometers. In one embodiment, the distance between the metal metamaterial layer and the active layer 530 is less than or equal to 50 nanometers. The active layer 530 can be seen as a near field light source of the metal metamaterial layer.
[0054] If the first semiconductor layer 520 is an N-type semiconductor, the second semiconductor layer 540 is a P-type semiconductor, and vice versa. The N-type semiconductor layer provides negative electrons, and the P-type semiconductor layer provides positive holes. The N-type semiconductor layer can be made of N-type gallium nitride, N-type gallium arsenide, or N-type copper phosphate. The P-type semiconductor layer can be made of P-type gallium nitride, P-type gallium arsenide, or P-type copper phosphate. The first semiconductor layer 520 can have a thickness of about 50 nanometers to about 3 micrometers. The second semiconductor layer 540 can have a thickness of about 50 nanometers to about 3 micrometers. If the first electrode 510 is a metal metamaterial layer, the thickness of the first semiconductor layer 520 should be less than 50 nanometers so that the distance between the first electrode 510 and the active layer 530 is less than 50 nanometers. If the second electrode 550 is a metal metamaterial layer, the thickness of the second semiconductor layer 540 should be less than 50 nanometers so that the distance between the second electrode 550 and the active layer 530 is less than 50 nanometers.
[0055] The active layer 530 is sandwiched between the first semiconductor layer 520 and the second semiconductor layer 540 . The active layer 530 is a photon exciting layer and can be one of a single quantum well layer or multilayer quantum well films. The active layer 530 can be made of gallium indium nitride (GaInN), aluminum indium gallium nitride (AlGaInN), gallium arsenide (GaSn), aluminum gallium arsenide (AlGaSn), gallium indium phosphide (GaInP), or aluminum gallium arsenide (GaInSn). The active layer 530 , in which the electrons fill the holes, can have a thickness of about 0.01 micrometers to about 0.6 micrometers.
[0056] The first electrode 510 may be a P-type or an N-type electrode and is the same type as the first semiconductor layer 520 . The second electrode 550 may be a P-type or an N-type electrode and is the same type as the second semiconductor layer 540 . The thickness of the first electrode 510 can range from about 0.01 micrometers to about 2 micrometers. The thickness of the second electrode 550 can range from about 0.01 micrometers to about 2 micrometers. The material of the first electrode 510 and the second electrode 550 is metal such as gold, silver, copper, iron, aluminum, nickel, titanium, or alloys thereof.
[0057] In one embodiment, the first semiconductor layer 520 is an N-type gallium nitride layer with a thickness of 0.3 micrometers, and the second semiconductor layer 540 is a P-type gallium nitride layer with a thickness of 100 nanometers, and the active layer 530 includes a GaInN layer and a GaN layer stacked with each other and has a thickness of about 0.03 micrometers. The first electrode 510 is N-type electrode and includes a nickel layer and a gold layer. The thickness of the nickel layer is about 15 nanometers. The thickness of the gold layer is about 200 nanometers. The second electrode 550 is P-type electrode and includes a metal metamaterial layer having the same pattern as the metamaterial layer 120 of FIG. 16 and a thickness of 100 nanometers.
[0058] In work, a voltage is supplied to the light emitting device 500 through the first electrode 510 and the second electrode 550 . The active layer 530 is activated to produce photons. The photons output from the second electrode 550 . Because the second electrode 550 is a metal metamaterial layer spaced from the active layer 530 with a distance less than 100 nanometers, the light emitting rate of the active layer 530 can be enhanced by the plasmons of the metal metamaterial layer. Furthermore, the light emitting device 500 can emit polarized light directly because of the polarization of the metal metamaterial layer.
[0059] In anther embodiment, both the first electrode 510 and the second electrode 550 is metal metamaterial layer, and both the first semiconductor layer 520 and the second semiconductor layer 540 has thickness less than 100 nanometers. The photons produced from the active layer 530 can output from both the first electrode 510 and the second electrode 550 .
[0060] Referring to FIG. 18 , a light emitting device 600 of one embodiment is a vertical structure LED and includes a reflection layer 580 , a first electrode 510 , a first semiconductor layer 520 , an active layer 530 , a second semiconductor layer 540 and a second electrode 550 .
[0061] The light emitting device 600 is similar with the light emitting device 500 except that a reflection layer 580 is located on a surface of the first electrode 510 that is spaced from the first semiconductor layer 520 . The reflection layer 580 covers the first electrode 510 . Because part of the light that is emitted from the active layer 530 and travel to the reflection layer 580 will be reflected by the reflection layer 580 to pass through, be polarized and enhanced by the metal metamaterial layer of the second electrode 550 , the light emitting efficiency of the light emitting device 600 is enhanced.
[0062] Referring to FIG. 19 , a light emitting device 700 of one embodiment is a horizontal structure LED and includes a substrate 560 , a first electrode 510 , a first semiconductor layer 520 , an active layer 530 , a second semiconductor layer 540 and a second electrode 550 .
[0063] The light emitting device 700 is similar with the light emitting device 500 except that part of the first semiconductor layer 520 is exposed to form an exposed part, and the first electrode 510 is located on the exposed part of the first semiconductor layer 520 . In one embodiment, the substrate 560 , the first semiconductor layer 520 , the active layer 530 , the second semiconductor layer 540 and the second electrode 550 are stacked with each other in that order. The area of the active layer 530 , the second semiconductor layer 540 and the second electrode 550 are the same and smaller than that of the first semiconductor layer 520 so that part of the first semiconductor layer 520 is exposed. The second electrode 550 is a metal metamaterial layer spaced from the active layer 530 with a distance less than 100 nanometers.
[0064] Referring to FIG. 20 , a light emitting device 800 of one embodiment is a LED and includes a first electrode 510 , a first semiconductor layer 520 , an active layer 530 , a second semiconductor layer 540 , a second electrode 550 and a metal metamaterial layer 570 .
[0065] The light emitting device 800 is similar with the light emitting device 500 except the metal metamaterial layer 570 . The metal metamaterial layer 570 is located on a side surface of the light emitting device 800 that is perpendicular with each of the first electrode 510 , the first semiconductor layer 520 , the active layer 530 , the second semiconductor layer 540 , and the second electrode 550 . In one embodiment, the light emitting device 800 is a cuboid and has four side surfaces. The metal metamaterial layer 570 is located on only one of the four side surfaces. The other three side surfaces can also be coated with metal reflection films. The first electrode 510 and the second electrode 550 can also be a metal metamaterial layer. The metal metamaterial layer 570 has a pattern same as that of the metamaterial layer 120 of FIG. 1 . Because the metal metamaterial layer 570 is in direct contact with the active layer 530 , the photons produced from the active layer 530 and output from the metal metamaterial layer 570 on the side surface can be enhanced and polarized by the metal metamaterial layer 570 . Thus, the light emitting device 800 has an enhanced brightness and can emit polarized light directly.
[0066] The embodiments shown and described above are only examples. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the detail, including in matters of shape, size and arrangement of the parts within the principles of the present disclosure up to, and including, the full extent established by the broad general meaning of the terms used in the claims.
[0067] Depending on the embodiment, certain of the steps of methods described may be removed, others may be added, and the sequence of steps may be altered. The description and the claims drawn to a method may include some indication in reference to certain steps. However, the indication used is only to be viewed for identification purposes and not as a suggestion as to an order for the steps. | The disclosure relates to a light emitting device. The light emitting device includes an insulative transparent substrate, a light emitting material layer, and a metal metamaterial layer. The metal metamaterial layer is located between the insulative transparent substrate and the light emitting material layer. The metal metamaterial layer includes a number of periodically aligned metamaterial units. Because the plasmon of the metamaterial can control electromagnetic properties in nanoscale, light from the light emitting device can be polarized in nanoscale. Thus, the light emitting device can emit polarized light. The display device using the light emitting device is also provided. | 1 |
This is a Division of Ser. No. 08/716,687 filed Sep. 16, 1996 now U.S. Pat. No. 5,810,241 issued Sep. 22, 1998.
FIELD OF THE INVENTION
The present invention, generally, relates to a method and apparatus for soldering small components automatically and, more particularly, to a new and improved component handling technique.
Prior U.S. Pat. No. 4,937,006 to Bickford et al. and assigned to the same Assignee as the present invention relates to a structure and method with which this invention is functional. Therefore, the description therein is incorporated by reference into the present description.
BACKGROUND OF THE INVENTION
Equipment and apparatus for handling microelectronic components during assembly, disassembly and rework phases must have an arrangement whereby the extremely small components are grasped for transporting and positioning accurately. In the past, such an arrangement has; included a small nozzle-like structure with its larger end formed to fit the equipment or apparatus with which it is being used and its smaller end formed to receive the component to be handled.
In the microelectronic industry, there are dozens of these extremely small components varying in size from several millimeters down to a fraction of one millimeter, each requiring equipment with special tools in order to pick up, transport and position each component. The equipment to move and otherwise handle these extremely small components has been standardized with all adjustments needed to operate.
However, to avoid the necessity of making adjustments to this apparatus every time a different component is to be placed, it has become the standard practice to size the nozzle-like structure end to receive the component within the end surface, so that the apparatus can be adjusted to position the end surface accurately relative to that end. A component of a different size must have its own nozzle-like structure sized to receive it within that end, so it will not project out requiring another adjustment in order to place it accurately.
This practice has worked well for many years, but with the recent increase in technological advances, usage of this equipment has increased also, because of the increased need for building the circuits using smaller and smaller components. Requiring different component-receiving ends for each different component has become almost a nightmare, because of the need to correlate these ends and the components in a practical manner.
REVIEW OF THE PRIOR ART
U.S. Pat. No. 4,767,047 to Todd et al. describes a device for grasping a component by suction and heating the solder that holds it in place to soften the solder, whereby the component is removed from a substrate.
U.S. Pat. No. 4,844,325 to Nishiguchi et al. describes apparatus with a collect to grasp a semiconductor chip by the use of a vacuum pump and blowing an inert gas to heat the entire assembly.
U.S. Pat. No. 5,222,655 to Moretti et al. describes apparatus with an open-channeled member for holding an element by a vacuum and a heated gas system to heat the element for soldering.
It is well recognized that soldering involves the application of heat in order to melt the solder so that it adheres to surfaces for creating both electrical and physical connections. It is recognized also in the microelectronics industry particularly that all such applications of heat must be controlled to avoid damage.
OBJECTS AND SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a method and a device to permit an object to be grasped and retained for moving and positioning accurately in a cost effective manner.
Another object of the present invention is to provide a method and apparatus that avoids previous problems of having to correlate electrical objects with object-handling equipment.
Briefly, the present invention involves forming a nozzle that has a larger end and a smaller end, the larger end being to fit standard, object.-handling equipment. The size and configuration of the smaller end is determined to receive a larger object. Forming an insert to be received within the smaller end opening of the nozzle. Forming the insert with an opening to receive a selected object to be handled. By changing inserts, objects of different sizes and configurations are handled readily.
These and other objects, features and advantages of the present invention will become more readily apparent from the following detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in elevation illustrating the insert of the present invention in an operative relationship with a nozzle as an aid in describing the invention in more detail.
FIG. 2 is a plan view of the nozzle of FIG. 1.
FIG. 3 is a plan view of one step in the process of fabricating an insert in accordance with the present invention.
FIG. 4 is a plan view of the insert fabricated according to the present invention with portions folded, as will be described in more detail hereinafter.
FIG. 5 is a view in elevation of the insert alone with portions folded as a further aid in the following description.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 of the drawings illustrates significant aspects of the invention, in that the numeral 10 identifies a nozzle having a larger end 11 and a smaller end 12. The larger end 11 is formed to make the nozzle 10 readily attachable to a movable apparatus to position a component relative to a fixed-location, such as to position a chip for soldering to a circuit of a substrate.
The smaller end 12 of the nozzle 10 is larger than the size of a component that is to be handled, but an insert 13 is located over the smaller end 12 to make the opening appropriate for receiving a component. By "appropriate" is meant that such component must fit closely within the opening without binding.
It is the custom in the art to form the nozzle 10 with a small opening for the purpose of receiving a particular component closely without binding, and the component is received completely inside of the nozzle so that the equipment to which the nozzle 10 is attached need be adjusted only once for positioning the small end relative to its final location to deliver the component it carries. However, according to the present invention, it is the insert 13 that determines the opening size, which means that only one size of nozzle 10 is necessary for a range of component sizes.
The insert 13 is formed, according to the present invention, with a number of flaps 14 extending around the border and bent to fit the slope of the nozzle 10. The friction between the flaps 14 against the slope of the nozzle is useful to retain the insert 13 over the opening in the smaller end 12.
A negative pressure is created within the nozzle by a vacuum pump usually connected by means of a pipe 15 to draw and to retain a component within the small end of the nozzle. More details concerning the structure of the insert 13, in accordance with the present invention, will be described presently hereinafter.
FIG. 2 of the drawings shows the nozzle 10 along the line 2--2 in FIG. 1. The flaps 14a and 14b are visible since they are on the outside of the nozzle, and flaps 14c and 14d are illustrated in dotted lines since they are on the inside of the nozzle.
In accordance with the present invention, the insert 13 is formed from a single sheet, illustrated in FIG. 3 of the drawings, that is approximately 1.500 inches square. This dimension is only approximate because it may vary with different nozzle arrangements with which it is adapted to fit.
The important feature that the insert 13 represents is that the nozzle end 12, seen in FIG. 2, is made with a larger opening than required for the smallest component, and the insert provides a way of obtaining the correct opening size, and shape, for each component to be picked up, transported and positioned correctly and accurately by equipment used for that purpose. Therefore, other and different ways may be provided by those skilled in this art for making this larger opening in a nozzle smaller as required for different sizes of components.
In FIG. 3, the four flaps are illustrated, and the opposite flaps 14a and 14b are identified more clearly, as are the opposite flaps 14c and 14d. While the length of the flaps 14 may vary and can be formed in accordance with various needs, it is found that a length of 1.5 inches from one edge 16 on the flap 14a to the edge 17 on the flap 14b is entirely satisfactory.
As described, supra, a central opening is formed in accordance with the dimensions of a particular component to be handled, such as a particular flip chip to be removed from a soldered position on a substrate and transported to a different location for reworking. With the nozzle 10 of the invention, only the insert 13 is needed.
FIG. 4 of the drawings illustrates a view of the insert 13 alone as it is seen from the line 2--2 in FIG. 1. That is, the two flaps 14a and 14b are extended over the outside surface of the nozzle while the two flaps 14c and 14d are on the inside of the nozzle and not visible.
FIG. 5 is a view of the insert 13 alone with the flaps 14a, 14b and 14c being visible, and a view of the flap 14d is blocked by the flap 14c.
While the invention has been described in substantial detail with what is presently considered to be the most practical and the presently preferred embodiment, it is to be understood that the invention is not limited by the embodiment described, but rather, the invention is intended to include various modifications and the equivalent arrangements that are covered by the spirit and scope of the appended claims. Therefore, anyone skilled in this field should understand that all such alterations and changes are included within the scope of the following claims. | In an apparatus for soldering/desoldering components having a nozzle with larger and smaller ends, the larger end for attaching to an exhaust for drawing a vacuum and to a supply of heated gas for at least softening solder, an insert is attached at the smaller end of the nozzle to adjust the size of that opening for receiving each of a plurality of components, fitting different inserts to different sizes of components. | 7 |
FIELD AND BACKGROUND OF THE INVENTION
This invention relates in general to sewing machines and in particular to a new and useful sewing machine feed mechanism which operates with very low inertia.
A sewing mechanism similar to the present invention is disclosed in U.S. Pat. No. 3,742,879. That prior art feed mechanism comprises two swing arms designated X and Y, which are mounted on fixed bolts and carry each a stepping motor as a positioning drive. The stepping motor secured to the Y arm drives through a pinion a geared rack which is mounted for displacement in the Y arm and hinged to the X arm. The stepping motor secured to the X arm drives, through the pinion, a geared rack which is mounted for displacement in the X arm and to which a work holder is secured. Even though the two-member drive linkage of this reference reduces the number of component parts to be moved, as compared to a prior art four member drive linkage, known for example from U.S. Pat. No. 3,983,845, inertia of this mechanism is still relatively too high since the stepping motors are secured to the swing arms and therefore are moved along with the arms.
A low inertia mechanism for driving a fabric clamp comprising a single sewing arm is known from U.S. Pat. No. 3,974,787. This is a telescopic structure where a slide is mounted in a swing carrier. Two stationary stepping motors drive the swing carrier and the slide by means of two ropes trained about rollers which are partly fixed and partly carried on the swing arm. The advantageous low inertia is outweighed by the disadvantage that this drive system is suitable only for small seam patterns, thus with a large radial displacement of the swing arm, a retracted swing arm produces small angular increments of the fabric clamp per step of the driving motor, while an extended swing arm causes large such increments. A relatively expensive stepping motor system would therefore be needed for driving the swing carrier, to obtain a highly accurate and fast feed, namely a system with small steps and a large stepping frequency.
Among other drawbacks, the ropes may become permanently extended, for example due to the material fatigue with the result of transmitting the motor steps inaccurately, or the drive system may oscillate at certain frequencies because of the shock absorbing springs provided between the machine frame and the stepping motors.
SUMMARY OF THE INVENTION
The present invention is directed to a low inertia feed device which is simple in construction and always accurately executes the control instructions supplied to the positioning motors, irrespective of whether the sewing pattern is small or large.
The two-member design of the linkage, mounting of the swing arm on slides which are driven by stationary positioning motors, and a slip-free positive drive connection between the motors and the slides, result not only in a low inertia of the system but also in a high accuracy in transmission of the movements to the work holder. The positive connection may be effected by a cog belt, geared rack, or screw spindle drive. Electrical or hydraulic stepping motors, or position controlled DC drives may be employed as the positioning motors.
Since the feed movements of the work holder are affected by shifting a slide and thus displacing the pivotal axes of the swing arms and, consequently, the length of the swing arms and spacing of the work holder from the pivotal axes do not vary, uniform steps of the positioning motors cause substantially constant displacements of the work clamp at any location of the sewing pattern. No modification of drive conditions need therefore be provided for small and large sewing patterns, or within large patterns. The inventive feed mechanism is universally usable for producing any sewing pattern.
With the design of the swing arm the spring steel strips are sufficiently prestressed to completely take up maximum bending loads introduced by the coupled swing arm, so that the center bar is subjected only to loads acting in the longitudinal direction thereof. It is therefore satisfactory to make the central bar resistant only to buckling. A non-buckling bar may be embodied simply by a low inertia hollow or I section of a light metal alloy. Since a sufficient prestressing may already be obtained with relatively thin and thus also light spring steel strips, the entire swing arm has a very small mass. The inertia of the feed mechanism is thus further reduced. Sufficiently prestressed spring steel strips make sure in addition that the swing arm cannot elastically bend under shocks. This still increases the accuracy transmission of the linkage.
The feature of a low inertia swing arm resistant to bending is not limited to feed mechanisms with two-member design of the linkage, it may advantageously be applied also to feed mechanisms of different design. To ensure an exactly equal prestressing of both of the steel spring strips, a clamping machanism may be associated with each of them.
In accordance with the invention, a sewing machine feed mechanism for a sewing machine having a needle which reciprocates over a support along which a workpiece is moved, comprises a work holder which is moved by two swing arms, each of which has one end which is pivotally mounted on a movable slide. One of the swing arms includes the transversely extending cross bar which is braced against a workpiece holder. The pivotal ends of each swing arm are moved along guide paths by stepping motors. The two swing arm members driven by the stationary motors results in a lightweight and unbending swing arm connection to the workpiece holder. One swing arm which is directly connected to the work holder includes a non-buckling center bar, a transverse bar at its end which is braced against the work holder and two prestressed spring steel strips which connect the ends of the cross bar to the swing arm adjacent its pivotal connection to the movable slides.
Accordingly, it is an object of the invention to provide an improved drive for a workpiece of a sewing machine in which a non-bending connection to the workpiece holder is effected with very low inertia of the feed mechanism.
A further object of the invention is to provide a feed mechanism which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a top plan view of a sewing assembly constructed in accordance with the invention;
FIG. 2 is a front elevation of the sewing machine of FIG. 1;
FIG. 3 is an enlarged sectional view taken along the line III--III of FIG. 1; and
FIG. 4 is a sectional view taken along the line IV--IV of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in particular the invention embodied therein comprises a feed mechanism for a sewing machine 3 having a needle 9 which reciprocates over a support for supporting plate 13 along which a workpiece is moved. The arrangement includes a work holder 10 which is moved by engagement of a cross member or cross bar 17 of a first swing arm assembly generally designated 15. The assembly 15 includes a first swing arm having a center arm portion 16 with a pivotal end pivotal on a pin 61 and an opposite end carrying the cross bar 17. The cross bar 17 extends outwardly from each side of the center arm 16. A second swing arm 34 has a first pivotal end pivotally mounted on a pin or bolt 39 and a second pivotal end opposite to the first end which is pivotally connected to the center arms 16 adjacent the end thereof which is connected to the cross bar 17. Means are provided for the control displacement of the pivotal end of each arm 16 and 34. This includes a first slide 62 pivotally supporting the pivotal end of the center arm 16 and a second slide 36 pivotally supporting a first pivotal end of the arm 34. The respective slides are moved along selected slide movement paths by stepping or positioning motors 55 and 69 respectively.
On a frame 1, a table plate 2 is supported to which a sewing machine 3 is secured. The sewing machine comprises a base plate 4, a post 5, and an arm 6 terminating with a head 7. Within head 7 a needle bar 8 is mounted in a manner known per se, carrying a needle 9.
The work to be sewed is clamped in a work holder 10 comprising a plate 11 for frictionally engaging the work, in which an aperture 12 having a shape corresponding to the seam to be produced is provided permitting the needle 9 to pass therethrough. Plate 11 is supported on a supporting plate 13 having a common upper level with base plate 4 of the sewing machine.
By means of tommy screws 14, work holder 10 is detachably connected to a swing arm 15 comprising a non-buckling center bar 16 having an I section (FIG. 4), and a cross bar 17 which is braced against center bar 16 by two gussets 18 and has two forked end extensions 19, 20. To each of these extensions, a spring steel strip 21, 22 is secured by its end. By its other end, each of these strips 21, 22 is secured to a clamping mechanism 31. Clamping mechanism 31 comprises a fork head 23, 24 with a threaded neck 25, 26 and an adjusting nut 27, 28.
The threaded necks 25, 26 are passed through extensions 29, 30 of center bar 16. Center bar 16 and cross bar 17 are made of a light metal alloy. Since spring steel strips 21, 22 can be made relatively thin, the inertia of the swing arm assembly 15 is low.
Center bar 16 is provided with an eye 32 (FIG. 4) in which a hinge bolt 33 is received. By means of bolt 33, the forked end forming two eyes of a swing arm 34 is hinged to center bar 16. Swing arm 34 also has an I section and is made of a light metal alloy. Bolt 33 is secured axially by two lock washers 34 (FIG. 4).
The other end of swing arm 34 is hinged to a slide 36. As shown in FIG. 3, this hinge connection comprises a bolt 39 which is secured to slide 36. Two ball bearings 37, 38 held axially by two lock washers 40, 41, two spacers 42, 43, and a plain washer 44. By means of a ball guide 45, slide 36 is displaceable on a slide rod 46 having its ends fixed in two clamps 47, 48 which are secured to table plate. Parallel to slide rod 46, a channel section guide rail 49 is secured to table plate 2 by one its leg portion. The other leg portion designated 50, of guide rail 49 forms two running surfaces for rollers 52, 54 which are carried on threaded bolts 51, 53 secured to slide 36, and are applied against portion 50 from above and below, respectively.
To the underside of table plate 2, a stepping motor 55 is secured. The shaft 56 of motor 55 is passed through table plate 2 and carries a cog wheel or gear 57 for a cog belt or gear belt 58. Belt 58 is further trained about a tail wheel 59, with the belt sections between wheels 57 and 59 extending parallel to slide rod 46. Cog belt 48 is firmly connected to slide 36 through a conformable pressure plate 60.
The other end of swing arm 15, opposite to hinge bolt 33, is hinged to a bolt 61 which is secured to a slide 62. This hinge connection is identical with that between swing arm 34 and slide 36 through bolt 39. Also identical is the mounting of slide 62 for displacement on a slide rod 63. Further, through two rollers (not shown), slide 62 applies against a guide rail 64 extending parallel to slide rod 63. Through a conformable pressure plate 65, slide 62 is connected to a cog belt 66. The belt is trained about a cog wheel 67 carried on the shaft 68 of a stepping motor 69 which is secured to the underside of table plate 2 and about a tail wheel 70 mounted for rotation on plate 2.
Stepping motors 55, 69, slides 36, 62 and swing arms 15, 34 form together with work holder 10 a feed mechanism 71.
The sewing assembly operates as follows:
The assembly is intended for sewing pockets on trousers for example, and forms a part of a larger operating unit comprising also a doubling station (not shown). At the doubling station, the pocket edges are folded in a manner known per se, and then the pocket is put in place on the trousers. Thereupon, work holder 10 detached from swing arm 15 is placed against the pocket and the trousers in such a position that aperture 12 coincides with the area of the seam. Next, work holder 10, now frictionally engaging the trousers and the pocket, is moved on supporting plate 13 to reestablish its connection with swing arm 15. Since the detachable connection between work holder 10 and swing arm 15 is not included in the subject matter of the present invention, this connection is indicated, for clarity, in a very simplified manner by tommy screws 14 to be actuated manually.
After work holder 10 has been connected to swing arm 15, the working cycle of the sewing assembly is started. With the sewing machine 3 initially at standstill, work holder 10 is moved from its rest position shown in FIG. 1 into its sewing position, by a program controlled action of stepping motors 55, 69 executing a corresponding number of drive steps. The control of stepping motors 55, 69 may be effected through a microcomputer (not shown) by which the number of drive pulses necessary for each of the motors is computed from position data recalled from a storage. Stepping motors 55, 69 drive cog belts 58, 66 by which slides 35, 62 are displaced on slide rods 46, 63. The motion of slides 36, 62 is transmitted to the respective swing arms 15, 34, whereby work holder 10 is displaced on supporting plate 13 relative to sewing machine 3 in accordance with the program, until the location at which the seam is to start is vertically aligned with needle 9. Then the sewing machine 3 is started and the desired seam is produced, with the stepping motors 55, 69 being controlled by the program.
While being displaced from its rest position to its sewing position, work holder 10 can be moved substantially continuously. During the sewing operation, however, it is moved only when needle 9 is not engaged in the work, so that it moves intermittently. The jerky stepwise movements thus transmitted from swing arm 34 to swing arm 15 act on the latter as bending loads with the maximum bending moment appearing in the area of hinge bolt 33. By correspondingly adjusting the two clamping mechanisms 31, the tension in spring steel strips 21, 22 is adjusted to amounts such that the maximum bending loads introduced by swing arm 34 are entirely taken up by strips 21, 22, and center bar 16 is exposed only to normal forces acting in the longitudinal direction thereof. Therefore, swing arm 15 cannot be elastically bent by the intermittent drive movements of swing arm 34.
The non-bending construction of swing arm 15 and the low inertia of the entire feed mechanism, as well as the slip-free drive connections between stepping motors 55, 69 and slides 36, 62 result in a highly accurate transmission of the movements produced by motors 55, 69 to work holder 10.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | A sewing assembly equipped with a feed mechanism comprises a work holder which is supported by two swing arms hinged to each other, and moved by two stationary positioning motors. Each of the positioning motors is in positive drive connection with a slide carrying one of the swing arms. The swing arm directly carrying the work holder comprises a non-buckling center bar, a cross bar, and two prestressed spring steel strips by which the ends of the cross bar are connected to the end close to the swing axis of the center bar. The two member linkage with the stationary motors and the light-weight and yet non-bending swing arm result in a very low inertia of the feed mechanism. | 3 |
FIELD
[0001] The present inventive concept relates generally to the delivery of fluids in the context of the lawn and garden industry. In particular, the general inventive concept relates to the delivery of fluids at specified droplet size, pressure, spray pattern, and dispersal location relative to the target. Specifically, the invention relates to an apparatus and related methods for efficiently and economically delivering various agricultural, horticultural, and gardening fluids, including but not limited to herbicides and fertilizers, to a targeted location in a manner that limits the physical exertion typically required of users for such applications and is highly precise and accurate, thus reducing the likelihood and extent of missing the target.
BACKGROUND
[0002] Agricultural, horticultural, and gardening endeavors often use fluids such as herbicides, pesticides, fertilizers and related products for a number of reasons, such as to maximize yield or to promote intended aesthetic design. The manner of delivery of these fluids often presents a quandary to users, whether the user is an individual or a larger scale commercial operation in the field at large. For example, the application of herbicides and other fluids often involves repetitive actions that can be physically taxing and labor intensive to the user, which can lead to fatigue, which in turn can lead to accidents, mistakes, injury or even death. Additionally, the matter of proper application of an herbicide or other fluid presents problems of efficient product use and effective product application.
[0003] Many devices and methods are available to assist in the application of agricultural fluids. Some examples include: U.S. Published Patent Application No. 2010/0288853; U.S. Published Patent Application No. 2011/0253803; U.S. Pat. No. 3,692,512; U.S. Pat. No. 6,190,077; U.S. Published Patent Application No. 2006/0049214; U.S. Published Patent Application No. 2005/0029310; U.S. Published Patent Application No. 2010/0044456; U.S. Pat. No. 5,419,078; and U.S. Published Patent Application No. 2005/0082389. Some additional examples include: U.S. Pat. No. 5,108,036; European Patent Publication No. 0 487 800; European Patent Publication No. 0 300 762; U.S. Pat. No. 6,443,368; U.S. Pat. No. 6,029,589; U.S. Pat. No. 7,036,751; U.S. Pat. No. 6,595,437; U.S. Pat. No. 6,047,900; U.S. Published Patent Application No. 2007/0119972; U.S. Published Patent Application No. 2010/0163646; U.S. Published Patent Application No. 2012/0223160; U.S. Pat. No. 5,395,052; U.S. Pat. No. 5,822,968; U.S. Pat. No. 6,367,714; U.S. Pat. No. 6,663,307; U.S. Pat. No. 7,588,198; and U.S. Pat. No. 8,083,155.
[0004] All of the above referenced examples have shortcomings. Some examples of the shortcomings of the prior art include requiring too much fluid. Often, the fluids to be dispersed require such high volumes that the fluid is sold in a concentrated state. These fluids must be diluted to reach optimal volume and concentration levels. Problems are encountered when fluid levels are too concentrated or too diluted, compromising effectiveness and potentially damaging plants and animals in the vicinity. A greater volume of fluid is heavier and bulkier than a lesser volume, increasing the physical exertion required for proper transport and use. The fluids being dispersed are expensive and environmental conditions such as wind can make it difficult to disperse the fluids in the intended quantities and limited to a specific target area. In other words, spraying too much results in waste and harm to nearby plants while spraying too little compromises effectiveness.
[0005] The inventors have developed new devices and related methods to overcome these and other shortcomings of the prior art. The inventors have discovered that by dispersing fluids at relatively high pressure and using a mist of preferred droplet size, a much lesser volume of concentrated fluids can be used to achieve the same or greater effectiveness at the same or lower costs than the prior art.
SUMMARY
[0006] One object of the present inventive concept is to provide a portable motorized fluid delivery device apparatus. The device includes a handle that is ergonomically designed to be comfortably held by the user with one hand. The handle is sized and shaped such that it can contain fluid. The handle also includes an electrical switch that, when activated, controls the dispersal of fluid. The switch is connected to an electrical power source.
[0007] The device includes an elongated shaft that extends away from the handle. At the end of the shaft are a base and a nozzle. The device includes an electrical motor and fluid pump. The electrical motor and fluid pump are connected to the switch and power source such that the fluid is pumped from the container in the handle, down the shaft and out through the nozzle in the base. The fluid is dispersed in a special spray pattern such that it exits the nozzle at approximately 10 to 45 psi and the fluid droplets are medium to coarse (100 to 450 microns) in size.
[0008] In some exemplary embodiments discussed in further detail below, the fluid is an herbicide and/or indicator (e.g., colored dye), the handle includes a removable container to hold and transfer the fluid, and the base includes a hood that surrounds the nozzle and extends beyond the point where fluid is ejected from the nozzle to aid the user in maintaining a consistent distance between the nozzle and the target and also to reduce the influence of wind and other environmental factors on fluid dispersal pattern after the fluid leaves the nozzle.
[0009] A device of the present inventive concept alleviates much of the fatigue and physical exertion typically associated with agricultural endeavors. For example, the application of herbicides and related liquids often involves bending, reaching, or straining to apply a given liquid to a particular target area of flora. A device of the present inventive concept virtually eliminates physical strain by virtue of a longitudinal shaft component that substantially reduces the need for bending, reaching, or straining. While many other devices require the user to carry a heavy container filled with the liquid to be applied to flora, a device of the present inventive concept greatly reduces this burden on the user by the efficiency of the nozzle component, which optimizes both droplet size and the pressure at which those droplets are applied to flora. When coupled with the hood component, the user is able to apply the liquid with a high degree of precision and efficiency. This uses a lesser volume of liquid, which permits the user to cover a larger area with a comparatively smaller volume of liquid. The hood component assists directionality of intended liquid dispersal, and it also serves the function of shielding the user from unintended spray that may arise in windy conditions. The hood is shaped in a generally conical or pyramid shape. While other devices require the user to impart manual activity to disperse a liquid (such as squeezing a trigger), which can lead to hand fatigue and possible physical maladies, a device of the present inventive concept solves this problem by incorporating an electrical motor component that can be activated with relative ease by the simple activation of a switch. A device of the present inventive concept significantly reduces the strain and physical exertion necessary for a user to engage in agricultural endeavors.
[0010] Additionally, a device of the present inventive concept offers improved precision and efficiency in delivering an herbicide or other liquid to a target area. A device of the present inventive concept achieves a high level of precision and efficiency by controlling the volume of liquid delivered and the pressure at which the liquid is delivered. The nozzle expels the liquid to a target area in a predetermined droplet size at a predetermined pressure optimized for delivery of the liquid to the target area. By utilizing such a nozzle, the liquid is delivered in a highly efficient manner, since the optimal droplet size and optimal pressure ensure that a minimal volume of liquid is used to achieve maximal effect (i.e., herbicidal properties). When the hood component is incorporated with a device of the present inventive concept, the precision and accuracy of liquid delivery is improved, while simultaneously shielding the user from potential exposure to the liquid droplets. By combining the hood component with the nozzle component, the liquid is delivered in an extremely precise and efficient manner to the target area. The incorporation of a dye also provides visual confirmation to the user that the intended area has been treated with the agricultural liquid. Thus, a device of the present inventive concept addresses the need for a device that delivers an agricultural liquid efficiently, which achieves the goals of reducing environmental impact and maximizing use of the liquid by only affecting targeted areas.
[0011] A device of the present inventive concept further includes an electrical motor. The incorporation of a motor removes the need for user manipulation of a trigger or other similar mechanism. The motor automates delivery of the agricultural liquid, while simultaneously removing user strain from the application process. The motor also interacts with the nozzle to deliver the liquid at an optimal pressure and at a controlled volume. The nozzle further controls droplet size, which optimizes precision and accuracy of application and also uses the liquid in a highly economical and efficient manner. The handle houses a container to hold liquid. The switch, which controls the motor component, is also located on the handle. A device of the present inventive concept may also incorporate an indicator component, such as a colored dye, which is added to the container of agricultural liquid. User movement mixes the indicator component and the agricultural liquid.
[0012] Another object of the present inventive concept is to provide a method of dispersing fluid by using a portable motorized fluid delivery device apparatus. The method includes adding a volume of fluid to the device. In some examples, the device includes a removable container to ease the handling of fluid transfer. The method further includes positioning the device such that the nozzle is located at a predetermined height directly over a target. In some embodiments, the hood component is sized and shaped such that it provides guidance to the user with respect to positioning the device. When the device is in the desired position, the electrical switch is activated such that the electrical motor engages the fluid pump to disperse a portion of the fluid from the handle of the apparatus, through the shaft, and out through the nozzle in the base. In some situations, the device is configured to disperse a predetermined volume of fluid automatically every time the switch is activated. In other situations, the device is configured to disperse fluid continuously until the switch is manually deactivated.
[0013] The user activates the motor component by turning the switch to the “on” position. The motor component then pumps the fluid (e.g., dye and herbicide mixture) from the container housed in the handle through the longitudinal shaft to the nozzle. The fluid is expelled through the nozzle at optimal droplet size and pressure for proper application to a target area. The hood component further ensures accurate placement of the liquid mixture to the target area, while also shielding the user from possible errant spray that can result in windy conditions.
[0014] When an indicator (e.g., a colored dye) is mixed with the fluid, additional advantages are realized. Once the dyed fluid is applied to a target area, the dye will show the user where the fluid has been applied. The dye dissipates after a period of time. Sometimes, the indicator is a liquid dye that is activated by ultraviolet light. The indicator acts as visual confirmation that the agricultural liquid has been applied to a target area. After a period of time, the indicator dissipates by virtue of its interaction with ultraviolet light, temperature, rain or other environmental factors.
[0015] Another object of the present inventive concept is to provide a method of manufacturing a portable motorized fluid delivery device apparatus. A switch, electronic circuitry to connect the switch to the power source and (eventually) the motor, and a sealed structure capable of containing a volume of fluid are arranged within a handle housing to form a handle of the device. A cavity capable of transferring fluids from one end of the shaft to the opposite end of the shaft and an electrical connection between opposing ends of the shaft are arranged alongside (i.e., non-coaxial) each other to form the elongated shaft of the device. An electrical motor, a fluid pump, and a nozzle are arranged within a housing to form a base of the device. The handle and base are affixed to the elongated shaft such that when the electrical switch is activated the electrical motor engages the fluid pump to disperse a portion of the fluid from the handle of the apparatus, through the shaft, and out through the nozzle in the base.
[0016] The foregoing and other objects are intended to be illustrative of the general inventive concept and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the entire specification and accompanying drawings comprising a part thereof. Various features and subcombinations of the general inventive concept may be employed without reference to other features and subcombinations. Other objects and advantages of the general inventive concept will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention and various features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and/or other aspects and utilities of the present general inventive concept will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings. For the purpose of illustration, forms of the present general inventive concept which are presently preferred are shown in the drawings; it being understood, however, that the general inventive concept is not limited to the precise arrangements and instrumentalities shown. In the drawings:
[0018] FIG. 1 is a perspective exterior view of an exemplary embodiment of the present general inventive concept.
[0019] FIG. 2 is an enlarged cutaway view of the base and distal shaft end of the exemplary embodiment of FIG. 1 .
[0020] FIG. 3 is an enlarged exterior view of the handle of the exemplary embodiment of FIG. 1 .
[0021] FIG. 4 is a perspective exterior view of a second exemplary embodiment of the present general inventive concept.
[0022] FIG. 5 is a top view of the exemplary embodiment of FIG. 4 .
[0023] FIG. 6 is a side view of the exemplary embodiment of FIG. 4 .
[0024] FIG. 7 is an enlarged perspective view of the handle of the exemplary embodiment of FIG. 4 .
[0025] FIG. 8 is an enlarged cutaway view of the handle of the exemplary embodiment of FIG. 4 .
DETAILED DESCRIPTION
[0026] The present general inventive concept provides a portable motorized fluid delivery device apparatus. The device includes a handle. The handle is ergonomically sized and shaped to be comfortably held by a user's hand(s). The handle includes a compartment where it can receive and hold a predetermined volume of fluid. In some embodiments, the fluid compartment is a container that is separable and removable from the device. In some embodiments, the fluid compartment includes a removable lid, such as a screw cap. In some embodiments, the fluid compartment is configured to hold approximately 16 ounces of fluid.
[0027] In some embodiments, the fluid is an herbicide. In some embodiments, the herbicide is mixed with an indicator, such as a colored dye. In some embodiments, the indicator is visible with unaided human eyesight in ordinary daylight. The incorporation of a dye provides visual confirmation to the user that the intended area has been treated with the fluid. Thus, a device of the present inventive concept addresses the need for a device that delivers an agricultural liquid efficiently, which achieves the goals of reducing environmental impact and maximizing use of the liquid by only affecting targeted areas. Use of the dye helps the user avoid inadvertent duplicate application of the fluid to overlapping target areas.
[0028] The handle also includes an electrical switch, which controls the dispersal of fluid. In some embodiments, the switch is located on the handle such that it can be easily activated by the user's thumb. In some embodiments, the switch is located on the handle such that it can be easily activated by the user's forefinger. In some embodiments, the switch is a simple switch, capable of being actuated between two positions—“on” and “off”. In some embodiments, the switch includes variable settings to vary the length of time that fluid is dispersed, the volume of fluid that is dispersed, or the intended distance from the nozzle to the target (which could depend in factors such as fluid viscosity, fluid pressure at the nozzle, or size and shape of the hood). In some embodiments, the switch is more complex.
[0029] The switch is connected to an electrical power source. In some embodiments, the power source is one or more electrical batteries, such as standard 9-volt, D size, or AA size batteries. In some embodiments, the one or more batteries are located within a cavity within the handle. In some embodiments, the one or more batteries are located within a cavity within the elongated shaft. In some embodiments, the one or more batteries are located within a cavity within the base of the device. In some embodiments, the power source is alternating current (NC) electrical power and the device is plugged in to the power source via an extension cord.
[0030] The device includes an elongated shaft. The elongated shaft extends outward and away from the handle. When in ordinary use, the shaft extends downward from the handle toward the ground. The shaft includes a cavity capable of transferring fluid from one end to the opposite end. At one end of the shaft that is proximal to the user, the shaft is connected to the handle. The shaft cavity is in fluid connection with the fluid compartment within the handle such that fluid can be pumped out of the handle and down through the shaft when the switch is activated. At the opposite end of the shaft, the end that is distal to the user, the shaft is connected to the base of the device. In some embodiments, the shaft is made of aluminum. In some embodiments, the shaft is about 30 inches in length.
[0031] The device includes an electrical motor and fluid pump. The electrical motor and fluid pump are connected to the switch and power source such that the fluid is pumped from the fluid compartment in the handle, down the shaft and out through a nozzle in the base when the switch is activated. In some embodiments, the motor and/or pump are located within the base of the device. In some embodiments, the motor and/or pump are located within the shaft of the device. In some embodiments, the motor and/or pump are located within the handle of the device.
[0032] In the base of the device is a nozzle. The nozzle is in fluid connection with the cavity of the shaft such that fluid can transfer out of the handle, through the shaft, through the base, and out the nozzle, when the switch is activated. The nozzle is sized and shaped to disperse fluid in a special spray pattern. The nozzle is sized and shaped such that, when the switch is activated and the pump is engaged, fluid exits the nozzle within the range of 10 to 45 psi. The nozzle also sized and shaped such that the fluid droplets expelled from the nozzle are medium to coarse in size, which means that the fluid droplets are between 100 and 450 microns in size.
[0033] In some embodiments, the base includes a hood. In some embodiments, the hood surrounds the nozzle on 4 sides to partially enclose the nozzle at the point where fluid is ejected from the nozzle. In some embodiments the hood is separate and removable from the base of the device. In some embodiments, the hood is permanently affixed to the base of the device. In some embodiments, the hood and the base are a single, unibody component. In some embodiments, the hood extends away from the nozzle at a predetermined distance to aid the user in maintaining a consistent and uniform minimum distance between the nozzle and the target. In some embodiments, the hood is shaped in a generally conical or pyramid shape. The hood also reduces the influence of wind and other environmental factors on fluid dispersal pattern after the fluid leaves the nozzle. The hood also helps the user more accurately focus on the target. The hood component assists directionality of intended liquid dispersal, and it also serves the function of shielding the user from unintended spray that may arise in windy conditions.
[0034] The present general inventive concept also provides methods of dispersing fluid by using the portable motorized fluid delivery device apparatus described herein. In some embodiments, fluid is added directly to the fluid compartment within the handle. In some embodiments, the fluid container is separate and removable from the device and fluid transfer is more efficiently performed by simply removing the empty fluid container and replacing it with a full container.
[0035] The device is positioned such that the nozzle is located at a predetermined height directly over a target. The optimal height above the target is dependent on a number of factors, for example the velocity of the wind at the time and location of use. On very windy days, to reduce the likelihood of unwanted misdirection of fluid, the bottom of the hood is placed on or in very close proximity to the ground and then the motor is engaged. When there is little to no wind, the device need not include the hood component, as long as the device is positioned such that the distance between the nozzle and the target is within the range of zero (i.e., in contact with the ground) to about 12 inches above the ground. In most instances, the optimal height (i.e., distance of nozzle from target) is between 2 to 6 inches.
[0036] Use of the hood component provides guidance to the user with respect to positioning the device. For example, the user can visually inspect the target and make sure that the target is located under the hood before engaging the motor and pump. Also, the hood component is sized and shaped such that the bottom of the hood component is a predetermined distance away from the nozzle. For example, in one embodiment, the hood component is sized and shaped such that the distance from the nozzle to the bottom of the hood component is about three (3) inches. In this example, the user is assured of consistent and optimal nozzle height over the target by simply positioning the hood over the target with the bottom of the hood touching or in very close proximity to the ground or target.
[0037] When the device is in the desired position, the electrical switch is activated such that the electrical motor engages the fluid pump to disperse a portion of the fluid from the handle of the apparatus, through the shaft, and out through the nozzle in the base. In some embodiments, the device is configured to disperse a predetermined volume of fluid automatically every time the switch is activated. In some embodiments, this predetermined volume of fluid is between less than 1 ml and 2 ml. In some embodiments, the device is configured to disperse fluid continuously until the switch is manually deactivated, at a rate of approximately 60 ml to 100 ml per minute. In some embodiments, manual deactivation of the switch occurs by actuating the switch to an “off” position. In some embodiments, manual deactivation of the switch occurs by pressing a button.
[0038] In some embodiments, the user activates the motor and pump by turning the switch to an “on” position. The motor then pumps the fluid (e.g., dye and herbicide mixture) from the container housed in the handle through the longitudinal shaft and out through the nozzle. The fluid is expelled through the nozzle at optimal droplet size and pressure for proper application to the target area. The hood component further ensures accurate placement of the liquid mixture to the target area at the optimal distance, while also shielding the user from possible errant spray that can result in windy conditions.
[0039] When an indicator (e.g., a colored dye) is mixed with the fluid, additional advantages are realized. Once the dyed fluid is applied to a target area, the dye will show the user where the fluid has been applied. The dye dissipates after a period of time. Sometimes, the indicator is a liquid dye that is activated by ultraviolet light. The indicator acts as visual confirmation that the agricultural liquid has been applied to a target area. After a period of time, the indicator dissipates by virtue of its interaction with ultraviolet light. Rain and other environmental factors also effect the dissipation of the indicator.
[0040] The present general inventive concept also provides methods of manufacturing a portable motorized fluid delivery device apparatus. A switch, electronic circuitry to connect the switch to the power source and (eventually) the motor, and a sealed structure capable of containing a volume of fluid are arranged within a handle housing to form a handle of the device. A cavity capable of transferring fluids from one end of the shaft to the opposite end of the shaft and an electrical connection between opposing ends of the shaft are arranged alongside (i.e., non-coaxial) each other to form the elongated shaft of the device. An electrical motor, a fluid pump, and a nozzle are arranged within a housing to form a base of the device. The handle and base are affixed to the elongated shaft such that when the electrical switch is activated the electrical motor engages the fluid pump to disperse a portion of the fluid from the handle of the apparatus, through the shaft, and out through the nozzle in the base.
[0041] Referring to the Figures, FIG. 1 depicts a perspective exterior view of an exemplary embodiment of the present general inventive concept. A base 3 is affixed to the distal end of an elongated shaft 2 . The proximal end of the elongated shaft 2 is affixed to a handle 1 . The handle 1 includes a primary grasping area 7 . A switch 4 is located on the handle 1 near the primary grasping area 7 . The switch 4 is sized, shaped and located in a manner that permits the user to simultaneously hold the primary grasping area 7 and also activate the switch 4 . A fluid container 6 is also included in the handle 1 via a housing area 5 . The handle 1 also includes a window 8 sized and shaped such that the user can visually determine the volume of fluid in the fluid container 6 . In some embodiments, the fluid container 6 and/or the window 8 include one or more markings such that the volume of fluid can be more easily measured. In use, the window 8 can optionally be used as a secondary grasping area, for example in a two-handed use configuration. Two-handed optional use is beneficial in some embodiments, as user stature and strength will vary. The two-handed optional use allows users of smaller stature or lesser strength to utilize the invention with greater ease. When prepared for application of a fluid, the user holds the primary grasping area 7 , positions the base 3 over a target area, and activates the switch 4 . Upon activation of the switch 4 , fluid is pumped from the fluid container 6 in the housing area 5 of the handle 1 , through the elongated shaft 2 , to the base 3 via a motor (not shown in the Figures) housed in the base 3 . The fluid is dispersed through the base 3 and out through a nozzle (not shown in the Figures) housed within the base 3 .
[0042] FIG. 2 shows an enlarged cutaway view of the base 3 and distal end of the elongated shaft 2 of the exemplary embodiment of FIG. 1 . In the exemplary embodiment shown in FIG. 2 , the distal end of the elongated shaft 2 is connected to the base 3 by an attachment 9 , including by way of example a series of screws, dowels, pegs, or clips. The removable nature of the elongated shaft 2 from the base 3 permits the user to easily clean and maintain the device. The removable property also provides the added benefit of creating a diversity of storage options.
[0043] FIG. 3 is an enlarged exterior view of the handle 1 of the exemplary embodiment of FIGS. 1 and 2 . As shown in FIG. 3 , the proximal end of the elongated shaft 2 is connected to the handle 1 by an attachment 11 , including by way of example a series of screws, dowels, pegs, or clips. The removable nature of the elongated shaft 2 from the handle 1 permits the user to easily clean and maintain the device. The removable property also provides the added benefit of creating a diversity of storage options. Fluid to be dispersed is contained in the fluid container 6 , which the invention accommodates in the housing area 5 . FIG. 3 also shows the window 8 in the handle 1 , through which the user can visually inspect fluid levels. The window 8 can also optionally be used as a secondary grasping area.
[0044] FIG. 4 is a perspective exterior view of a second exemplary embodiment of the present general inventive concept. In FIG. 4 , a base 43 is attached to the distal end of an elongated shaft 42 . The proximal end of the elongated shaft 42 is connected to a handle 41 of the device. A user holds a primary grasping area 47 on the handle 41 . FIG. 4 also shows a window 48 in the handle 41 , which the user can optionally utilize as a secondary grasping area. A fluid container 46 holds the fluid to be dispersed. The device accommodates the fluid container 46 via a housing area 45 , such that the fluid container 46 is integrated into the device.
[0045] FIG. 5 is a top view of the exemplary embodiment of FIG. 4 . FIG. 5 depicts the handle 41 being affixed to the elongated shaft 42 at the proximal end. FIG. 5 further shows the distal end of the elongated shaft 42 affixed to the base 43 of the device.
[0046] FIG. 6 is a side view of the exemplary embodiment of FIGS. 4 and 5 . As shown in FIG. 6 , a switch 44 is located on the underside of the handle 41 . A user operates the device of this embodiment by holding the primary grasping area 47 . The user's other hand is used to activate the switch 44 , or alternatively, the user can simultaneously hold the window 48 and activate the switch 44 .
[0047] FIG. 7 is an enlarged perspective view of the handle 41 of the exemplary embodiment of FIGS. 4-6 . The proximal end of the elongated shaft 42 is affixed to the handle 41 . FIG. 7 shows the switch 44 . When the switch 44 is activated, the motor housed in the base 43 pumps fluid out of the fluid container 46 in the housing area 45 , through the elongated shaft 42 , and out of the base 43 and nozzle. FIG. 7 also shows the window 48 in the handle 41 .
[0048] FIG. 8 is an enlarged cutaway view of the handle 41 of the exemplary embodiment of FIGS. 4-7 . FIG. 8 shows the switch 44 , the fluid container 46 , and the primary grasping area 47 of the handle 41 .
[0049] Thus, while the present general inventive concept has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment(s) of the invention, it will be apparent to those of ordinary skill in the art that many modifications thereof may be made without departing from the principles and concepts set forth herein, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use; applications in contexts outside of lawn and garden care.
[0050] It is also to be understood that the claims to follow are or will be intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. Hence, the proper scope of the present general inventive concept should be determined only by the broadest interpretation of such claims so as to encompass all such modifications as well as all relationships equivalent to those illustrated in the drawings and described in the specification.
[0051] Finally, it will be appreciated that the purpose of the annexed Abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. Accordingly, the Abstract is neither intended to define the invention or the application, which only is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. | Devices and methods are provided relating generally to the delivery of fluids in the context of the lawn and garden industry. The devices and methods provide for the delivery of fluids at specified droplet size, pressure, spray pattern, and dispersal location relative to the target. The devices and methods deliver various fluids to a targeted location in a manner that limits the physical exertion typically required of users for such applications and is highly precise and accurate, thus reducing the likelihood and extent of missing the target and wasting expensive resources. | 8 |
BACKGROUND OF THE INVENTION
It is well known to fabricate a building under mass production assembly line conditions, thereafter to transport the prefabricated building unit to its building site and to lift the prefabricating building unit into place on a prepared foundation at the site.
Examples of assembly line techniques for prefabricating building units such as house structure are to be seen in U.S. Pat. Nos. 3,805,365, 3,820,216 and 3,994,060.
Specialized units for transporting the building unit through the assembly line during fabrication are to be seen, for example, in U.S. Pat. Nos. 3,962,773 and 4,450,617.
An example of transporting modular home sections from the fabricating assembly line to the placement site, by means of flatbed trucks, is to be seen in U.S. Pat. No. 4,512,120.
Finally, lifting devices for use with cranes to lift the prefabricated unit and place it in its final place are to be seen, for example in U.S. Pat. Nos. 3,800,493 and 4,501,098.
Such systems suffer from the disadvantage that the assembly line is located remote from the building site. These previous arrangements have also suffered drawbacks in that the building unit during fabrication has required a great deal of handling on the assembly line and the systems for moving the units being fabricated though the assembly line have been complex, or suffered from handling drawbacks when moving the prefabricated structure on to a truck to transport it to the building site. Also the devices for lifting the prefabricated building units into position have been complex and somewhat difficult to use.
SUMMARY OF THE INVENTION
The present invention seeks to mitigate the drawbacks of the prior art by providing a method and system for use in fabricating, transporting and placing the building units on foundations, all being effected on site.
According to the present invention there is provided a system of fabricating, transporting and a base member upon which the building unit is erected. The base member of the system comprises a rectangular metal frame, at least two opposing sides of which are L-section, inwardly directed to provide, on the opposing sides, a marginal shelf and a marginal outer wall upstanding from the marginal shelf aligned cross-beam receiving brackets inwardly directed from the opposing sides, cross beam members received in the brackets and secured to the frame; and building unit lifting lugs attached to, and projecting outwardly from, the rectangular frame.
According to a preferred feature of the base member, tensioned members extend parallel to the cross-beam members and are detachably attached to the opposing sides of the frame. The tensioned members are preferably provided with turnbuckles to control the tension in the members.
According to one preferred feature of the base member spacer members are positioned along the marginal shelves within the marginal outer walls and carry the cross-beam receiving brackets.
Preferably the device of the system for transporting the base member during fabrication of the building unit comprises a flatbed for supporting the base member; rail engaging wheels beneath the flatbed, and an anti-friction surface on the flatbed (such as a roller conveyor) to permit the fabricated building unit to be slid off the flatbed after completion of fabrication.
According to yet a further preferred feature, the means to transport the prefabricated building unit to its site comprises a flatbed truck provided with an anti-friction surface and dimensioned to receive the prefabricated building unit when slid off the transporting device.
According to still a further feature of the invention, a prefabricated building unit lifting frame is provided for attachment to the base member and preferably the lifting frame comprises a rectangular structure, crane hook attaching elements on the structure, and a plurality of building unit lifting cord, straps, or like members on the structure, the cord or like members having lifting lug engaging attachments. According to one preferred feature of the invention the lifting cords or like members may be of unitary configuration.
According to another aspect of the invention there is provided a system of fabricating, transporting, and placing a building unit at a site, comprising: at least one production line for fabricating a building unit having an input end and an output end and including a transport device having a flatbed, said transport device being movable from the input end to the output end of the production line through a series of workstations, said building unit being fabricated on an upper surface of said flatbed, said flatbed having an anti-friction surface on the upper surface thereof for permitting sliding movement of said building unit relative to said transport device; a first transport means to transport said building unit from the output end of said production line to a preselected foundation, said transport means having a flatbed with an anti-friction surface on the upper surface thereof for permitting sliding movement of said building unit thereon; a means to slide the building unit from the flatbed of said transport device when said transport device is at the output end of said production line to the flatbed of said transport means; a second transport means to transfer the transported building unit from the flatbed of said transport means to said preselected foundation of said site.
According to another aspect of the invention there is provided a system for fabricating and transporting building units to a plurality of building sites, comprising (a) a factory site having at least one production line for fabricating a building unit, said production line having an input end and an output end; (b) a road array comprising an outer ring road, a first inner ring road located inside said outer ring road, a second inner ring road located inside said outer ring road, positioned remote from said first inner ring road, a first connecting road linking said outer ring road and said first inner ring road, a second connecting road linking said outer ring road and said second inner ring road, at least one factory site connecting road linking said factory site to said outer ring road; (c) a plurality of building sites located adjacent said inner and outer ring roads; (d) means to transport a building unit fabricated on the at least one production line along the road array; said factory site being disposed inside said outer ring road and between said first and second inner ring roads.
DESCRIPTION OF THE DRAWINGS
The following is a description by way of example of one preferred embodiment of the invention reference being had to the accompanying drawings in which:
FIG. 1 is plan view of an assembly line for assembling prefabricated building units;
FIG. 2 is a perspective sketch of the transportation device which carries the building unit through the assembly line during its fabrication;
FIG. 3 is a perspective sketch of the device for transporting the prefabricated structure to the building site and the means for lifting the prefabricated unit into place on its foundations;
FIG. 4 is a detail, to an enlarged scale, of the system shown in FIG. 3;
FIGS. 5, 6, and 7 are details, to an enlarged scale, of the items circled and numbered 5, 6, and 7, in FIG. 4; and
FIG. 8 is a schematic view of a subdivision building plan.
DESCRIPTION OF PREFERRED EMBODIMENT
Turning now to the drawings. In FIGS. 1 and 2 a fabricating production line 10 is a factory-like facility in which two parallel production lines, 11 and 12, are placed side by side. The production lines each include its own railway track 14, 15 extending through the assembly facility past a basic construction area 16 and then past a plurality of bays 18 providing storage space for light construction and finishing materials such as window frames and doors, plumbing and electrical supplies. Basic construction area 16 and bays 18 are collectively referred to as "work stations". Running on the tracks 14 and 15 are a plurality of transporting devices 20 each comprising a flatbed 21 (see FIG. 2) having a series of railway track engaging wheels 22 therebeneath and anti-friction surfaces, such as roller conveyors 24, on the upper surfaces of the flatbed.
As the devices 20 proceed from left to right as seen in FIG. 1, the building unit 30 is erected on the base member of the system, which base member will be described in more detail hereinafter with reference to FIGS. 4, 5 and 6. Fabrication of the building unit 30 continues throughout the production line until finally it is rolled out to a loading bay 25 on the right hand side of FIG. 1. Here a means to transport the prefabricating building unit to the building site is provided in the form of a flatbed truck 26 which is dimensioned so that the building unit 30 can be slid off the roller conveyors 24 on the flatbed 21, onto the flatbed 27 of the truck 26 which itself has an anti-friction surface on top of its flatbed, which anti-friction surface may be a roller conveyor 28 similar to the roller conveyor 24.
The prefabricated unit 30 is then conveyed to the building site by the truck 26 where it is lifted into position by means of a crane 32 (see FIG. 3) onto the building foundation 33. In order to provide a means by which the crane 32 can lift the unit 30 and set it into place, the system of the present invention provides a lifting frame 35 (see also FIG. 4). The lifting frame 35 is a rectangular structure 36 provided at its corners with crane hook attaching elements, such as eye bolts 37 which receive crane cables 34. Attached to, and depending from opposite sides of the rectangular structure 36 are a series of building unit lifting cord members 39. Lifting cord members 39 may be of any suitable configuration such as cables, or straps, or the like and the cord members terminate in lifting attachments 40 which will be described more fully hereinafter. The lifting cord members 39 are shown in FIG. 4 as of unitary configuration, that is to say they are a single unit from their point of attachment to the rectangular structure 36 to the attachment elements 40, passing through prefabricated slots 41 in the roof 42 of the building unit 30. However, it is to be understood that in some forms of construction it may be desirable to split the cords above their slots 41 such as at point 45 in FIG. 4, the upper part of the cord 39a being disconnectably connected at the point 45 to the lower end of the cord 39b. By having the cords 39 detachably attached in this fashion it is possible to leave the lower part of the cord 39b in place after the building unit 30 has been arranged on its placement site.
Turning now to FIGS. 4, 5 and 6, these Figures show in more detail the base member 50 which provides the uniting feature of the system and on which the building unit 30 is assembled. The base member 50 comprises a rectangular steel frame 51 at least two opposing sides 52 of which are of inwardly directed L-section to provide on opposite sides a marginal shelf 54 and a marginal outer wall 55 upstanding from the shelf. Preferably all four sides of the rectangular frame are of similar inwardly directed L-section. Lugs 56, only one of which is shown in FIG. 5, upstand from the shelves 54 to receive a cross-beam 60, preferably of I-section wood. Spacer members, seen here as two plank-like wooden elements 62, rest on the shelves 54 at opposite sides of the rectangular metal frame inside the marginal outer walls 55 and carry aligned cross-member receiving brackets 65. The cross-members 60 are positioned firmly in the brackets 65 and span the rectangular steel frame 51, as seen in FIGS. 5, 6 and 7. The ends of the cross-beams 60 are received in the receiving brackets 65 and a bolt 67 is passed through the lugs 56 and through holes in a pair of filler blocks 69 located one on each side of the I-beam 60. A nut 68 engages the bolt 67 and is tightened to clamp the cross-beam 60 to the frame 51 in the brackets 65.
It will be understood that in FIG. 5 although the frame 50 appears to be in place on the foundation with the bolt 67 and nut 68 disconnected, this is for the purposes of illustration only. Obviously the cross-beams 60 will be well secured as an early step in fabrication of the base member 50 and before the rest of the building unit 30 is assembled on the base member 50.
Building unit lifting lugs 70 are provided on the opposite sides of the rectangular metal frame 51. These lugs receive lifting lug attachment elements 40 at the ends of the straps 39.
It will be noted that when the elements 40 are hooked onto the lugs 70 the entire building unit can be lifted on its own base frame 50.
In order to decrease any tendency for the rectangular frame 51 of the base member 50 to be warped during assembly and transportation of the building unit, a plurality of tensioned members 72 (see FIGS. 4 and 7) are detachably attached by suitable means such as hooks 74 to eyes 76 fixed to the opposing sides of the frame. The members 72 extend parallel to the cross-beams 60 and are preferably provided with turnbuckles 78, or the like, whereby the tension in the member 72 can be controlled. When the building unit 30 has been arranged on its placement site and bolted to its foundation 33, the turnbuckles 72 can be slackened and the members 70 removed for reuse.
It will be understood that although the lugs 70 have been shown of U-shape with the attachment elements 40 of hook configuration, different shapes of lug and hook could be provided to accommodate different situations.
Thus the base member 50 provides a jig upon which the fabrication of the unit 30 takes place, provides for cooperation with the transporting device 20 for ease of movement through the assembly line and transfer onto the flatbed truck 26, and provides the means whereby the lifting frame 35 can lift the building unit 30 from the truck and deposit it on its foundation 33, thereby achieving a smooth unitary flow from fabrication through transportation, to final placement.
The plan of FIG. 8 shows a land subdivision or site 80 parcelled into individual building lots 82 and including a parkland area 84. Prefabricated units 30 are located each on a lot 82 which has a foundation 33. Production line 10 is erected on parkland area 84 and the service roads 86 of subdivision 80 are used to transport each building unit 30 from the production line to a preselected lot 82 and foundation 33.
The road array constituted by service roads 86 includes an outer ring road 86a and two inner ring roads 86b, 86c. Inner ring roads 86b and 86c are linked to outer ring road 86a by first and second connecting roads 86d and 86e respectively. Production line 10, having an input end 10a and an output end 10b, is located at a factory site located inside outer ring road 86a and between inner ring roads 86b and 86c. The factory site is linked to outer ring road 86a proximate input end 10a by a first factory site connecting road 86f. The factory site is also linked to outer ring road 86a proximate output end 10b by a second factory site connecting road 86g. Factory site connecting roads 86f and 86g both take the shortest distance possible to link to outer ring road 86a. Located outside of outer ring road 86a and linked thereto are a plurality of access roads 86h. Interior roads 86j and 86k are linked to inner ring roads 86c and 86b respectively and disposed therein. When the placement of building units 30 on lots 82 has been completed, production line 30 may be dismantled and parkland area 84 converted to its true use.
It will be seen from the layout of FIG. 8 that by locating production line 10 on site 80 the time and cost problems associated with transporting the building units 30 to foundations 33 are avoided. | There is described a method and system for fabricating, transporting and placing building units at a site. A production line is located at the site for fabrication of the building units, each unit is transported from the assembly line to a preselected foundation, and the unit is placed on the foundation. Each unit is fabricated on a flatbed and slid onto a flatbed truck. Each unit is constructed on a base member to which a lifting device is attachable to transpose the unit from the truck to the foundation. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to techniques for the manufacture of peripherally contoured fabric blanks that are adapted to be folded over and sewn to form a finished panty, and more particularly to techinques for forming such blanks when the latter are provided with reinforcing strips located at the crotch area of the finished panties.
In known techniques of this type, the contoured blanks for the panties are initially cut out or punched out of a cloth web that is continuously or cyclically withdrawn from a delivery spool. The so-formed blanks are then subjected to a further hand or machine operation in which suitable edge seams are sewn on the opposed contoured surfaces of the panty blank, after which the blank is folded over and sewn along its remaining edges to complete the waist and leg openings of the finished garment.
In the event that a crotch reinforcement for the finished panty is desired, a separate joining and seaming operation must be effected on the cut-out or punched-out fabric blank, after which the reinforced blank must be separated from the remainder of the reinforcing strip.
Such prior-art techniques for the manufacture and reinforcement of peripherally contoured fabric blanks for panty manufacture have been found to be slow and inefficient.
SUMMARY OF THE INVENTION
The present invention provides a rapid and efficient automatic technique for the manufacture and reinforcing of peripherally contoured fabric blanks that are adapted to be folded over and sewn in later operations to form finished panties. In an illustrative embodiment, a plurality of blank-forming fabric segments, each larger than the contoured periphery of the final blank, are cyclically advanced on a conveyor in overlying relation to a reinforcing strip whose longitudinal edges are parallel to the direction of advance and whose width is smaller than the width of each of the segments.
The output end of the conveyor is in registration with a first of a plurality of work stations that are circumferentially distributed around the periphery of a turret that is rotatably carried on a fixed support.
A plurality of spider-like turret arms extend from the turret periphery, each arm carrying on its outer end a rotatable, magnetically-actuable fabric holder whose cooperating upper and lower plates are peripherally contoured identical in size and in configuration to the fabric blanks.
As each segment advances to the outward end of the conveyor, the edges of the underlying reinforcing strip are sewn thereto, and each so-reinforced segment is severed from the remainder of the strip. Each severed reinforced segment is introduced into the then-aligned holder at the first work station. The corresponding turret arm is then indexed into a first one of four successive work stations, at which separate contour sewing machines are disposed.
As the segment is carried by the arm from the first work station to the first second work station and thereafter to the remaining three work stations, the associated holder is successively rotated through 90° to present four different portions of the holder periphery to the respective sewing machines at the second work stations. Each sewing machine is adapted to cut off the area of the first segment projecting beyond the confronting portion of the holder periphery, after which the sewing machine sews an edge seam on the segment along the contour of the periphery of such holder portion.
As a result, the segment exiting from the last of the second work stations has the form of the final panty blank, complete with edge seams around substantially the entire periphery thereof. At this point, the turret can then be indexed into a discharge station, where the finished blank can be removed from the holder and folded over parallel to the seams of the central reinforcing strips thereon, and thereafter sewn to complete the panty manufacture. In order to effect the required 90° rotation of each holder as the associated arm is indexed between successive work stations, a transmissions element such as a chain or a sun gear segment is secured to the periphery of the fixed turret support, and extends between the first work station and the last of the second work stations. A second transmission element, which in the case of the above-mentioned chain is in the form of a sprocket and in the case of the above-mentioned segment is in the form of a gear, is rotatably carried on the inner end of the same turret arm. The second transmission element is adapted to roll along the first transmission element as such turret arm is indexed between successive work stations, and the rolling movement of such second transmission element is dynamically converted, by suitable facilities associated with the same arm, to the required rotational motion of the holder.
In an additional feature of the invention, the respective ends of the first transmission element are selectively decoupled from the remainder of such element to stop the rotation of each holder in the correct position at the first work station and at the last of the second work stations. Illustratively, such decoupling device may be a hinged or slidable element that carries the end chain links or gear teeth, as the case may be, for the respective embodiments of the first transmission element indicated above.
Additionally, each holder may be maintained immobilized in the desired position at each of the second work stations by means of a lever-actuated bolt which cooperates with one of a plurality of slots in the lower plate of the holder, the lever-actuating mechanism being disposed at each relevant work station.
In order to support the portions of the areas of the holder-carrying fabric segments that project beyond the contoured periphery of the holder until such portions are to be cut away and seamed, a pair of auxiliary holder plates are associated with the main lower plate of each holder. Each of such auxiliary plates has a peripheral contour that is complementary to and interfitting with the contours of respective opposed portions of the main contoured lower plate. Suitable means, such as a pneumatic piston-cylinder set, are provided for selectively moving the auxiliary plates into and out of registration with the main lower plate.
In order to releasably secure each fabric segment in the holder, the main upper and lower plates of such holder are provided with cooperable permanent magnets, with the magnet in the upper plate being rotatable to present a selected one of its poles opposite the poles of the magnet in the underlying lower plate. The upper magnet may illustratively be rotated by means of a follower arm that is rotatably coupled to a carrier member, which in turn is supported for reciprocal movement between the first work station and the discharge work station immediately downstream of the last second work station.
BRIEF DESCRIPTION OF THE DRAWING
The invention is further set forth in the following detailed description taken in conjunction with the appended drawing, in which:
FIG. 1 is a top view of a portion of an automatic installation for cutting and reinforcing fabric segments that are to be later worked into peripherally contoured fabric blanks in accordance with the invention;
FIG. 2 is a side elevation of the installation of FIG. 1;
FIG. 3 is a top view of a turret-like installation for receiving reinforced fabric segments from the installation of FIGS. 1-2 and successively forming adjacent areas thereof into a peripherally contoured fabric blank having edge seams thereon;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3, illustrating details of the first work station serviced by the installation of FIG. 3;
FIG. 5 is a fragmentary enlarged top view of a portion of the arrangement of FIG. 3, illustrating one embodiment of an apparatus for rotating each work holder as the associated turret arm is indexed between successive work stations;
FIG. 6 is an enlarged plan view of a portion of the arrangement of FIG. 3, illustrating a technique for providing selective magnetic coupling between opposed upper and lower plates of each fabric holder;
FIG. 7 is a fragmentary view in section of a portion of the arrangement of FIG. 4, illustrating one manner of engaging and rotating a magnet associated with the upper plate of each holder means;
FIG. 8 is a sectional view taken along line 8--8 of FIG. 7;
FIG. 9 is a fragmentary view, similar to FIG. 7, but illustrating an alternative manner of rotating the magnet in the upper plate of the holding member;
FIG. 10 is a side elevation of an additional work station associated with the turret arrangement of FIGS. 3 and 4, illustrating a contour sewing machine and associated facilities for its positioning and operation;
FIG. 11 is a perspective view of the sewing machine of FIG. 10, illustrating further details of a reciprocable guide plate disposed upstream thereof;
FIG. 12 is a plan view, similar to FIG. 3, illustrating an alternative embodiment of an arrangement for selectively rotating each work station about its axis during the indexing of the associated turret arms between successive work stations;
FIG. 13 is a sectional view taken along line 13--13 of FIG. 12, illustrating certain details of the first work station of FIG. 12;
FIG. 14 is an enlarged fragmentary view of a portion of the arrangement of FIG. 13; and
FIG. 15 is a plan view of the arrangement of FIG. 14.
DETAILED DESCRIPTION
Referring first to FIGS. 1-2, an illustrative manufacturing installation constructed in accordance with the invention for the production of peripherally contoured panty blanks includes a delivery roller 2 supported on a drive axis 1. The roller 2 is wound with a web 3 of a suitable fabric forming the basic constituent of the blank. The web 3 is pulled from the roller 2 in the form of hanging loops which extend between the roller 2 and a plurality of delivery rollers 4 in the nip of which the web 3 is suitably advanced to a conventional storage area 6. Downstream of the area 6 is a circular knife 7, which is movable transversely to the direction of advance of the web 3 and forwardly of a discretely recessed front surface 201 of the area 6, such movement of the knife serving to separate individual fabric segments 8 from the web 3. As shown, the segments 8 are substantially rectilinear in shape, and have an overall size larger than the blanks to be manufactured. Upon the cutting of each segment 8, a selvedge 9 is produced on the remaining front surface of the web 3 within the area 6.
A plural-band conveyor 12 is supported on a pair of shafts 10 and 11 downstream of the storage area 6 for receiving the cut-off segments 8 from the storage area 6. The conveyor 12 extends along an axis 202 perpendicular to the longitudinal direction of advance of the web 3 and the separated segments 8. The length of the bands of the conveyor 12 is suitably chosen so that the conveyor 12 can accommodate at least three segments (designated 8, 8', 8") at any one time.
A shaft 13 is supported parallel to and upstream of the shaft 10, such shaft 13 serving to support a delivery roller 14 on which a reinforcing band 15 is wound. The band 15 may illustratively be a web of cotton or the like for reinforcing the portion of the segments 8 which will ultimately correspond to the crotch area of the finished panties.
The band 15, pulled from the roller 14, is advanced centrally along the conveyor 12 in alignment with and directly below the lower surface of the segments 8 as shown in FIG. 2, with the opposed longitudinal edges (designated 16 and 17) of the band 15 overhanging the underlying bands of the conveyor 12.
A tong-actuating mechanism 18 is arranged in alignment with the rollers 4 on the opposite side of the conveyor 12. The mechanism 18 carries a plurality of tongs 19, which may be selectively opened or closed by a pneumatic cylinder 20. In particular, the tongs 19 are connected with push rods 21 of the cylinder 20, whereby the tongs are movable in a direction to the left as viewed in FIG. 1 from an inactive position to a selvedge-gripping position wherein the tongs extend into recesses 5 in the front surface of the storage area 6 to grip the selvedge 9 of the web 3.
A pair of sewing machines 22 and 23 are arranged perpendicular to the direction of advance of the conveyor 12. The sewing heads of the machines are positioned in alignment with the lateral edges 16 and 17 of the reinforcing band 15, in order to sew the edges 16 and 17 on the underlying segment 8' to form overlapping seams 24 and 25.
A circular knife 26 is supported behind the machine 23 perpendicular to the direction of advance of the conveyor 12. The knife 26 is movable cyclically across the band 15 in order to separate the reinforced segments from the main portion of the band 15.
The longitudinal edges of the reinforced segments 8" are engaged by a plurality of tongs 28 of a second actuating mechanism 29 similar to the mechanism 18. The tongs 28 are operated via pushrods 30 to pull the reinforced segments 8" from the position represented in FIGS. 1 and 3, at the outlet end of the conveyor 12, onto a contoured lower plate 31 of a magnetically-actuated holder 34.
A plurality of the holders 34 are individually rotatably carried on outer ends of six circumferentially spaced radial arms 47, whose inner ends are secured to the periphery of a rotary turret 33.
The contour of each lower plate 31 corresponds to that of the panty blank (designated 38 in FIG. 3) to be manufactured, and is smaller than such blank by about twice the width of the peripheral edge seams to be sewn on such blank in the manner described below. Each plate 31, correspondingly, has peripheral cutouts 45 and 46.
Each holder 34 also has an upper plate 32 identical to and cooperable with the contoured lower plate 31.
The turret 33 is rotatably carried in a fixed support 35, and is cyclically driven by a motor 37 by means of a hollow shaft 36. The turret 33 serves to circumferentially index the reinforced segment 8" from an input position A (FIG. 3), in which the tong mechanism 29 pulls the segment onto the lower plate of the then-aligned one of the holders 34, and thereafter through four successive sewing positions B-E, in which the segment 8" is shaped into the panty blank 38, and finally to an output position F, in which the blank 38 can be removed from the installation for further processing. Such processing can take the form, for example, of folding the blank 38 parallel to the reinforcing seams 16, 17, and then sewing the now-confronting edges of the folded garment to form the waist and leg openings of the garment.
In each sewing position B-E, a separate contour sewing machine 39 (FIGS. 10-11) is arranged. Each machine 39, which may be a twin-needle overlap seam machine, is equipped with a knife 40 for cutting away of the excess area of the segment 8" which extends beyond the associated peripheral portion of the holder 34. The knife 40 is adapted to cut the excess segment area shortly before the stitching operation, so that the resulting selvedge is taken into account in the final edge seam. Specifically, edge seams identified at 41-44 are respectively sewn by the machines 39 on the segments 8" at the successive stations B-E to complete the blank.
The outer end of each arm 47 supports a vertical shaft 48 (FIG. 4) for rotation therein. Each shaft 48 in turn carries a cross-shaped member 49, to which the lower plate 31 of the associated holder 34 is affixed.
A sprocket 50 is secured to the lower end of each shaft 48. Each sprocket 50 is connected over a chain 51 with a sprocket 52, which forms the output of a speed-reducer 53 carried by an angle member 54 on the associated arm 47.
A sprocket 55 is mounted on the input end of the arm 47, and forms the input of the speed reducer 53. The sprocket 55 is adapted for rolling movement on a chain 56, which is secured by means of tongues 57 (one of which is shown in FIG. 5) disposed on a circular edge surface 58 of the support 35. As indicated below, the rotation of the sprocket 55 during the circumferential indexing movement of the turret 33 will effect a rotational movement of the holder 34 at the outer end of the same arm via the speed-reducer 53 and the shaft 48.
As indicated in FIG. 3, the chain 56 extends around an angle of about 240°, with a first end thereof arranged in the input position A and the other end in the last sewing position E. In FIG. 5, the end portion of the chain terminating in the position E is provided with facilities for decoupling such chain end from the then-adjacent sprocket 55. (A substantially identical decoupling arrangement is provided at the input position A).
In particular, the portion of the edge surface 58 of the support 35 adjacent the position E has a cutout 59 (FIG. 5), which receives a member 60 that carries the last several links or rollers of the chain 56 in operative alignment. The member 60 is hinged at one end to a holder 61 carried on the support 35. The free end of the member 60 is pivoted to an operating rod 62 of a pneumatic cylinder 63, which in turn is pivotally coupled to the support 35.
Each of the arms 47 (FIG. 4) is equipped with a carrier 64, on which a lever 65 is hinged. One end of each layer 65 has a spherical head 66. The other end of the lever has a roller 67, which is received in a curved groove 68 of a bolt 69. The bolt 69 in turn is movably supported in the arm 47, and has a conical upper end 70 which is received in one of four conical bores 71 disposed on each arm of the cross-shaped carrier 49 on the outer end of the arm 47. When the bolt 69 is engaged in the bore 71, the associated holder 34 affixed to the carrier 49 is effectively immobilized against rotation.
A carrier arm 72 is secured to the support 35 at each of the positions A-E. A pneumatic cylinder 73 is arranged on each arm 72. Each pneumatic cylinder 73 is provided with an operating rod 74, which has a switching head 75 with a semi-circular cutout 76 for selectively receiving the spherical head 66 of the lever 65.
The lower plate 31 of each holder 34 (FIG. 7) has a plurality of circular recesses 77, each of which may be covered by means of a take-up plate 78 secured on the underside of the lower plate 31. A circular permanent magnet 79 is secured in each plate 78, and has sector-shaped poles that extend upwardly into the associated recess 77 to terminate flush with the upper surface of the lower plate 31.
The upper plate 32 cooperates with the lower plate 31 to securely hold the reinforced segment 8" during its formation into the blank 38. The upper plate 32 is provided with a plurality of recesses 80 corresponding to the recesses 77 in the lower plate 31. Each recess 80 is covered by means of a take-up plate 81 rotatably supported in a covering ring 82 secured to the upper plate 32. A permanent magnet 79 is mounted in each take-up plate 81 and extends downwardly into the associated recess 80 to terminate flush with the lower surface of the upper plate 32. Each take-up plate 81 is also provided with an inclined annular wall 83 (FIG. 8), which surrounds a bore 84 and is interrupted by two radial slots 85.
A shaft 86 is coaxially supported in the hollow shaft 36 (FIG. 4) on the turret 33 for independent rotation therein. The shaft 36 is driven by a motor 87. A support piece 88 is secured to the upper end of the shaft 86 projecting outside the turret 33.
An arm 89 of a holder plate transfer arrangement 90 is supported for vertical oscillation on the piece 88 and for reciprocation between the positions F and A illustrated in FIG. 3. A penumatic cylinder 91 (FIG. 4) rotatably supported on the piece 88 serves for oscillation of the arm 89; for this purpose, the cylinder 91 is provided with an operating rod 92 which engages a lever 93 fixedly connected with the arm 89.
A frame 94 (FIGS. 6-9) is secured on the front end of the arm 89. A plurality of shafts 95, corresponding to the number of take-up plates 81 arranged on the upper plate 32 and thereby with the number of bores 84, are supported on the frame 94. The shafts 95 are so constructed and arranged that they cooperate for joint movement into the several bores 84 of the plates 81.
As indicated in FIG. 7, a plurality of sprockets 96 are secured to the shafts 95, and are mutually interconnected by means of a chain 97. A lever arm 98 shown in dashed lines in the figure is connected with one of the shafts 95, and an operating rod 99 is hinged to the arm 94. The operating rod 99 is associated with a pneumatic cylinder 100 supported on the frame 94.
Each shaft 95 has a follower 101 (FIG. 9) disposed on its lower end. The follower 101 extends into the radial slots 85 of the annular wall 83 (FIG. 8) in each plate 81 during the insertion of the corresponding shaft 95 into the appropriate bore 84. The side walls of the radial slots 85 have engagement surfaces for the follower 101. In addition, two of the illustrated shafts 95 are provided with followers 104 (FIGS. 7-8). The followers 104 terminate in bolts 105, which during the rotation of the shafts 95 selectively enter recesses 106 which are disposed in blocking pieces 107 attached to the covering rings 82.
Four fixed supports 108 are provided outside the rotary turret 33 (FIG. 3) at the respective positions B-E. Respective arms 109 are hinged to the supports 108. An arm 110 (FIG. 10) is pivotally joined to each arm 109. A plate 111 is rotatably connected to the arm 110 for carrying the associated one of the four sewing machines 39.
A drive motor 113 is secured to a carrier 112 beneath each plate 111. By means of bevel gears 114, 115, the drive motor 113 operates a shaft 117 that is supported in the carrier 112 essentially coaxial with the needles 116 of the sewing machine 39.
A sprocket 119 is secured to the shaft 117 for engagement with a chain 118. The chain 118 is carried on a side wall 120 of a patterning mechanism 121, which is fixedly secured to the support 35 and along which the machine 39 is adapted to move to cut and sew one of the edge seams on the contoured blank being manufactured. In particular, the profile of the mechanism 121 at each of the stations B-E corresponds to the shape of the appropriate one of the edge seams 41-44 (FIG. 3). Therefore, as the machine 39 is moved along the profiling mechanism 121, the needles 116 of the machine 39 will define the contours of the appropriate edge seam.
A spacing roller 122 (FIG. 10) is supported on the shaft 117 for rolling movement on one side wall 120 of the profiling mechanism 121 in the direction of cutting and sewing of the machine 39, i.e., a direction perpendicular to the plane of the drawing. A pair of rods 123 (only one of which is visible in the drawing), extend parallel to the longitudinal axis of the machine 39 and are guided in the carrier 112, whose ends are secured with each other by means of an angle 124. A pair of parallel shafts 125, only one of which is visible in the drawing, are secured in the angle member 124. The shafts 125 individually carry counter rollers 126, which are individually supported for rolling movement, one behind the other, perpendicular to the plane of the drawing along a side wall 127 of the profiling mechanism 121. The spacing roller 122 and the counter rollers 126 are pressed against the respective side walls 120 and 127 by means of a pair of springs 128 supported in the angle member 124 and the carrier 112. The shafts 125 of the counter rollers 126 and the shaft 117 of the roller 122 are arranged to define corners of an isosceles triangle whose plane extends perpendicular to the plane of the paper, with the apex of such triangle being disposed along the axis of the shaft 117. With such construction, a frictionally closed, three-point linkage for accurately moving the sewing machine 39 in the desired contoured path is accomplished.
As elongated guide plate 129 (FIGS. 10-11) is disposed immediately upstream of the stitching position of each sewing machine 39. The plate 129, which extends in the direction of advance of the sewing machine, is secured to a lever arm 130, which is rotatably supported parallel to a shaft 132 also extending in the direction of advance. The shaft 132, which is disposed beneath an edge 131 of the guide plate 129 remote from the holder 34, is carried on a support arm 133 secured to the sewing machine 39.
The guide plate 129 exhibits an upward incline in the direction of advance, while its upstream end terminates in a downward bend. The lever arm 130 is actuated by an operating rod 135 of a pneumatic cylinder 136, which is pivotally secured on the machine 39. With this arrangement, the cylinder 136 is adapted to oscillate the guide plate 129 between the operative sewing position shown in FIGS. 10-11 and a rest position which is tilted off to the left as viewed in the drawing.
In order to avoid ripples or pulls of the outer portions of the segments 8" (FIGS. 3-4) that would normally hang over the periphery of the support plate 31 during the transfer of the segment to the plate 31 in the input position A, the holder 34 is further provided with a pair of auxiliary lower support plates 137 and 138. The plates 137 and 138 are respectively contoured in a manner complementary to the plate 31 as described below.
The auxiliary plate 137 is secured on two parallel displacement rods 139, which are movable vertically in a carrier arm 140 secured to the support 35. The rods 139 are displaceable, by means of a pneumatic cylinder 141, between a rest position underneath the lower plate 31 and a working position in which the top surface of the auxiliary plate 137 is in alignment with the top surface of the plate 31.
Specifically, the contour of the auxiliary plate 137 is selected to be complementary to the cutout 45 (FIG. 3) on one side of the lower plate 31, and to enter the cutout 45 when moved into its working position.
The other auxiliary support plate 138, whose form is complementary to the cutout 46 on the opposite side of the lower plate 31, is connected over an angle member 142 with two parallel push rods 143. The rods 143 are supported, with a slight incline, in a carrier arm 144 fixedly connected with the support 35. A pneumatic cylinder 145 is provided for moving the support plate 138 between its inoperative and working positions.
The manner of indexing of the arms 47 with the turret 33 in the manner shown in FIG. 3 is fully conventional, and is instrumented with standard pneumatic construction and control techniques.
The operation of the arrangement thusfar described is as follows. After each segment 8 (FIGS. 1-2) is advanced by the conveyor 12 to the position of the segment 8', the push rods 21 of the tong actuating mechanism 18 are displaced to the left, and the tongs 19 are placed in their open position. In the left end position of the mechanism 18, the tongs 19 extend into the recesses 5 of the storage area 6, after which the pneumatic cylinder 20 closes the tongs 19 to grip the edge 9 of the web 3. Upon a following retractive (right-ward) movement of the mechanism 18 obtained by an opposite stroke of the push rod 21, the rod 21 pulls the web 3 over the conveyor 12 and into contact with the underlying reinforcing band 15. In order to prevent any binding of the web during the retractive movement of the mechanism 18, the delivery rolls 4 may be synchronously operated at that time.
After the mechanism 18 has been retracted to its initial position shown in FIG. 1, the drive of the circular knife 7 is actuated to separate the segment 8 from the remainder of the web 3.
After the return of the knife 7 into its starting position, the conveyor shafts 10 and 11 are rotated, whereby the segments 8 and the underlying band 15 are moved to the position of the segments 8'. At the same time, the segment 8' disposed previously at such latter position is moved to the position of the segment 8", and so forth. During the advance of the conveyor, the sewing machines 22 and 23 are operated, whereby the two longitudinal edges 16 and 17 of the band 15 are sewn onto the overlying segment 8" to form seams 24 and 25.
As soon as each segment 8 has reached the position of the segment 8' represented in FIG. 1, the drive of the conveyor 12 and the sewing machines 22 and 23 is switched off, and the web 3 is again pulled onto the conveyor 12 via the tong mechanism 18.
At this time, the knife 28 is actuated to cut the aligned portion of the band 15, thereto separate the fully reinforced segment 8" from the segment 8' disposed rearwardly thereof.
Before the now-separated, reinforced segment 8" on the conveyor 12 (FIG. 3) is advanced from the output position of the conveyor onto the lower plate 31 of the holder 34 then disposed in the input position A of the rotary turret 33, the pneumatic cylinders 141 and 145 (FIG. 4) are operated to move the lower auxiliary support plates 137 and 138 from their rest position to their operated position. In such operated position, the upper surfaces of the plates 137 and 138 cooperate with the upper surface of the contoured lower plate 31 to provide a wide-area planar support surface that accommodates the relatively large rectangular periphery of the segment 8".
The pneumatic cylinder 63 (FIG. 5) at the last sewing position E oscillates the member 60 out of its normal position in the cutout 59, so that the links at the associated end of the roller chain 56 engages the then-aligned sprocket 55. The pneumatic cylinder 63 disposed at the input position A is correspondingly operated to engage the other end of the chain 56 with the adjacent sprocket 55.
Also, at this time the lever 65 (FIG. 4) is maintained in its normal position, wherein the end 70 of the bolt 69 is pushed into the then-aligned bore 71 of the holder 49 to immobilize the lower plate 31 on the associated arm 47.
Immediately prior to the time that the segment 8" is moved into the input position A (FIG. 3), the arm 89 (FIG. 4) of the transfer arrangement 90 (which is assumed to be at the position F) is lowered by lever 93, by operation of the pneumatic cylinder 91, to push the shafts 95 (FIGS. 6-9) connected to the frame 94 into the bores 84 of the upper plate 32 of the holder 34 then situated at position F. The followers 101, 104 are thereby moved into the corresponding radial slots 85.
The cylinder 100 (FIG. 6) is then actuated to turn the lever 98, which causes the sprocket 96 on the associated shaft 95 to advance the chain 97 and thereby to rotate the remaining shafts 95. As a result, each bolt 105 is rotated into the capturing recess 106 of the blocking piece 107, thereby securing the frame 94 to the upper plate 32 of the holder 34.
Such latter rotation also causes the followers 101, 104 to rotate the take-up plates 81 (FIG. 7), so that the poles of the magnet 79 associated with the upper plate 32 comes into registration with like poles of the magnet 79 of the lower plate 31. This action eliminates the magnetic attraction of the plates for each other.
Once the plates 31 and 32 are magnetically decoupled, the cylinder 91 may be actuated to lift the arm 89 (with its now-secured plate 32), after which the motor 87 moves the transfer arrangement 90 from position F to position A for operation as indicated below.
At such position A, the longitudinal edges of the segment 8" at the outlet end of the conveyor 12 are now gripped by the tongs 28 (FIG. 3), which via the displacement of the rods 30 serve to move the segment 8" onto the composite planar support surface defined by the lower plate 31 and the auxiliary support plates 137 and 138 of the then-aligned one of the holders 34.
Once the segment 8" is situated on the lower plate 31 at station A, the pneumatic cylinder 91 is again actuated to move the upper plate 32 now carried by the overlying frame 94 onto the top surface of the segment 8" supported on the lower plate 31. The cylinder 100 (FIG. 6) then oscillates the lever 98 via its operating rod 99, whereby the sprocket 96 connected therewith turns the chain 97 in the opposite direction, and thereby imparts an opposite rotation to the shafts 95.
As a result, the followers 101, 104 arranged on the shafts 95 (FIGS. 7-9) rotate the associated take-up plates 81, and consequently the permanent magnets 79 therein, to place the poles of the magnet 79 associated with the top plate 32 into registration with the unlike poles of the magnet 79 situated in the lower plate 31. The resulting magnetic attraction causes the segment 8" to be securely clamped between the plates 31 and 32.
During the last-mentioned opposite rotation of the shafts 95, each bolt 105 (FIG. 8) is rotated out of the associated holding recess 106 of the blocking plate 107, so that the connection between the frame 94 of the transfer arrangement 90 and the top plate 32 is released. Accordingly, during a subsequent lifting of the arm 89 (FIG. 4) by means of the pneumatic cylinder 91, the upper plate 32 remains securely connected with the lower plate 31 at position A, while the arrangement 90 may be rotated back empty to the output position F.
The two lower support plates 137 and 138 at position A are now pulled back into their rest position by means of the cylinders 141 and 145, so that the outer end of the segment 8" overlap the periphery of the plates 31, 32. Simultaneously, the cylinder 73 oscillates the lever 65 over the switching head 75, whereby the lever 65 pulls the bolt 69 downwardly to disengage the conical end 70 of such bolt from the opening 71 in the holder 45. As a result, the holder 34 is free to rotate as the turret 33 is indexed.
The motor 37 is now actuated to index the turret 33 by 60° via the shaft 36. During the rotation of the turret 33, the sprocket 55 on each arm 47 extending between the positions A-E rolls on the chain 56. Such action effects, over the speed reducer 53 and the shaft 48, a simultaneous rotation of the holder 34 through 90° with respect to the arm 47. (Because of the absence of the chain 56 between positions E and A in the downstream direction, the holders 34 on the arms which are then movable between these positions do not rotate).
During the indexing of the holder 34, the cylinder 63 (FIG. 5) at position E rotates the element 60 carrying the end of the chain 56 back into its original position within recess 59, so that the sprocket 55 on the arm 47 moving into position E is accurately stopped in this position. At the same time, the corresponding cylinder 63 located in position A oscillates its associated element 60 into the recess 59, so that the opposite end of the chain 56 is decoupled from the sprocket 55 that is connected with the arm moving from position F to position A.
In order to prevent any further rotational movement of the holders 34 as they enter the positions A-E, the spherical head 66 of the lever 65 disposed at each such position enters the cutout 76 of the switching head 75.
The apparatus functions associated with the sewing positions B-E and the output position F will now be briefly described.
At the instant in which the auxiliary support plates 137 and 138 are lifted into operative positions in cooperation with the lower plate 31 in position A in the manner described above, the cylinders 73 in each of the sewing positions B-E are actuated to oscillate the lever 35 over the operating rod 34, so that the lever 65 pushes the bolt 69 into the bores of the holder to arrest the rotation of the holder 34. After the locking of the holder 34 by the bolts 69 at positions B-E, the motor 113 at each of such positions B-E (FIG. 10) move the shaft 117 into operative position via bevel gears 114, 115. The sprocket 119 thereupon rolls on the chain 118 and advances the associated sewing machine 39 along the contour of the profiling mechanism 121. Because of the above-described frictionally closed, three-point linkage between the spacer roller 122 and the counter rollers 126, the sewing machine 39 will always be aligned accurately perpendicular to the tangent to the curved walls of the profiling member 121.
During the time that each sewing machine 39 is moved into operative position, the guide plate 129 is oscillated, by means of the cylinder 136 and the rod 135, from its tipped rest position to its operative position in alignment with the sewing platform of the sewing machine. When the plate 129 is in its operative position, it supports and smooths the adjacent overlying, overhanging edge of the segment 8" extending beyond the periphery of the holder 34 (FIG. 10). Such smoothing operation is aided by the upward inclination of the top surface of the plate 129, and by the downwardly rounded-off rear corner 134 thereof.
As the sewing machine 39 advances along the profiling mechanism 121, such machine is operated to sew the appropriate one of the peripheral edge seams 41-44 (FIG. 3) on the segment 8" tensioned in the holder 34, while the overlying fabric edge is cut off with the knife 40.
After the successive formation of the edge seams 41-43, the associated holder 34 at positions B-D is unlocked through operation of the cylinder 73 as already described. In the sewing position E, however, the holder 49 remains connected with the arm 47 after formation of the seam 44. To accomplish this, the cylinder 63 at position E also oscillates the element 60 into the cutout 59, so that the adjacent end of the chain 56 is decoupled from the sprocket wheel 55.
After this, turret 33 (FIG. 4) may be indexed in the manner described above, while at each of the positions B-E spherical head 66 of the lever 65 moves into the cutout 76 of the associated switching head 75. During such indexing movement, the drive motor 113 (FIG. 10) of each sewing machine 39 moves back along the profiling mechanism 121 in the opposite direction to the starting position.
When the now-completed blank 38 is transferred from the last sewing position E to the delivery position F, the upper plate 32 of the holder 34 at position F is lifted off the lower plate 31 by the transver mechanism 90 to expose the finished blank 38. At this time, such blank can be removed by hand or machine for completion of the finished panty.
FIGS. 12-15 illustrate a modified arrangement for rotating the holder 34 on the arm 47 while such arm is circumferentially indexed between successive ones of the positions A-E. Corresponding elements in FIGS. 1-11 and in FIGS. 12-15 have been given corresponding reference numerals.
In the modification of FIGS. 12-15, the chain 56 of FIGS. 1-11, extending between the positions A and E, has been replaced by a sun gear segment 147. Similarly, the sprocket 55 of FIGS. 1-11, carried by the respective arms 47 to roll on the chain 56, has been replaced in FIGS. 12-15 by a planetary gear 146, which is adapted to orbit around the segment 147.
FIG. 12 illustrates an arrangement for selectively decoupling the planetary gear 146 from each end of the sun gear segment 147. For this purpose, a slider 146 is arranged on the support 35 at each of positions A and E for carrying the end teeth 148 of the segment 147. The slider 149 is adaptable for radial movement between an inward position, in which the teeth 148 are decoupled from the planetary gear 146, and an outer position wherein the teeth 148 are engaged with the gear 146.
As shown in FIGS. 13-15, the slider 147 is displaceably supported in the radial direction in a cutout 155 of the support 35. The displacement of the slider 149 is accomplished by means of a cylinder-piston set 150 secured to the support 35. The piston rod of the arrangement 150 is connected, over a rod structure 152, with a bolt 151 secured to the slider 149.
Except for the above, the structure and operation of the arrangement of FIGS. 12-15 corresponds identically to that of FIGS. 1-11.
In the foregoing, some illustrative arrangements of the invention have been described. Many variations and modifications will now occur to those skilled in the art. It is accordingly desired that the scope of the appended claims not be limited to the specific disclosure herein contained. | An improved technique for automatically producing a reinforced, peripherally contoured fabric blank adapted to be folded over and sewn to form a finished panty is described. A plurality of fabric segments to the central portion of which an underlying reinforcing strip is sewn is advanced along a conveyor and into a first one of a plurality of work stations distributed around a turret that is rotatably carried on a fixed support. A plurality of magnetically-actuable fabric holders are rotatably supported on the outer ends of corresponding spider arms that extend toward the work stations from the turret. Each holder has a contoured periphery corresponding to that of the panty blank, and after receiving the fabric segment from the conveyor indexes it successively into a plurality of second work stations each equipped with a contour sewing machine. During each such indexing movement, the holder is rotated about its axis to present, to each sewing machine, a different portion of its periphery, and each corresponding sewing machine is adapted to cut off the excess of the fabric segment projecting beyond the then-presented periphery of the holder and to sew an edge seam on the segment along such peripheral portion of the holder. After all four sides of the segment have been cut away and seamed, the resulting blank can be folded over parallel to the edges of the reinforcing strip and provided with closing seams to complete the panty. | 3 |
This is a divisional application of application Ser. No. 09/145,530, filed Sep. 2, 1998, now U.S. Pat. No. 6,117,959.
FIELD OF THE INVENTION
The present invention is directed to Group 8-10 transition metal-containing complexes and their use in olefin polymerizations.
BACKGROUND OF THE INVENTION
Olefin polymers are used in a wide variety of products, from sheathing for wire and cable to film. Olefin polymers are used, for instance, in injection or compression molding applications, in extruded films or sheeting, as extrusion coatings on paper, for example photographic paper and digital recording paper, and the like. Improvements in catalysts have made it possible to better control polymerization processes, and, thus, influence the properties of the bulk material. Increasingly, efforts are being made to tune the physical properties of plastics for lightness, strength, resistance to corrosion, permeability, optical properties, and the like, for particular uses. Chain length, polymer branching and functionality have a significant impact on the physical properties of the polymer. Accordingly, novel catalysts are constantly being sought in attempts to obtain a catalytic process for polymerizing olefins which permits more efficient and better controlled polymerization of olefins.
Conventional polyolefins are prepared by a variety of polymerization techniques, including homogeneous liquid phase, gas phase, and slurry polymerization. Certain transition metal catalysts, such as those based on titanium compounds (e.g. TiCl 3 or TiCl 4 ) in combination with organoaluminum cocatalysts, are used to make linear and linear low density polyethylenes as well as poly-α-olefins such as polypropylene. These so-called “Ziegler-Natta” catalysts are quite sensitive to oxygen and are ineffective for the copolymerization of nonpolar and polar monomers.
Recent advances in non-Ziegler-Natta olefin polymerization catalysis include the following.
L. K. Johnson et al., WO Patent Application 96/23010, disclose the, polymerization of olefins using cationic nickel, palladium, iron, and cobalt complexes containing diimine and bisoxazoline ligands. This document also describes the polymerization of ethylene, acyclic olefins, and/or selected cyclic olefins and optionally selected unsaturated acids or esters such as acrylic acid or alkyl acrylates to provide olefin homopolymers or copolymers.
European Patent Application Serial No. 381,495 describes the polymerization of olefins using palladium and nickel catalysts which contain selected bidentate phosphorous containing ligands.
L. K. Johnson et al., J. Am. Chem. Soc., 1995, 117, 6414, describe the polymerization of olefins such as ethylene, propylene, and 1-hexene using cationic α-diimine-based nickel and palladium complexes. These catalysts have been described to polymerize ethylene to high molecular weight branched polyethylene. In addition to ethylene, Pd complexes act as catalysts for the polymerization and copolymerization of olefins and methyl acrylate.
G. F. Schmidt et al., J. Am. Chem. Soc. 1985, 107, 1443, describe a cobalt(III) cyclopentadienyl catalytic system having the structure [C 5 Me 5 (L)CoCH 2 CH 2 -μ-H] + , which provides for the “living” polymerization of ethylene.
M. Brookhart et al., Macromolecules 1995, 28, 5378, disclose using such “living” catalysts in the synthesis of end-functionalized polyethylene homopolymers.
U. Klabunde, U.S. Pat. Nos. 4,906,754, 4,716,205, 5,030,606, and 5,175,326, describes the conversion of ethylene to polyethylene using anionic phosphorous, oxygen donors ligated to Ni(II). The polymerization reactions were run between 25 and 100° C. with modest yields, producing linear polyethylene having a weight-average molecular weight ranging between 8K and 350K. In addition, Klabunde describes the preparation of copolymers of ethylene and functional group containing monomers.
M. Peuckert et al., Organomet. 1983, 2(5), 594, disclose the oligomerization of ethylene using phosphine, carboxylate donors ligated to Ni(II), which showed modest catalytic activity (0.14 to 1.83 TO/s). The oligomerizations were carried out at 60 to 95° C. and 10 to 80 bar ethylene in toluene, to produce linear α-olefins.
R. E. Murray, U.S. Pat. Nos. 4,689,437 and 4,716,138, describes the oligomerization of ethylene using phosphine, sulfonate donors ligated to Ni(II). These complexes show catalyst activities approximately 15 times greater than those reported with phosphine, carboxylate analogs.
W. Keim et al., Angew. Chem. Int. Ed. Eng. 1981, 20, 116, and V. M. Mohring, et al., Angew. Chem. Int. Ed. Eng. 1985, 24, 1001, disclose the polymerization of ethylene and the oligomerization of α-olefins with aminobis(imino)phosphorane nickel catalysts; G. Wilke, Angew. Chem. Int. Ed. Engl. 1988, 27, 185, describes a nickel allyl phosphine complex for the polymerization of ethylene.
K. A. O. Starzewski et al., Angew. Chem. Int. Ed. Engl. 1987, 26, 63, and U.S. Pat. No. 4,691,036, describe a series of bis(ylide) nickel complexes, used to polymerize ethylene to provide high molecular weight linear polyethylene.
WO Patent Application 97/02298 discloses the polymerization of olefins using a variety of neutral N, O, P, or S donor ligands, in combination with a nickel(0) compound and an acid.
Brown et al., WO 97/17380, describes the use of Pd α-diimine catalysts for the polymerization of olefins including ethylene in the presence of air and moisture.
Fink et al., U.S. Pat. No., 4,724,273, have described the polymerization of α-olefins using aminobis(imino)phosphorane nickel catalysts and the compositions of the resulting poly(α-olefins).
Recently Vaughan et al., WO 97/48736, Denton et al., WO 97/48742, and Sugimura et al., WO 97/38024 have described the polymerization of ethylene using silica supported α-diimine nickel catalysts.
Additional recent developments are described by Sugimura et al., in JP96-84344, JP96-84343, by Yorisue et al., in JP96-70332, by Canich et al., WO 97148735, McLain et al., WO 98/03559, Weinberg et al., WO 98/03521 and by Matsunaga et al., WO 97/48737.
Notwithstanding these advances in non-Ziegler-Natta catalysis, there remains a need for efficient and effective Group 8-10 transition metal catalysts for effecting polymerization of olefins. In addition, there is a need for novel methods of polymerizing olefins employing such effective Group 8-10 transition metal catalysts. In particular, there remains a need for Group 8-10 transition metal olefin polymerization catalysts with both improved temperature stability and functional group compatibility. Further, there remains a need for a method of polymerizing olefins utilizing effective Group 8-10 transition metal catalysts in combination with a Lewis acid so as to obtain a catalyst that is more active and more selective.
SUMMARY OF THE INVENTION
The present invention is directed to novel Group 8-10 transition metal catalysts and to batch or continuous polymerizations using these catalysts. The catalysts used in the processes of the present invention readily convert ethylene and α-olefins to high molecular weight polymers, and allow for olefin polymerizations under various conditions, including ambient temperature and pressure, and in solution. Preferred catalysts include certain dipyridyl ligands coordinated to Group 8-10 transition metals.
The catalysts and processes of the present invention are useful in the preparation of homopolymers of olefins, such as polyethylene, polypropylene, and the like, and olefin copolymers. As an example, ethylene homopolymers can be prepared with strictly linear to highly branched structures by variation of the catalyst structure, cocatalyst composition, and reaction conditions, including pressure and temperature. The effect these parameters have on polymer structure is described herein. These polymers and copolymers have a wide variety of applications, including use as packaging materials and in adhesives.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a process for the polymerization of olefins, comprising contacting one or more monomers selected from compounds of the formula R 2 CH═CHR 2 with a catalyst comprising (a) a Ni(II), Pd(II), Co(II), or Fe(II) metal atom, (b) a ligand of the formula I, and optionally (c) a Bronsted or Lewis acid,
wherein
R 1 and R 2 are each, independently, hydrogen, hydrocarbyl, or fluoroalkyl, and may be linked to form a cyclic olefin;
L 1 and L 2 are each, independently, a 5- or 6-membered, monodentate N-donor, heterocyclic ring connected to Q at the position adjacent to the donor nitrogen; and
Q is a group of the formula —C(Y)(Z)— wherein Z is H or a heteroatom connected monoradical and Y is hydrocarbyl or substituted hydrocarbyl.
In the above process, it should be appreciated that the Group 8-10 transition metal has coordinated thereto a bidentate ligand having the formula I and that component (c) is optionally reacted with this metal-ligand complex.
As a further aspect of the invention, there is provided a process for the polymerization of olefins, comprising contacting one or more monomers of the formula R 1 CH═CHR 2 with a catalyst of formula II:
wherein
R 1 and R 2 are each, independently, hydrogen, hydrocarbyl, or fluoroalkyl, and may be linked to form a cyclic olefin;
L 1 and L 2 are each, independently, a 5- or 6-membered, monodentate N-donor, heterocyclic ring connected to Q at the position adjacent to the donor nitrogen;
Q is a group of the formula —C(Y)(Z)— wherein Z is H or a heteroatom connected monoradical and Y is hydrocarbyl or substituted hydrocarbyl;
T is hydrogen or hydrocarbyl;
L is a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;
M is Ni(II), Pd(II), Co(II), or Fe(II); and
X − is a weakly coordinating anion.
We believe that when T is hydrogen or hydrocarbyl and L is ethylene or a mono-olefin in formula II above, then II is the catalytically active species. This active species can be prepared by a number of different methodologies, including reaction of a zero-valent metal complex with a ligand of formula I and a Bronsted acid in the presence of ethylene or a mono-olefin. An example of this methodology includes the reaction of bis(cyclooctadiene)Ni(0) with a bidentate ligand of formula I and hydrogen tetrakis[3,5-(bistrifluoromethyl)phenyl]borate in the presence of ethylene or a mono-olefin to generate an active catalyst of formula II.
In a further aspect of the invention, there is provided a process for the polymerization of olefins, comprising contacting one or more monomers of the formula R 1 CH═CHR 2 with a catalyst formed by combining a compound of formula III:
with a compound A, wherein
R 1 and R 2 are each, independently, H, hydrocarbyl, or fluoroalkyl, and may be linked to form a cyclic olefin;
L 1 and L 2 are each, independently, a 5- or 6-membered, monodentate N-donor, heterocyclic ring connected to Q at the position adjacent to the donor nitrogen;
Q is a group of the formula —C(Y)(Z)— wherein Z is H or a heteroatom connected monoradical and Y is hydrocarbyl or substituted hydrocarbyl;
U is alkyl, chloride, iodide or bromide;
W is alkyl, chloride, iodide or bromide;
M is Ni(II), Pd(II), Co(II), or Fe(II); and,
A is selected from the group consisting of a neutral Lewis acid capable of abstracting U − or W − to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, and a Bronsted acid whose conjugate base is a weakly coordinating anion.
As a further example of a methodology useful to prepare the catalytically active specie II includes, when U and W are both independently bromide, the complex III can be reacted with a compound A (e.g., an alkyl aluminum specie, such as methylaluminoxane (MAO)), in the presence of ethylene or a mono-olefin to provide the active catalyst of formula II.
Also provided are the catalysts described above. Accordingly, as a further aspect of the invention there is provided a compound of formula II:
wherein
L 1 and L 2 are each, independently, a 5- or 6-membered, monodentate N-donor, heterocyclic ring connected to Q at the position adjacent to the donor nitrogen;
Q is a group of the formula —C(Y)(Z)— wherein Z is H or a heteroatom connected monoradical and Y is hydrocarbyl or substituted hydrocarbyl;
T is H or hydrocarbyl;
L is a mono-olefin or a neutral Lewis base wherein the coordinated atom is nitrogen, oxygen, or sulfur;
M is Ni(II), Pd(II), Co(II), or Fe(II); and
X − is a weakly coordinating anion.
Also provided is a compound of formula III:
wherein
L 1 and L 2 are each, independently, a 5- or 6-membered, monodentate N-donor, heterocyclic ring connected to Q at the position adjacent to the donor nitrogen;
Q is a group of the formula —C(Y)(Z)— wherein Z is H or a heteroatom connected monoradical and Y is hydrocarbyl or substituted hydrocarbyl;
U is alkyl, chloride, iodide, or bromide;
W is alkyl, chloride, iodide, or bromide; and
M is Ni(II), Pd(II), Co(II), or Fe(II).
Also provided is a composition comprising (a) a Group 8-10 transition metal M, (b) one or more Lewis acids, and (c) a binucleating or multinucleating compound of the formula I:
wherein
the Lewis acid or acids are bound to one or more heteroatoms which are π-conjugated to the donor atom or atoms bound to the transition metal M;
L 1 and L 2 are each, independently, a 5- or 6-membered, monodentate N-donor, heterocyclic ring connected to Q at the position adjacent to the donor nitrogen;
Q is a group of the formula —C(Y)(Z)— wherein Z is H or a heteroatom connected monoradical and Y is hydrocarbyl or substituted hydrocarbyl.
In this disclosure certain chemical groups or compounds are described by certain terms and symbols. These terms are defined as follows:
Symbols ordinarily used to denote elements in the Periodic Table take their ordinary meaning, unless otherwise specified. Thus, N, O, S, P, and Si stand for nitrogen, oxygen, sulfur, phosphorus, and silicon, respectively.
Examples of neutral Lewis acids include, but are not limited to, methylaluminoxane (hereinafter MAO) and other aluminum sesquioxides, R 7 3 Al, R 7 2 AlCl, R 7 AlCl 2 (where R 7 is alkyl), organoboron compounds, boron halides, B(C 6 F 5 ) 3 , BPh 3 , and B(3,5-(CF 3 )C 6 H 3 ) 3 . Examples of ionic compounds comprising a cationic Lewis acid include: R 9 3 Sn[BF 4 ], (where R 9 is hydrocarbyl), MgCl 2 , and H + X − , where X − is a weakly coordinating anion.
Examples of neutral Lewis bases include, but are not limited to, (i) ethers, for example, diethyl ether or tetrahydrofuran, (ii) organic nitrites, for example acetonitrile, (iii) organic sulfides, for example dimethylsulfide, or (iv) monoolefins, for example, ethylene, hexene or cyclopentene.
A “hydrocarbyl” group means a monovalent or divalent, linear, branched or cyclic group which contains only carbon and hydrogen atoms. Examples of monovalent hydrocarbyls include the following: C 1 -C 20 alkyl; C 1 -C 20 alkyl substituted with one or more groups selected from C 1 -C 20 alkyl, C 3 -C 8 cycloalkyl or aryl; C 3 -C 8 cycloalkyl; C 3 -C 8 cycloalkyl substituted with one or more groups selected from C 1 -C 20 alkyl, C 3 -C 8 cycloalkyl or aryl; C 6 -C 14 aryl; and C 6 -C 14 aryl substituted with one or more groups selected from C 1 -C 20 alkyl, C 3 -C 8 cycloalkyl or aryl; where the term “aryl” preferably denotes a phenyl, napthyl, or anthracenyl group. Examples of divalent (bridging) hydrocarbyls include: —CH 2 —, —CH 2 CH 2 —, —CH 2 CH 2 CH 2 —, and 1,2-phenylene.
A “heteroatom” refers to an atom other than carbon or hydrogen. Preferred heteroatoms include oxygen, nitrogen, phosphorus, sulfur, selenium, arsenic, chlorine, bromine, silicon and fluorine.
A “substituted hydrocarbyl” refers to a monovalent or divalent hydrocarbyl substituted with one or more heteroatoms. Examples of monovalent substituted hydrocarbyls include: —C(O)R 13 (wherein R 13 is hydrocarbyl), —C(O)NR 13 2 (wherein R 13 is hydrocarbyl), 2-hydroxyphenyl, 2-methoxyphenyl, 2-ethoxyphenyl, 2-fluorophenyl, 2-chlorophenyl, 2-trifluoromethylphenyl, 2,6-bis(trifluoromethyl)phenyl, 2-(trialkylsiloxy)phenyl, 2-(triarylsiloxy)phenyl, 2,6-bis(diphenylamino)phenyl, 2,6-bis(phenoxy)phenyl, 2-hydroxy-6-phenylphenyl, 2-cyanophenyl, 2-(diphenylamino)phenyl, 4-nitrophenyl, 2-nitrophenyl, —CH 2 OR 13 (wherein R 13 is hydrocarbyl), cyano, —CH 2 NR 13 2 (wherein R 13 is hydrocarbyl), and —H 2 OSiR 13 3 (wherein R 13 is hydrocarbyl).
A “monodentate N-donor, heterocyclic ring” refers to an aromatic substituted hydrocarbyl ring containing at least one sp 2 hybridized nitrogen atom, which provides a single point of coordination to the transition metal M, and which optionally may contain additional heteroatoms which are π-conjugated to the nitrogen that is bound to the transition metal M, in the ring. While not wishing to be bound by theory, the present inventors believe certain Lewis acid cocatalysts (e.g. alkyl aluminum species such as trimethylaluminum or MAO) may coordinate to said additional heteroatoms, thereby rendering the catalysts herein more active or more selective or both. A nonlimiting example of this secondary Lewis acid binding would include the following:
wherein T, L, M, and X are as defined above. Preferred examples of monodentate N-donor heterocyclic rings include:
wherein E is selected from H, OCH 3 , NO 2 , CN, SO 2 R 6 , CO 2 R 6 , and CONR 6 2 where R 6 is hydrocarbyl or substituted hydrocarbyl; and, R 5 is hydrocarbyl or substituted hydrocarbyl. More preferred monodentate N-donor heterocycles include:
wherein:
R 5 is hydrocarbyl or substituted hydrocarbyl.
A “heteroatom connected monoradical” refers to a mono-radical group in which a heteroatom serves as the point of attachment. Examples include: —OH, —O(hydrocarbyl), —O(subtituted hydrocarbyl), —O(aluminum), —O(solid support), —N(C 6 H 5 ) 2 , —NH(C 6 H 5 ), —SH, —Cl, —F and SPh, where Ph is phenyl.
A “mono-olefin” refers to a hydrocarbon containing one carbon-carbon double bond.
The term “fluoroalkyl” as used herein refers to a C 1 -C 20 alkyl group substituted by one or more fluorine atoms.
The term “polymer” as used herein is meant a species comprised of monomer units and having a degree of polymerization (DP) of ten or higher.
The term “α-olefin” as used herein is a 1-alkene with from 3 to 40 carbon atoms.
The term “weakly coordinating anion” is well-known in the art per se and generally refers to a large bulky anion capable of delocalization of the negative charge of the anion. Suitable weakly coordinating anions include, but are not limited to alkyl aluminates, the anion formed from the reaction of MAO and a halogen ligated metal complex, PF 6 − , BF 4 − , SbF 6 − , (Ph) 4 B − wherein Ph=phenyl, and − BAr 4 wherein − BAr 4 =tetrakis[3,5-bis(trifluoromethyl)phenyl]borate. The coordinating ability of such anions is known and described in the literature (Strauss, S. et al., Chem. Rev. 1993, 93, 927).
As used herein, the terms “monomer” or “olefin monomer” refer to the olefin or other monomer compound before it has been polymerized; the term “monomer units” refers to the moieties of a polymer that correspond to the monomers after they have been polymerized.
In some cases, a compound A is required as a cocatalyst. Suitable compounds A include a neutral Lewis acid capable of abstracting Q − or W − to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, or a Bronsted acid whose conjugate base is a weakly coordinating anion. Preferred compounds A include: methylaluminoxane (hereinafter MAO) and other aluminum sesquioxides, R 7 3 Al, R 7 2 AlCl, R 7 AlCl 2 (wherein R 7 is alkyl), organoboron compounds, boron halides, B(C 6 F 5 ) 3 , R 9 3 Sn[BF 4 ] (wherein R 9 is hydrocarbyl), MgCl 2 , and H + X − , wherein X − is a weakly coordinating anion.
Examples of “solid support” include inorganic oxide support materials, such as: talcs, silicas, titania, silica/chromia, silicalchromia/titania, silica/alumina, zirconia, aluminum phosphate gels, silanized silica, silica hydrogels, silica xerogels, silica aerogels, and silica co-gels. An especially preferred solid support is one which has been pre-treated with A compounds as described herein, most preferably with MAO. Thus, in a preferred embodiment, the catalysts of the present invention are attached to a solid support (by “attached to a solid support” is meant ion paired with a component on the surface, adsorbed to the surface or covalently attached to the surface) which has been pre-treated with an A compound. In an especially preferred embodiment, the compounds of the present invention are attached to silica which has been pretreated with MAO. Such supported catalysts are prepared by contacting the compound, in an inert solvent—by which is meant a solvent which is either unreactive under the conditions of catalyst preparation, or if reactive, acts to usefully modify the catalyst activity or selectivity—with MAO treated silica for a sufficient period of time to generate the supported catalysts. Examples of unreactive solvents include toluene, mineral spirits and hexane. Examples of potentially reactive solvents include CH 2 Cl 2 and CHCl 3 .
Thus, in a further preferred embodiment of the invention, there is provided a supported catalyst comprising the reaction product of a compound of formula III
wherein
L 1 and L 2 are each, independently, a 5- or 6-membered, monodentate N-donor, heterocyclic ring connected to Q at the position adjacent to the donor nitrogen;
Q is a group of the formula —C(Y)(Z)— wherein Z is H or a heteroatom connected monoradical and Y is hydrocarbyl or substituted hydrocarbyl;
U is alkyl, chloride, iodide or bromide;
W is alkyl, chloride, iodide or bromide;
M is Ni(II), Pd(II), Co(II), or Fe(II); and,
with a solid support which has been pre-treated with a compound A, wherein A is selected from the group consisting of a neutral Lewis acid capable of abstracting U − or W − to form a weakly coordinating anion, a cationic Lewis acid whose counterion is a weakly coordinating anion, and a Bronsted acid whose conjugate base is a weakly coordinating anion.
In general, ligands of formula I can be synthesized by nucleophilic addition of a Grignard reagent, which can be prepared in situ from the corresponding aryl or alkyl bromide and Mg turnings, on a di-heterocyclic ketone. The diheterocyclic ketones can be purchased and used without further purification, or prepared according to the procedure of Newkome, et al. (Newkome, G. R., Joo, Y. J., Evans, D. W., Pappalardo, S., Fronczek, F. R., J. Org. Chem. 1988, 53, 786-790) from a heterocyclic substituted acetonitrile, as in the following example (scheme I-mCPBA denotes meta-chloro perbenzoic acid and DMF denotes N,N-dimethylformamide):
The polymerizations may be conducted as solution polymerizations, as non-solvent slurry type polymerizations, as slurry polymerizations using one or more of the olefins or other solvent as the polymerization medium, or in the gas phase. One of ordinary skill in the art, with the present disclosure, would understand that the catalyst could be supported using a suitable catalyst support and methods known in the art. Substantially inert solvents, such as toluene, hydrocarbons, methylene chloride and the like, may be used. Propylene and 1-butene are excellent monomers for use in slurry-type copolymerizations and unused monomer can be flashed off and reused.
Temperature and olefin pressure have significant effects on copolymer structure, composition, and molecular weight. Suitable polymerization temperatures are preferably from about −100° C. to about 200° C., more preferably in the 20° C. to 150° C. range.
After the reaction has proceeded for a time sufficient to produce the desired polymers, the polymer can be recovered from the reaction mixture by routine methods of isolation and/or purification.
In general, the polymers of the present invention are useful as components of thermoset materials, as elastomers, as packaging materials, films, compatibilizing agents for polyesters and polyolefins, as a component of tackifying compositions, and as a component of adhesive materials.
High molecular weight resins are readily processed using conventional extrusion, injection molding, compression molding, and vacuum forming techniques well known in the art. Useful articles made from them include films, fibers, bottles and other containers, sheeting, molded objects and the like.
Low molecular weight resins are useful, for example, as synthetic waxes and they may be used in various wax coatings or in emulsion form. They are also particularly useful in blends with ethylene/vinyl acetate or ethylenelmethyl acrylate-type copolymers in paper coating or in adhesive applications.
Although not required, typical additives used in olefin or vinyl polymers may be used in the new homopolymers and copolymers of this invention. Typical additives include pigments, colorants, titanium dioxide, carbon black, antioxidants, stabilizers, slip agents, flame retarding agents, and the like. These additives and their use in polymer systems are known per se in the art.
The molecular weight data presented in the following examples is determined by gel permeation chromatography (GPC) at 135° C. in 1,2,4-trichlorobenzene using refractive index detection, calibrated using narrow molecular weight distribution poly(styrene) standards.
EXAMPLES
Example 1
Synthesis of VI: A solution of 2-bromobiphenyl (740 μl, 4.29 mmol) in diethyl ether (Et 2 O) (4 ml) was slowly added to a suspension of Mg (125 mg, 5.14 mmol) in Et 2 O (4 ml). A crystal of iodine and 1,2-dibromoethane (70 μl) were added, and the suspension was heated to reflux for 1 hour. The resulting suspension was cooled to room temperature and treated with a solution of di-2-pyridyl ketone (788 mg, 4.28 mmol) in Et 2 O (8 ml), which resulted in the immediate formation of an orange precipitate. THF (10 ml) was added to dilute the suspension. The reaction was stirred at room temperature overnight, quenched with saturated aqueous NaHCO 3 (25 ml) and concentrated in vacuo. The residue was partitioned between H 2 O (25 ml) and CHCl 3 (25 ml). The aqueous layer was further extracted with CHCl 3 (2×25 ml). The combined organic layers were washed with saturated aqueous Na 2 S 2 O 3 (25 ml) and brine (25 ml), dried over Na 2 SO 4 , filtered and concentrated in vacuo to afford the tertiary alcohol VI (1.37 g) contaminated with a small amount of 2-dipyridyl ketone: FDMS m/z 338 (M+).
Example 2
Synthesis of VII: VI (107 mg, 0.32 mmol) was charged to a 50 ml flame dried Sclenk tube, and pumped into an Ar filled dry box. In the box, (dimethoxyethane(DME))NiBr 2 (77 mg, 0.25 mmol) was added, the tube was capped with a septum and removed from the box. CH 2 Cl 2 (15 ml) was added via syringe. The reaction was stirred at room temperature overnight, and concentrated under a stream of Ar. The resulting solid was washed with hexanes (2×10 ml), and dried in vacuo to afford VII as a green solid.
Example 3
Ethylene Polymerization with VII: The dibromide complex VII (10 mg, 0.018 mmol) was suspended in toluene (50 ml). The suspension was equilibrated at room temperature under 1 atm of ethylene for 15 min, then treated with methylaluminoxane (MAO) (2 ml, 10 wt % solution in toluene) and stirred vigorously under 1 atm ethylene. The reaction exothermed to 50° C. After 10 min, the reaction was quenched by the addition of acetone, methanol and 6 N HCl. The toluene layer was separated and concentrated in vacuo to afford 760 mg of polyethylene (9100 TO/hr) (TO/hr=turnovers per hour). 1 H NMR (300 MHz, CDCl 3 ) ˜80-100 branches/1000 C's, M n =4500; gas phase chromatography (GPC) M n =3550, M w =7950.
Example 4
Ethylene Polymerization with VII: The dibromide complex VII (9 mg, 0.016 mmol) was suspended in toluene (50 ml). The suspension was equilibrated at 0° C. in an ice water bath under 1 atm of ethylene, then treated with MAO (2 ml, 10 wt % solution in toluene) and stirred vigorously under 1 atm of ethylene at 0° C. After 2 hr., the reaction was quenched by sequential addition of acetone, methanol and 6 N HCl. The resulting polymer was filtered and dried in vacuo to to afford 1.42 g of polyethylene (1600 TO/hr). 1 H NMR (400 MHz, o-dichlorobenzene-d 4 ) 41 branches/1000 C's, M n =16,400; GPC M n =13,100, M w =50,700.
Example 5
Ethylene Polymerization with VII: The dibromide complex VII (10 mg, 0.018 mmol) was suspended in toluene (100 ml) in a Fisher pressure bottle. The suspension was equilibrated at 0° C. under 20 psig ethylene for 10 min, then treated with MAO (2 ml, 10 wt % solution in toluene) and stirred vigorously under 60 psig ethylene at 0° C. After 80 min., the reaction was quenched by the sequential addition of acetone, methanol, and 6 N HCl. The resulting polymer was collected by filtration and dried to afford 542 mg of polyethylene (811 TO/hr). 1 H NMR (400 MHz, o-dichlorobenzene-d 4 ) 15 branches/1000 C's, M n =23,300; GPC M n =15,900, M w =74,200.
Example 6
Ethylene Polymerization with VII: The dibromide complex VII (10 mg, 0.016 mmol) was suspended in toluene (50 ml). The suspension was equilibrated at 0° C. in an ice water bath under 1 atm of ethylene, then treated with MAO (2 ml, 10 wt % solution in toluene) and stirred vigorously under 1 atm of ethylene at 0° C. After 1 hr., the reaction was quenched by sequential addition of acetone, methanol and 6 N HCl. The resulting polymer was filtered and dried in vacuo to afford 944 mg of polyethylene (2100 TO/hr). 1 H NMR (400 MHz, o-dichlorobenzene-d 4 ) 46 branches/1000 C's, M n =12,860; GPC M n =12,800, M w =39,700.
Example 7
Ethylene Polymerization with VII: The dibromide complex VII (10.5 mg) was suspended in toluene (50 ml). The suspension was equilibrated at room temperature (immersed in a water bath) under 1 atm of ethylene for 10 min, then treated with MAO (2 ml, 10 wt % solution in toluene). The resulting solution was stirred vigorously under 1 atm of ethylene at room temperature for 30 min, then quenched by the sequential addition of acetone, methanol, and 6N HCl. The resulting polymer was filtered and dried in vacuo to afford 878 mg of polyethylene (3300 TO/hr). 1 H NMR (400 MHz, o-dichlorobenzene-d 4 ) 70 branches/1000 C's, M n =6300; GPC M n =7360, M w =14,400.
Example 8
Ethylene Polymerization with VII: The dibromide complex VII (3 mg, 0.0054 mmol) was charged to a stainless steel Parr® autoclave, which was then evacuated and backfilled with ethylene. Toluene (300 ml) and MAO (2 ml, 10 wt % solution in toluene) were added sequentially with vigorous stirring. The reactor was rapidly pressurized to 600 psig ethylene and heated to ˜45° C. Over ˜5 min, the pressure reached 800 psig ethylene. After 13 min of vigorous stirring, the rupture valve on the reactor blew, resulting in a loss of ˜⅓ of the volume of the reactor. The remaining suspension was filtered and dried in vacuo to afford 1.07 g of polyethylene (48,850 TO/hr based on a loss of 33% of the volume of the reactor). 1 H NMR (400 MHz, o-dichlorobenzene-d 4 ) 36 branches/1000 C's, M n =9,670; GPC M n =9,730, M w =25,500.
Example 9
Synthesis of VIII: A solution of 2-dipyridyl ketone (1 g, 5.43 mmol) in THF (16 ml) was added via cannula with stirring to a solution of phenyl magnesium bromide (5.97 ml, 1 M in THF) in THF (16 ml). The resulting suspension was stirred at room temperature for 18 hr, then quenched with aqueous saturated NH 4 Cl (25 ml). The volatiles were removed in vacuo and the residue was partitioned between CH 2 Cl 2 (25 ml) and H 2 O (25 ml). The aqueous layer was further extracted with CH 2 Cl 2 (2×25 ml). The combined organic layers were washed with brine (25 ml) dried over Na 2 SO 4 filtered and concentrated in vacuo to afford an oil, which crystallized on standing. The resulting crystals were filtered, washed with methanol and dried in vacuo to afford VIII (572 mg, 40%) as white crystals: FDMS m/z 262 (M+).
Example 10
Synthesis of IX: Alcohol VIII (108.5 mg, 0.414 mmol) was charged to a 50 ml Schlenck tube and pumped into an Ar filled glove box. The tube was charged with (DME)NiBr 2 (101 mg, 0.331 mmol), capped with a septum and removed from the box. CH 2 Cl 2 (10 ml) was added to the tube and the resulting solution was stirred under Ar overnight. The CH 2 Cl 2 was removed under a stream of Ar, the resulting solid was washed with hexanes (2×10 ml) and dried in vacuo to afford IX as a green solid.
Example 11
Ethylene Polymerization with IX: A suspension of dibromide complex IX (9.5 mg, 0.0196 mmol) in toluene (50 ml) was allowed to equilibrate at 0° C. under 1 atm of ethylene, then treated with MAO (2 ml, 10 wt % solution in toluene). The resulting suspension was stirred vigorously at 0° C. under 1 atm of ethylene for 11 min, then quenched by the sequential addition of acetone, methanol, and 6 N HCl. The resulting polymer was filtered and dried in vacuo to afford 63 mg of polyethylene (690 TO/hr). GPC M n =910, M w =2230.
Example 12
Synthesis of X: A 1 ml portion of a solution of 4-bromobiphenyl (900.6 mg, 3.86 mmol) in Et 2 O (5 ml) and tetrahydrofuran (THF) (1 ml) was added to a suspension of Mg turnings (93.9 mg, 3.86 mmol) in Et 2 O (5 ml). 1,2-Dibromethane (0.25 ml) was added. After initiation, the remainder of the 4-bromobiphenyl solution was added in 1 ml portions. The reaction was then stirred at room temperature for 1 hr, heated to reflux for 2 hr and cooled to rt. A solution of 2-dipyridyl ketone (741 mg, 4.02 mmol) in Et 2 O (5 ml) was added, resulting in the immediate formation of a precipitate. Additional THF (5 ml) was added, and the suspension stirred at rt. After 2 hr, the reaction was quenched with saturated aqueous NH 4 Cl, and extracted with CH 2 Cl 2 . The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to afford X as an oil, which crystallized on standing: FDMS m/z 339 (M+1).
Example 13
Synthesis of XI: A mixture of (DME)NiBr 2 (76 mg, 0.246 mmol) and alcohol X (100 mg, 0.295 mmol) was dissolved in CH 2 Cl 2 (2 ml). The resulting solution was stirred at rt under Ar for 45 min. The CH 2 Cl 2 was removed in vacuo to afford XI as a solid.
Example 14
Ethylene Polymerization with XI: A suspension of dibromide complex XI (11 mg, 0.0197 mmol) in toluene (50 ml) was allowed to equilibrate at 0° C. under 1 atm of ethylene, then treated with MAO (2 ml, 10 wt % solution in toluene). The resulting solution was stirred vigorously at 0° C. under 1 atm of ethylene for 30 min, then quenched by the sequential addition of acetone, ethanol, and 6 N HCl. The resulting polymer was filtered and dried in vacuo to afford 206.5 mg of polyethylene (800 TO/hr). GPC M n =4440, M w =11,200.
Example 15
Synthesis of XII: To a stirred room temperature suspension of Mg turnings (97.8 mg, 4.02 mmol) in tetrahydrofuran (5 ml) was added 1,2-dibromoethane (0.15 ml) and a 1 ml portion of a solution of 2-bromonaphthalene (803.2 mg, 3.88 mmol) in tetrahydrofuran (5 ml). The suspension was warmed slightly to initiate the reaction then the rest of the 2-bromonaph tale ne solution was added in 1 ml portions over 20 min. The reaction was heated at reflux for an additional 20 mm, then cooled to room temperature and treated with a solution of 2-dipyridyl ketone (715 mg, 3.88 mmol) in tetrahydrofuran (5 ml). The resulting suspension was stirred at room temperature for 50 min an d at reflux for 15 min, after which it was cooled to room temperature and quenched with aq. saturated NH 4 Cl and extracted with Et 2 O. The combined organic layers were dried over MgSO 4 , filtered and dried in vacuo. The residue was chromatographed (SiO 2 , 3/1 hexane/ethyl acetate) to afford XII (195.6 mg, 16%): R f 0.24 (3/1 hexane/ethyl acetate); FDMS m/z 312 (M+).
Example 16
Synthesis of XIII: A solution of XII (97.8 mg, 0.31 mmol) in CH 2 Cl 2 (10 ml) was added to dry (DME)NiBr 2 (90.0 mg, 0.294 mmol) under nitrogen at room temperature. The resulting solution was stirred at room temperature for 45 min., t hen concentrated in vacuo to afford XIII as a green powder.
Example 17
Ethylene Polymerization with XII: A suspension of dibromide complex XIII (11 mg, 0.020 mmol) in toluene (50 ml) was allowed to equilibrate at 0° C. under 1 atm of ethylene, then treated with MAO (2 ml, 10 wt % solution in toluene). The resulting solution was stirred vigorously at 0° C. under 1 atm of ethylene for 30 min, then quenched by the sequential addition of acetone, methanol, and 6 N HCl. The resulting polymer was filtered and dried in vacuo to afford 160.8 mg of polyethylene (575 TO/hr). GPC M n =4180, M w =16,600.
Example 18
Synthesis of XIV: To a stirred suspension of Mg turnings (488 mg, 20 mmol) in Et 2 O (2.6 ml) was added a 0.20 ml portion of a solution of 2-bromothiazole (0.458 ml, 5.1 mmol) in 1,2-dibromoethane (1.32 ml, 15 mmol). The resulting suspension was stirred at room temperature for 30 min. The remainder of the 2-bromothiazole solution was added in 0.10 ml portions at a rate such that a gentle reflux was maintained. After the final addition, the reaction was stirred at room temperature for 30 min, then treated with a solution of 2-phenyl ethyl benzoate (0.524 ml, 2.55 mmol) in Et 2 O (4 ml). The resulting suspension was stirred at room temperature for 3.5 hr, then quenched with aqueous saturated NH 4 Cl (25 ml) and extracted with CH 2 Cl 2 (2×25 ml). The combined organic layers were dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was flash chromatographed (SiO 2 , 12% ethyl acetate/hexanes followed by 25% ethyl acetate/hexanes) to afford XIV (143 mg, 1.6%): R f 0.07 (12% ethyl acetate/hexanes).
Example 19
Synthesis of XV: To (DME)NiBr 2 (100 mg, 0.33 mmol) was added a solution of XIV (143 mg, 0.41 mmol) in CH 2 Cl 2 (19 ml). The resulting solution was stirred at room temperature for 1.5 hr. The solvent was removed under a stream of Ar and the residue was dried in vacuo to afford XV as a brown/green solid.
Example 20
Ethylene polymerization with XV: A suspension of dibromide complex XV (10.8 mg, 0.019 mmol) in toluene (50 ml) was allowed to equilibrate at 0° C. under 1 atm of ethylene, then treated with MAO (2 ml, 10 wt % solution in toluene). The resulting solution was stirred vigorously at 0° C. under 1 atm of ethylene for 200 min, then quenched by the sequential addition of acetone, methanol, and 6 N HCl. The resulting polymer was filtered and dried in vacuo to afford 243.9 mg of polyethylene (138 TO/hr). GPC M n =860, M w =3080.
Example 21
Synthesis of XVI: A solution of 2-pyridylacetonitrile (0.472 ml, 4.23 mmol) in DMF (41 ml) was treated with NaH (677 mg, 17 mmol, 60% dispersion in mineral oil) and stirred under Ar for 30 min. The resulting suspension was treated with chloropyrazine (0.378 ml, 4.23 mmol) and heated to 90° C. for 5 hr. The reaction was then cooled to room temperature, quenched with H 2 O (100 ml) and extracted with CH 2 Cl 2 (2×100 ml). The combined organic layers were dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was flash chromatographed (SiO 2 , 4% methanol/CH 2 Cl 2 ) to afford XVI (713.9 mg, 86%): R f 0.5 (4% methanol/CH 2 Cl 2 ); FDMS m/z 196 (M+).
Example 22
Synthesis of XVII: An ice cold solution of XVI (215 mg, 1.1 mmol) in CHCl 3 (48 ml) was treated with 3-chloroperoxybenzoic acid (387 mg, 1.6 mmol). The resulting solution was stirred overnight, allowing the ice bath to expire, then quenched with 0.5 M NaOH (50 ml). The organic layer was removed and washed with brine (50 ml). The combined aqueous layers were further extracted with CH 2 Cl 2 (2×40 ml). The combined organic layers were dried over Na 2 SO 4 , filtered and concentrated in vacuo to afford XVII (169.1 mg, 83%) as a yellow solid: FDMS m/z 185 (M+).
Example 23
Synthesis of XVII: A suspension of Mg turnings (12 mg, 0.49 mmol) in Et 2 O (0.5 ml) was treated with a 0.25 ml of a solution of 2-bromobiphenyl (0.0591 ml, 0.343 mmol) in Et 2 O (0.5 ml) and 1,2-dibromoethane (0.006 ml). After initiation, the remaining 2-bromobiphenyl solution was added, and the suspension heated at reflux for 1 hr. The resulting suspension was cooled to room temperature, and treated with a solution of XVII (63.4 mg, 0.343 mmol) in Et 2 O (0.5 ml) and THF (1.0 ml). The suspension was stirred under Ar at room temperature for 1 hr, then quenched with aqueous saturated NH 4 Cl (10 ml) and extracted with CH 2 Cl 2 (2×10 ml). The combined organic layers were dried over Na 2 SO 4 , filtered and concentrated in vacuo. The residue was flash chromatographed (SiO 2 , 20% ethyl acetate/hexanes followed by 40% ethyl acetate/hexanes) to afford XVIII (25 mg, 22%): R f 0.58 (50% ethyl acetateihexanes); FDMS m/z 339 (M+).
Example 24
Synthesis of XIX: To (DME)NiBr 2 (18 mg, 0.0588 mmol) was added a solution of XVIII (25 mg, 0.074 mmol) in CH 2 Cl 2 (5 ml). The resulting solution was stirred at room temperature under Ar for 30 min, then concentrated in vacuo to afford XIX as a green solid.
Example 25
Ethylene Polymerization with XIX: A solution of dibromide complex XIX (9.0 mg, 0.016 mmol) in toluene (100 ml) was allowed to equilibrate at 0° C. under 1 atm of ethylene, then treated with MAO (4 ml, 10 wt % solution in toluene). The resulting solution was stirred vigorously at 0° C. under 1 atm of ethylene for 30 min, then quenched by the sequential addition of acetone, methanol, and 6 N HCl. The resulting polymer was filtered and dried in vacuo to afford 1.13 g of polyethylene (5,027 TO/hr). 1 H NMR (400 MHz, o-dichlorobenzene-d 4 ) 7 branches/1000 C's, M n =13,700; GPC M n =15,700, M w =127,900.
Example 26
Ethylene Polymerization with XIX: A solution of dibromide complex XIX (7.0 mg, 0.0125 mmol) in toluene (100 ml) was allowed to equilibrate at 23° C. under 1 atm of ethylene, then treated with MAO (4 ml, 10 wt % solution in toluene). The resulting solution was stirred vigorously at 23° C. under 1 atm of ethylene for 15 min, then quenched by the sequential addition of acetone, methanol, and 6 N HCl. The resulting polymer was filtered and dried in vacuo to afford 600.3 mg of polyethylene (6860 TO/hr): 1 H NMR (400 MHz, o-dichlorobenzene-d 4 ) 28 branches/1000 C's; GPC M n =5750, M w =66,300. | This invention is directed to novel Group 8-10 transition metal catalysts and to batch or continuous polymerizations using these catalysts. The catalysts of the present invention readily convert ethylene and α-olefins to high molecular weight polymers, and allow for olefin polymerizations under various conditions, including ambient temperature and pressure, and in solution. Preferred catalysts are group 8-10 transition metals having certain dipyridyl ligands bonded thereto. | 2 |
BACKGROUND OF THE INVENTION
Bis-β-hydroxy alkyl ethers of halogenated bisphenols are known and are used as hydroxy components for the production of flame resistant synthetic resins. These bis-ethers are generally solid, crystalline or vitreous (i.e. glass-like) resins. The esters produced from these ethers and dicarboxylic acids are also known and have already been used in the production of flameproof plastics. Canadian Pat. No. 663,542 relates, for example, to the production of an ester by esterifying bis-β-hydroxy ethyl dibromobisphenol and 1,2-propylene glycol with a mixture of phthalic acid anhydride and maleic acid anhydride. This ester contains 25.2% of bromine and is a glass-like resin at room temperature. However, to produce polyurethane and polyisocyanurate plastics, it is advantageous for the starting components to be in the form of low-viscosity liquids to enable the foaming mixture to be poured.
Polyethers containing free hydroxyl groups such as, for example, polyethylene glycol or polypropylene glycol, have long been used as low-viscosity components for the production of polyurethane and polyisocyanurate plastics. The polyethers of bisphenols containing hydroxyl groups are also known for this purpose. However, it is apparent from U.S. application Ser. No. 373,230, filed June 25, 1973, now abandoned, that polyethers of halogenated bisphenols cannot be produced under normal manufacturing conditions. The treatment of highly halogenated bisphenols, such as, tetrabromobisphenol, with alkylene oxides in the formation of bis-ethers of the kind referred to above, even in cases where an excess of alkylene oxide is used.
It would be an obvious solution to dissolve these bis-ethers in low-viscosity polyalkylene glycols in order to incorporate them as halogen carriers into the foaming mixture for producing substantially non-inflammable plastics. Unfortunately, the solubility of these bis-ethers in hydroxyl compounds of this kind is very poor. The ether quickly crystallizes out from solutions in which it is present in the high concentrations required, or alternatively the solution solidifies into a solid crystalline mass which can no longer be poured. According to U.S. Application No. 373,230, it is possible to obtain low-viscosity, pourable polyether derivatives of halogenated bisphenols. To achieve this, the polyethers of halogen-free bisphenols containing hydroxyl groups are initially prepared in known manner and are subsequently halogenated by treatment with elemental halogen, such as bromine. The polyethers thus obtained have a pourable consistency and the foams produced from them, especially polyisocyanurate foams, show outstanding flameproof properties. Unfortunately, they have the disadvantage that they tend to turn brittle at their surface and they exhibit poor bond strength with surface layers. In addition, the process described in the aforementioned U.S. application is complicated by the fact that polyetherification and halogenation are two completely different reactions each of which has to be carried out in specially designed apparatus and, hence, in two separate production units. The considerable outlay on apparatus (the use of corrosion-proof apparatus, for example, of special steels) involved in halogenation necessitates obtaining as high a degree of halogenation as possible in order to make the fullest possible use of the reaction. Accordingly, it is more rational, in order to produce a halogen-containing, substantially non-inflammable plastic or intermediate product, to start with a highly halogenated starting material than it is to subsequently halogenate the particular plastics material used or the intermediate product to a correspondingly lower degree of halogenation.
DESCRIPTION OF THE INVENTION
It has now been found that intermediate products for the production of substantially flame-resistant plastics having favorable properties can be obtained in a particularly simple manner by treating a solution of a halogenated bis-phenol in a hydroxyl-containing polyester of a dicarboxylic acid and a glycol under heat with an alkylene oxide until the free phenolic groups have been substantially quantitatively alkoxylated. The resulting products, which have virtually no acid number, are pourable, viscous oils which remain liquid, even when stored at low temperatures. This is particularly surprising because, as demonstrated hereinafter in a comparison test, a composition having the same gross constitution prepared using separately produced bis-β-hydroxyalkyl halogen bisphenol ether is converted into a nonpourable, pasty composition during storage as a result of the bis-ether crystallizing out. According to the invention, it is readily possible to obtain products which have acid numbers of less than 1.
Accordingly, the invention relates to compositions containing hydroxyl groups which have an acid number of less than 1 and a hydroxyl number of from 150 to 300, preferably from 180 to 250, obtained by mixing 25 to 75% by weight, and preferably 40 to 60% by weight, of a halogenated 2,2-diphenylol propane corresponding to the general formula ##STR1## in which R 1 , R 2 , R 3 , R 4 , R 1 ', R 2 ', R 3 ', and R 4 ' may be the same or different and represent H, C 1 -C 4 -alkyl, or halogen, at least 1 R is halogen, and is preferably Cl or Br, with 75 to 25% by weight and preferably with 60 to 40% by weight of a polyester containing hydroxyl groups obtained from saturated, unsaturated or halogenated aliphatic and/or cycloaliphatic and/or aromatic polycarboxylic acids and a molar excess of dialcohols corresponding to the following formula: ##STR2## in which X 1 to X 8 = H or C 1 -C 4 -alkyl, and preferably represents H, CH 3 or C 2 H 5 ,
n = 1 - 10,
A = o or S
and by subsequently alkoxylating the aforementioned mixture with an alkylene oxide corresponding to the formula: ##STR3## in which R = H, CH 3 , CH 2 OH, CH 2 Cl, CH 2 Br or C 2 H 5 .
The compositions prepared in accordance with the invention generally have a viscosity in the range from 10 to 200 poises at 25° C. and preferably in the range from 20 to 100 poises at 25° C.
Acids which are suitable for use in the production of the polyesters which contain hydroxyl groups include aliphatic, cycloaliphatic and aromatic polycarboxylic acids, such as, carbonic acid, oxalic acid, malonic acid, succinic acid, maleic acid, fumaric acid, itaconia acid, adipic acid, sebacic acid, dichlorosuccinic acid, cyclohexane dicarboxylic acid, tetrahydrophthalic acid, 4,5-dibromocyclohexane-1,2-dicarboxylic acid, o-, iso- and terephthalic acid, tetrachlorophthalic acid, tetrabromophthalic acid, endomethylene tetrahydrophthalic acid, endomethylene hexachlorotetrahydrophthalic acid, diglycolic acid, thiodiglycolic acid, citric acid, tartaric acid and maleic acid. Instead of using the free polycarboxylic acids, it is also possible to use the corresponding carboxylic acid anhydrides or corresponding polycarboxylic acid esters of lower alcohols. The aforementioned acids may be used either individually or even in admixture for producing the polyesters.
Polyalcohols of the above general formula which are suitable for esterification with the dicarboxylic acids are, in particular, compounds of the following kind:
H--[O--CH.sub.2 --CH.sub.2 ].sub.n --OH (n = 2 - 10)
Examples of compounds such as these are diethylene glycol and triethylene glycol. It is also possible to use thiodiglycol, bis-β-hydroxy ethyl sulphone and the polyethers and polythioethers specified hereinafter, also dipropylene glycol and polypropylene glycol corresponding to the formula: ##STR4## In addition to the aforementioned diols, it is also possible to use up to 20 mol % of monoalkylene glycols such as, for example, ethylene glycol, 1,2-propylene glycol, 1,2-butylene glycol, neopentyl glycol, α-chlorhydrin, for esterification.
Esterification is generally carried out at temperatures in the range from 120° to 200° C. and preferably at temperatures in the range from 160° to 180° C., under normal pressure and/or in vacuo in the presence of an inert gas. Esterification catalysts such as toluene sulphonic acid, litharge, dibutyl tin oxide, antimony trioxide, salts and alcoholates of titanium, may be added. Although esterification may be carried out in the presence of solvents acting as azeotropic entraining agents, it is preferably carried out in the absence of solvents.
In general, it would seem to be advisable to continue esterification until as low an acid number as possible is reached. Nevertheless, it can be advantageous in certain cases (for example in order to improve compatibility with the bisphenols to be dissolved in the polyester) to terminate esterification at a relatively high acid number and subsequently to alkyxylate the free carboxyl groups together with the free phenol groups of the bisphenol to be added.
The hydroxyl-containing polyesters thus obtained are mixed with the halogenated bisphenols, preferably under heat, a solution generally being formed. Although tetrabromobisphenol is most preferably used as the bisphenol, it is also preferable to use dibromobisphenol or tetrachlorobisphenol.
The bisphenol/polyester mixtures are then alkoxylated. Alkoxylation may be carried out in known manner. Catalysts which are preferably used for accelerating the reaction include alkaline-reacting substances such as NaOH, KOH, sodium methylate, sodium phenolate, potassium acetate, potassium carbonate, and the like. Alkoxylation is carried out at temperatures in the range from 80° to 180° C. and preferably at temperatures in the range from 110° to 130° C. The alkylene oxides used correspond to the general formula: ##STR5## in which R = H, CH 3 , CH 2 OH, CH 2 Cl, CH 2 Br or C 2 H 5 . Specific examples include ethylene oxide, 1,2-propylene oxide, epichlorhydrin and 1,2-butylene oxide.
The end point of alkoxylation is readily determined by titrating a sample of the reaction mixture with sodium hydroxide using the technique normally adopted for determining acid number.
The compositions produced in accordance with the invention are valuable starting materials for the production of isocyanate-based plastics, and especially for the production of substantially non-flammable isocyanurate foams having outstanding mechanical properties and non-flammability.
The starting isocyanates suitable for use in accordance with the invention in the production of plastics include aliphatic, cycloaliphatic, araliphatic, aromatic and heterocyclic polyisocyanates of the type described, for example by W. Siefken in Justus Liebigs Annalen der Chemie, 562, pages 75 to 136. Examples include ethylene diisocyanate; 1,4-tetramethylene diisocyanate; 1,6-hexamethylene diisocyanate; 1,12-dodecane diisocyanate; cyclobutane-1,3-diisocyanate; cyclohexane-1,3- and 1,4-diisocyanate, and mixtures of these isomers; 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl cyclohexane (German Auslegeschrift Pat. No. 1,202,785, U.S. Pat. No. 3,401,190), 2,4- and 2,6-hexahydrotolylene diisocyanate and mixtures of these isomers; hexahydro-1,3- and/or -1,4-phenylene diisocyanate; perhydro-2,4'- and/or -4,4'-diphenyl methane diisocyanate; 1,3- and 1,4-phenylene diisocyanate; 2,4- and 2,6-tolylene diisocyanate, and mixtures of these isomers; diphenyl methane-2,4'- and/or -4,4'-diisocyanate; naphthylene-1,5-diisocyanate; triphenyl methane-4,4',4"-triisocyanate; polyphenyl polymethylene polyisocyanates of the type obtained by condensing aniline with formaldehyde, followed by phosgenation, is described in British Pat. Nos. 874,430 and 848,671; m- and p-isocyanatophenyl sulphonyl isocyanates as described in U.S. Pat. No. 3,454,606; perchlorinated aryl polyisocyanates of the type described in U.S. Pat. No. 3,277,138; polyisocyanates containing carbodiimide groups of the type described in U.S. Pat. No. 3,152,162; diisocyanates of the type described in U.S. Pat. No. 3,492,330; polyisocyanates containing allophanate groups of the type described in British Pat. No. 994,890, Belgian Pat. No. 761,626 and Published Dutch Pat. application No. 7,102,524; polyisocyanates containing isocyanurate groups of the type described in U.S. Pat. No. 3,001,973, in German Pat. Nos. 1,022,789; 1,222,067 and 1,027,394 and in German Offenlegungsschrifts Nos. 1,929,034 and 2,004,048; polyisocyanates containing urethane groups of the type described, in Belgian Pat. No. 752,261 or in U.S. Pat. No. 3,394,164; polyisocyanates with acylated urea groups as described in German Pat. No. 1,230,778; polyisocyanates containing biuret groups of the type described in U.S. Pat. Nos. 3,124,605 and 3,201,372 and in British Pat. No. 889,050; polyisocyanates obtained by telomerization reactions of the type described, in U.S. Pat. No. 3,654,106; polyisocyanates containing ester groups of the type described in British Pat. Nos. 965,474 and 1,072,956; in U.S. Pat. No. 3,567,763 and in German Pat. No. 1,231,688; reaction products of the aforementioned isocyanates with acetals is described in German Pat. No. 1,072,385; and, polyisocyanates containing polymeric fatty acid radicals as described in U.S. Pat. No. 3,455,883. It is also possible to use the distillation residues containing isocyanate groups which accumulate during the commercial scale production of isocyanates, optionally in solution in one or more of the above-mentioned polyisocyanates. It is also possible to use any mixtures of the aforementioned polyisocyanates.
In general, it is preferred to use available polyisocyanates such as 2,4- and 2,6-tolylene diisocyanate, and mixtures of these isomers ("TDI"); polyphenyl polymethylene polyisocyanates of the type obtained by condensing aniline with formaldehyde, followed by phosgenation ("crude MDI"); and polyisocyanates containing carbodiimide groups, urethane groups, allophanate groups, isocyanurate groups, urea groups or biuret groups ("modified polyisocyanates").
According to the invention, water and/or readily volatile organic substances can be used as blowing agents. Examples of organic blowing agents include acetone; ethyl acetate; halogen-substituted alkanes such as methylene chloride, chloroform, ethylidene chloride, vinylidene chloride, monofluorotrichloromethane, chlorodifluoromethane, dichlorodifluoromethane; butane; hexane; heptane; and diethyl ether. A blowing effect can also be obtained by adding compounds which decompose at temperatures above room temperature to give off gases such as nitrogen, for example azo compounds, such as azoisobutyronitrile. Further examples of blowing agents and information on the use of blowing agents may be found in Kunststoff-Handbuch, Vol. VII, Published by Vieweg und Hochtlen, Carl-Hanser-Verlag, Munich 1966, pages 108 and 109, 453 to 455 and 507 to 510.
Where isocyanurate products are desired, catalysts used for the polymerization reactions are used, and include compounds which initiate a polymerization reaction involving the NCO-group at temperatures as low as room temperature. Examples of this kind of catalyst are described, for example, in French Pat. No. 1,441,565, Belgian Pat. Nos. 723,153 and 723,152 and German Pat. No. 1,112,285. Catalysts of this kind include, mononuclear or polynuclear Mannich bases of condensible phenols optionally substituted by alkyl, aryl or aralkyl radicals, oxo compounds and secondary amines, especially those in which formaldehyde has been used as the oxo compound and dimethyl amine as the secondary amine. According to analyses by IR-spectroscopy, more or less large proportions of carbodiimide structures are generally formed in the foams, depending upon the conditions, especially upon the reaction temperature reached. Other suitable polyisocyanate catalysts are the alkali and alkaline-earth salts of carboxylic acids and phenols. The quantity of polymerization catalyst is essentially determined by the type (and optionally the basicity) of the catalyst used. It is possible to use from 0.1 to 100% by weight and preferably from 0.3 to 25% by weight of catalyst component, based on the isocyanate component.
According to the invention, the polyurethane reaction may be catalyzed by the usual catalysts, for example tertiary amines, such as triethyl amine, tributyl amine, N-methyl morpholine, N-ethyl morpholine, N-cocomorpholine, N,N,N',N'-tetramethyl ethylene diamine, 1,4-diazabicyclo-(2,2,2)-octane, N-methyl N'-dimethyl aminoethyl piperazine, N,N-dimethyl benzyl amine, bis-(N,N-diethyl aminoethyl)-adipate, N,N-diethyl benzyl amine, pentamethyl diethylene triamine, N,N-dimethyl cyclohexyl amine, N,N,N',N'-tetramethyl-1,3-butane diamine, N,N-dimethyl-β-phenyl ethyl amine, 1,2-dimethyl imidazole and 2-methyl imidazole.
Tertiary amines containing isocyanate-reactive hydrogen atoms may also be used and include triethanolamine, triisopropanolamine, N-methyl diethanolamine, N-ethyl diethanolamine, N,N-dimethyl ethanolamine, also their reaction products with alkylene oxides such as propylene oxide and/or ethylene oxide.
Other suitable catalysts are sila-amines having carbonsilicon bonds of the type described in German Pat. No. 1,229,290, including 2,2,4-trimethyl-2-silamorpholine and 1,3-diethyl aminomethyl tetramethyl disoloxane.
According to the invention, organometallic compounds, especially organo tin compounds, may also be used as catalysts.
Preferred organo tin compounds are tin(II) salts of carboxylic acids such as tin(II)acetate, tin(II)octoate, tin(II)-ethyl hexoate and tin(II)laurate, and the dialkyl tin salts of carboxylic acids, such as for example dibutyl tin diacetate, dibutyl tin dilaurate, dibutyl tin maleate or dioctyl tin diacetate.
Other examples of catalysts suitable for use in accordance with the invention and information on the way in which the catalysts work may be found in Kunststoff-Handbuch, Vol. VII, Published by Vieweg und Hochtlen, Carl-Hanser-Verlag, Munich 1966, on pages 96 to 102.
These catalysts are generally used in quantities of from about 0.001 to 10% by weight, based on the total weight of the novel compositions described herein and any compounds mentioned hereinafter having at least two isocyanate-reactive hydrogen atoms and a molecular weight in the range from 62 to 10,000.
According to the invention, it is also possible to use surface-active additives (emulsifiers and foam stabilizers). Examples of emulsifiers are the sodium salts of castor oil sulphonates or even of fatty acids or salts of fatty acids with amines, such as diethyl amine oleate or diethanolamine stearate. It is also possible to use alkali or ammonium salts of sulphonic acids, for example of dodecyl benzene sulphonic acid or dinaphthyl methane disulphonic acid, or even of fatty acids such as ricinoleic acid, or polymeric fatty acids, as surface-active additives.
Especially suitable foam stabilizers are water-soluble polyether siloxanes. The structure of these compounds is generally such that a copolymer of ethylene oxide and propylene oxide is attached to a polydimethyl siloxane radical. Foam stabilizers of this kind are described, for example, in U.S. Pat. Nos. 2,834,748; 2,917,480 and 3,629,308.
According to the invention, it is also possible to use reaction retarders, for example acid-reacting substances such as hydrochloric acid, or organic acid halides; cell regulators known per se, such as paraffins or fatty alcohols or dimethyl polysiloxanes; pigments or dyes; flameproofing agents known per se, for example tris-chloroethyl phosphate or ammonium phosphate and polyphosphate; stabilizers against the effects of ageing and weather; plasticizers and fungistatic and bacteriostatic substances; and fillers such as barium sulphate, kieselguhr, carbon black or prepared chalk.
Further examples of the surface-active additives and foam stabilizers, cell regulators, reaction retarders, stabilizers, flameproofing substances, plasticizers, dyes and fillers, fungistatic and bacteriostatic substances, optionally used in accordance with the invention and information on the way in which these additives are used and the way in which they work, may be found in Kunststoff-Handbuch, Vol. VII, Published by Vieweg und Hochtlen, Carl-Hanser-Verlag, Munich 1966, pages 103 to 113.
Other suitable components suitable in accordance with the invention for use in the production of plastics are compounds having at least two isocyanate-reactive hydrogen atoms and a molecular weight of generally from 400 to 10,000. In addition to compounds containing amino groups, thiol groups or carboxyl groups, compounds of this kind are, preferably, polyhydroxyl compounds, and in particular compounds containing 2 to 8 hydroxyl groups, especially those having molecular weights in the range from 800 to 10,000, preferably from 1,000 to 6,000. Examples include polyesters, polyethers, polythioethers, polyacetals, polycarbonates, polyester amides containing at least 2, generally 2 to 8 but preferably 2 to 4 hydroxyl groups, of the type commonly used for the production of homogeneous and cellular polyurethanes.
The hydroxyl-containing polyesters used in accordance with the invention include reaction products of polyhydric, preferably dihydric and, optionally, trihydric alcohols with polyvalent, preferably divalent, carboxylic acids. Instead of using the free polycarboxylic acids, it is also possible to use the corresponding polycarboxylic acid anhydrides or corresponding polycarboxylic acid esters of lower alcohols or mixtures thereof for producing the polyesters. The polycarboxylic acids may be aliphatic, cycloaliphatic, aromatic and/or heterocyclic and may optionally be substituted, for example by halogen atoms, and/or unsaturated. Examples of polycarboxylic acids of this kind are succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, phthalic acid, isophthalic acid, trimellitic acid, phthalic acid anhydride, tetrahydrophthalic acid anhydride, hexahydrophthalic acid anhydride, tetrachlorophthalic acid anhydride, endomethylene tetrahydrophthalic acid anhydride, glutaric acid anhydride, maleic acid, maleic acid anhydride, fumaric acid, dimeric and trimeric fatty acids such as oleic acid, optionally in admixture with monomeric fatty acids, terephthalic acid dimethyl ester and terephthalic acid bis-glycol ester. Examples of suitable polyhydric alcohols are ethylene glycol, 1,2-and 1,3-propylene glycol, 1,4- and 2,3-butylene glycol, 1,6-hexane diol, 1,8-octane diol, neopentyl glycol, cyclohexane dimethanol (1,4-bis-hydroxy methyl cyclohexane), 2 -methyl-1,3-propane diol, glycerol, trimethylol propane, 1,2,6-hexane triol, 1,2,4-butane triol, trimethylol ethane, pentaerythritol, quinitol, mannitol and sorbitol, methyl glycoside, also diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycols, dipropylene glycol, polypropylene glycols, dibutylene glycol and polybutylene glycols. The polyesters may contain terminal carboxyl groups. It is also possible to use polyesters of lactones, for example ε-caprolactone or hydroxy carboxylic acids, for example ω-hydroxy caproic acid.
The polyethers containing at least two, generally two to eight and preferably two to three hydroxyl groups used in accordance with the invention are also known per se and are obtained, for example, by polymerizing epoxides such as ethylene oxide, propylene oxide, butylene oxide, tetrahydrofuran, styrene oxide or epichlorhydrin alone, for example in the presence of BF 3 , or by dding these epoxides, optionally in admixture or in succession, to starting components having reactive hydrogen atoms such as water, alcohols or amines, including ethylene glycol, 1,3- or 1,2-propylene glycol, trimethylol propane, 4,4'-dihydroxy diphenyl propane, aniline, ammonia, ethanolamine and ethylene diamine. Sucrose polyethers, of the type described in German Auslegeschrifts Pat. Nos. 1,176,358 and 1,064,938, may also be used in accordance with the invention. In many cases, it is preferred to use polyethers of the type which contain predominant amounts of primary OH-groups (up to 90% by weight, based on all the OH-groups present in the polyether). Polyethers modified by vinyl polymers, of the type formed for example by polymerizing styrene and acrylonitrile in the presence of polyethers (U.S. Pat. Nos. 3,383,351; 3,304,273; 2,523,093; 3,110,695; and, German Pat. No. 1,152,536), are also suitable, as are polybutadienes containing OH-groups.
Among the polythioethers, reference is made to the condensation products of thiodiglycol on its own and/or with other glycols, dicarboxylic acids, formaldehyde, aminocarboxylic acids or aminoalcohols. Depending upon the cocoponents, the products are polythio mixed ethers, polythioether esters or polythioether ester amides.
Examples of suitable polyacetals include the compounds which can be obtained from glycols such as diethylene glycol, triethylene glycol, 4,4'-dioxethoxy diphenyl dimethyl methane, hexane diol and formaldehyde. Polyacetals suitable for the purposes of the invention can also be obtained by polymerizing cyclic acetals.
The hydroxyl-containing polycarbonates used are known per se and may be obtained by reacting diols (such as 1,3-propane diol, 1,4-butane diol and/or 1,6-hexane diol, diethylene glycol, triethylene glycol and tetraethylene glycol) with diaryl carbonates (for example diphenyl carbonate) or phosgene.
The polyester amides and polyamides include the predominantly linear condensates obtained from polyvalent, saturated and unsaturated carboxylic acids or their anhydrides and polyhydric, saturated and unsaturated aminoalcohols, diamines, polyamines and mixtures thereof.
Polyhydroxyl compounds already containing urethane or urea groups, and optionally modified natural polyols, such as castor oil, carbohydrates and starch, may also be used. Addition products of alkylene oxides with phenol-formaldehyde resins, or even with urea-formaldehyde resins, may also be used in accordance with the invention.
Examples of these compounds suitable for use in accordance with the invention are described, for example, in High Polymers, Vol. XVI, "Polyurethanes, Chemistry and Technology," by Saunders-Frisch, Interscience Publishers, New York, London, Vol. I, 1962, pages 32 to 42 and pages 44 to 54, and Vol. II, 1964, pages 5 to 6 and 198 to 199, and in Kunststoff-Handbuch, Vol. VII, Vieweg und Hochtlen, Carl-Hanser-Verlag, Munich 1966, on pages 45 to 71.
Other starting components suitable for use in accordance with the invention are compounds having at least two isocyanate-reactive hydrogen atoms and molecular weights in the range from 32 to 400. In this case, too, compounds of this kind are compounds containing hydroxyl groups and/or amino groups and/or thiol groups and/or carboxyl groups and are preferably compounds containing hydroxyl groups and/or amino groups and which are used as chain extenders or crosslinking agents. Compounds of this kind generally contain from 2 to 8 isocyanate-reactive hydrogen atoms, preferably 2 or 3 reactive hydrogen atoms. The following are mentioned as examples of compounds such as these: ethylene glycol, 1,2- and 1,3-propylene glycol, 1,4-butylene glycol and 2,3-butylene glycol, 1,5-pentane diol, 1,6-hexane diol, 1,8-octane diol, neopentyl glycol, 1,4-bis-hydroxy methyl cyclohexane, 2-methyl-1,3-propane diol, glycerol, trimethylol propane, 1,2,6-hexane triol, trimethylol ethane, pentaerythritol, quinitol, mannitol and sorbitol, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycols having a molecular weight of up to 400, dipropylene glycol, polypropylene glycols having a molecular weight of up to 400, dibutylene glycol, polybutylene glycols, having a molecular weight of up to 400, 4,4'-dihydroxy diphenyl propane, dihydroxy methyl hydroquinone, ethanolamine, diethanolamine, triethanolamine, 3-aminopropanol, ethylene diamine, 1,3-diaminopropane, 1-mercapto-3-aminopropane, 4-hydroxy- or -amino-phthalic acid, succinic acid, adipic acid, hydrazine, N,N'-dimethyl hydrazine and 4,4'-diaminodiphenylmethane.
According to the invention, the reaction components can be reacted by the one-pot process known per se, by the prepolymer process or by the semi-prepolymer process, in many cases using machines of the type described, for example, in U.S. Pat. No. 2,764,565. Information on other processing machines which may be used for the purposes of the invention may be found in Kunststoff-Handbuch, Vol. VI, Published by Vieweg und Hochtlen, Carl-Hanser-Verlag, Munich 1966, pages 121 to 205.
Examination of the isocyanurate foams produced in accordance with the invention by IR-spectroscopy reveals high proportions of isocyanurate rings in addition to small quantities of carbodiimide groups.
The foams obtained in accordance with the invention may be used as insulating materials in the building industry or in engineering or as a structural material and in the furniture industry.
The compositions obtained in accordance with the invention may also be used as starting materials in the production of cellular or homogeneous polyurethane plastics which, in turn, may be used for coating, insulation or for lacquering.
EXAMPLE 1
Production of the hydroxyl-containing polyester
750 parts by weight of triethylene glycol and 403 parts by weight of adipic acid are heated for 6 hours to 170° C. in the presence of 2 parts by weight of titanium tetrabutylate. At the same time, nitrogen is passed through the reactor. The reaction mixture has an acid number of 47.5 mg. of KOH/g. A vacuum of 20 Torr is then applied and the reaction solution is heated for another 8 hours to 170° C. The acid number is then less than 1.
A. COMPARISON TEST
50 parts by weight of bis-β-hydroxy ethyl tetrabromobisphenol ether are added to 50 parts by weight of the hydroxyl-containing polyester prepared in accordance with Example 1 and dissolved under heat to form a clear solution. On cooling to room temperature, the bis-ether crystallizes out again. After a while in finely crystalline form, the mass becomes pasty and can no longer be poured.
B. FURTHER PROCESSING IN ACCORDANCE WITH THE INVENTION
51.6 parts by weight of the hydroxyl-containing polyester prepared in accordance with Example 1 are dissolved under heat with 48.4 parts by weight of tetrabromobisphenol and heated to 120° C. Following the addition of 2 g of sodium phenolate, ethylene oxide is introduced with vigorous stirring until the titration of a sample of the reaction mixture with NaOH-solution reveals no further consumption of alkali. The reaction product is then heated in vacuo for 1 hour to 100° C. in order to remove unreacted ethylene oxide. A yellowish colored oil having the following characteristics is obtained:
______________________________________Viscosity 61 P/25° CBromine content 26.1 to 3%Hydroxyl number 199 to 200Phenol groupcontent <0.1%______________________________________
EXAMPLE 2
A mixture of 30 parts by weight of the composition prepared in accordance with Example 1B, 10 parts by weight of trichloroisopropyl phosphate, 3 parts by weight of an aminopolyether (propoxylated ethylene diamine having an OH-number of 650), 1 part by weight of glycerol, 1 part by weight of a standard commercial-grade foam stabilizer, (L 5320, Union Carbide Co.), 1.5 parts by weight of a 25% by weight solution of potassium acetate in diethylene glycol and 22 parts by weight of trichlorofluoromethane, is mixed in a foaming machine (type HK 500 manufactured by Messrs. Hennecke/Birlinghoven) with 100 parts by weight of a prepolymer containing isocyanate groups produced from 95 parts by weight of crude 4,4'-diphenyl methane diisocyanate, (NCO content 31% b.w.), and 5 parts by weight of a polypropylene glycol having an OH-number of 200. The reaction mixture is introduced for 15 seconds into a mold having a base area of 1 × 1 meter. The foam rises to a height of 52 cm and sets after 45 seconds.
The foam predominantly containing polyisocyanurate groups has a gross density of 34.7 kg/m 3 and is "substantially non-flammable" according to DIN 41 02. The foam block can be used in the form of sheeting, rough half-shells, as an insulating material in the building industry and for insulating pipes. | The instant invention is broadly directed to novel hydroxyl containing compositions and the use thereof in producing polyurethane resins. The novel products are produced by mixing a halogenated bisphenol with a hydroxypolyester and thereafter alkoxylating the mixture. | 2 |
CROSS REFERENCE TO RELATED PATENT APPLICATION
This application claims priority to and benefit from U.S. Provisional Patent Application No. 61/893,451, filed Oct. 21, 2013, the contents of which are expressly incorporated herein by reference.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a removable arm rest shroud for aircraft passenger seats.
Seating arm rest boxes are typically manufactured from either a Comex panel, aluminum honeycomb, or machined aluminum for aircraft applications. The invention of this application allows for a panel and support structure to be attached to the aircraft seat frame. A box-like structure, i.e., a “shroud”, is then inserted over the top, covering the structural arm rest, and having connection points that snap, click, or fit into place while attaching it permanently with a screw at some location below the seat cushion mark. This structure allows the upholstery of the arm rest shroud to be structurally separate from the seat upholstery of the seat bottom, seat back and head rest. This can reduce the amount of time and the complexity presently required to upholster a complete seat.
Designing, manufacturing, and assembling the seat in this manner allow the upholstery of the arm rest shroud to be a separate, removable component. In addition, the separately movable shroud allows for repairs to be made after the seat has been delivered and installed without removing the seat from the aircraft.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an aircraft seat manufactured such that an internal arm rest structure is attached to a seat frame which provides structural integrity of the arm rest.
It is another object of the invention to provide an aircraft seat with an arm rest shroud that has an inside panel, outside panel, top panel, forward panel, and rear panel forming a box with an open bottom.
It is another object of the invention to provide an aircraft seat with an arm rest shroud that has an open bottom that allows the shroud to be slipped over the structural panel and attached to the structural arm rest.
It is another object of the invention to provide an aircraft seat with an arm rest shroud that is simple to remove, in that the shroud can lift up over the structural arm rest and be upholstered and then installed back onto the structural arm rest in the same manner.
According to one preferred embodiment of the invention, a seat having a seat bottom, a seat back, a head rest and a leg rest is mounted on a seat frame, and includes a right hand arm rest panel and a left hand arm rest panel mounted to respective right and left hand sides of the seat frame, and a right hand arm rest assembly positioned over the right hand arm rest panel. A left hand arm rest assembly is positioned over the left hand arm rest panel. The right hand arm rest assembly and the left hand arm rest assembly include an upholstered surface.
According to another embodiment of invention, the right hand arm rest assembly and the left hand arm rest assembly each include an outer shroud and an inner arm rest support that are nested together to form a hollow structure that fits over respective right hand arm rest panel and left hand arm rest panel.
According to another embodiment of invention, the seat frame includes a pair of outwardly-extending right hand arm rest braces and a pair of outwardly extending left hand arm rest braces, and the right hand inner arm rest support and the left hand inner arm rest support each have attachment members adapted to cooperate with the respective arm rest braces to mount the right hand arm rest panel and left hand arm rest panel.
According to another embodiment of invention, the right hand and left hand arm rest braces are vertically-oriented, and the attachment members have cut-outs in the right hand arm rest panel and left hand arm rest panel that are adapted to fit over and be supported by the respective right hand and left hand arm rest braces.
According to another embodiment of invention, the right hand arm rest panel and the left hand arm rest panel each include a support plate positioned on an upper extent to support the respective a right hand arm rest assembly and left hand arm rest assembly.
According to another embodiment of invention, a seat is provided having a seat bottom, a seat back, a head rest and a leg rest mounted on a seat frame, and includes a right hand arm rest panel and a left hand arm rest panel mounted to respective right and left hand sides of the seat frame. A right hand arm rest assembly is positioned over the right hand arm rest panel, and a left hand arm rest assembly is positioned over the left hand arm rest panel. The right hand arm rest assembly and the left hand arm rest assembly includes an upholstered surface. The right hand arm rest assembly and the left hand arm rest assembly are each provided with an outer shroud and an inner arm rest support that are nested together to form a hollow structure that fits over respective right hand arm rest panel and left hand arm rest panel. The seat frame includes a pair of outwardly-extending right hand arm rest braces and a pair of outwardly extending left hand arm rest braces. The right hand inner arm rest support and the left hand inner arm rest support each have attachment members adapted to cooperate with the respective arm rest braces to mount the right hand arm rest panel and left hand arm rest panel. The right hand and left hand arm rest braces are vertically-oriented, and the attachment members include cut-outs in the right hand arm rest panel and left hand arm rest panel that are adapted to fit over and be supported by the respective right hand and left hand arm rest braces.
According to another embodiment of invention, the right hand arm rest panel and the left hand arm rest panel each include a support plate positioned on an upper extent to support the respective a right hand arm rest assembly and left hand arm rest assembly.
According to another embodiment of invention, a method of providing arm rests for passenger seats that are removable for repair or replacement is provided, and includes the steps of providing a seat that includes a seat bottom, a seat back, a head rest and a leg rest mounted on a seat frame, a right hand arm rest panel and a left hand arm rest panel mounted to respective right and left hand sides of the seat frame, a right hand arm rest assembly positioned over the right hand arm rest panel, and a left hand arm rest assembly positioned over the left hand arm rest panel. The right hand arm rest assembly and the left hand arm rest assembly include an upholstered surface. The right hand arm rest assembly and the left hand arm rest assembly each include an outer shroud and an inner arm rest support that are nested together to form a hollow structure. The method steps also include providing an upholstery cover for the outer shrouds, and installing the right hand arm rest assembly and the left hand arm rest assembly over the respective right hand arm rest panel and left hand arm rest panel.
According to another embodiment of invention, the seat frame includes a plurality of outwardly-extending right hand arm rest braces and a plurality of outwardly extending left hand arm rest braces, and the right hand inner arm rest support and the left hand inner arm rest support each have attachment members adapted to cooperate with the respective arm rest braces to mount the right hand arm rest panel and left hand arm rest panel.
According to another embodiment of invention, the right hand and left hand arm rest braces are vertically-oriented, and the attachment members have cut-outs in the right hand arm rest panel and left hand arm rest panel that are adapted to fit over and be supported by the respective right hand and left hand arm rest braces.
According to another embodiment of invention, the right hand arm rest panel and the left hand arm rest panel each include a support plate positioned on an upper extent to support the respective a right hand arm rest assembly and left hand arm rest assembly.
According to another embodiment of invention, the method includes the step of removing the right hand arm rest assembly and left hand arm rest assembly from the respective right hand arm rest panel and the left hand arm rest panel by lifting the right hand arm rest assembly and left hand arm rest assembly vertically upwardly from the respective right hand arm rest panel and the left hand arm rest panel.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The present invention is best understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of a seat according to an embodiment of the invention;
FIG. 2 is an exploded view of the seat shown in FIG. 1 , showing the arm rest shell assembly attachment to the arm rest panel assembly;
FIG. 3 is a perspective view of an arm rest panel according to an embodiment of the invention;
FIG. 4 is a perspective view of the seat showing attachment of the arm rest panel to the seat structure;
FIG. 5 is a perspective view showing the right hand side arm rest shell assembly and arm rest shroud before assembly;
FIG. 6 is a perspective view showing installation of the left hand arm rest shell and shroud over the arm rest panel; and
FIG. 7 is a partial, exploded perspective view showing the back rest shell assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now specifically to the drawings, a seat 10 according to an embodiment of the present invention is shown in FIGS. 1 and 2 , and includes right hand and left hand arm rest assemblies 12 and 14 , a back rest assembly 16 , a head rest assembly 18 , and a back rest beam 20 . As shown in FIG. 2 , the head rest assembly 18 mounts to the top of the back rest assembly 16 , and the back rest assembly 16 is positioned over the back rest beam 20 . The right hand arm rest assembly 12 slides down over a right hand arm rest panel 22 . In the same manner, the left hand arm rest assembly 14 slides downwardly over a left hand arm rest panel 48 , as best shown in FIG. 6 .
Seat 10 also includes a seat pan 30 and a leg rest 32 mounted for selective movement between a retracted position, as shown, and an outward and upwardly-extended deployed use position. The seat 10 includes legs 34 adapted with feet for being attached to track fittings mounted into the deck of the aircraft.
Referring now to FIG. 3 , the right hand arm rest panel 22 includes an arm rest support plate 40 that is located at the top end of the right hand arm rest panel 22 and extends laterally inwardly to provide weight-bearing support. The arm rest panel 22 is fabricated of a flame-resistant meta-aramid material, such as sold by DuPont under the registered trademark Comex. The arm rest panel 22 includes appropriate access holes 42 to receive fasteners, such as fasteners 44 .
As shown in FIG. 4 , the left hand arm rest panel 48 is mounted to seat frame 50 by attachment with fasteners 54 to arm rest braces 56 carried by the seat frame 50 . The right hand arm rest panel 22 is mounted to the seat frame 50 in the same manner. See FIG. 2 .
Referring now to FIGS. 2 and 6 , the arm rest assembly 12 is formed from a shroud 60 and an arm rest support 70 . The shroud 60 includes a pocket 62 for providing the seat occupant with a place to store a mobile phone or other electronics, magazines or small clothing or other personal items. The aim rest support 70 is attached to the arm rest panel 22 . A flange 72 on the top of the arm rest support 70 supports the top of the arm rest shroud 60 . Holes 74 are formed to provide weight reduction, and an opening 76 on the forward end of the arm rest support 70 permits installation of the seat controls. An opening 78 permits installation of push buttons to activate the seat pan 30 , leg rest 32 and back rest 16 recline mechanisms. Tapered cut-outs 80 , 82 at the bottom of the arm rest support 70 are provided for ease of installation of the shroud 60 over the arm rest support 70 .
After the right and left hand arm rest panels 22 and 48 have been mounted on the frame 50 , and the right and left hand arm rest assemblies 12 and 14 have been assembled as illustrated, the right hand arm rest assembly 12 , which includes the shroud 60 , is mounted onto the right hand arm rest support 70 , as shown in FIG. 6 . The right hand arm rest assembly 12 is shown already in its use position, and the left arm rest panel assembly 14 is shown as it is being lowered onto the left hand arm rest panel 48 .
The back rest assembly 16 includes a back rest cover 90 , and head rest guide and bezel 92 , together with right hand and left hand back rest frames 94 and 96 . Holes 98 are used to assemble with the back rest beam 20 , which is part of the seat frame 50 . The back rest assembly 16 also includes rivet holes 100 , weight reduction holes 102 . The back rest frames 94 and 96 include flanges 94 A, 96 A on which upholstery is mounted. Weight reduction holes 94 B, 96 B, respectively, are also provided in the back rest frames 94 and 96 . In the same manner described above, a removable shroud, not shown, may be provided for being positioned over the seat back for removal, repair or replacement as required.
A removable arm rest shroud for aircraft seating according to the invention have been described with reference to specific embodiments and examples. Various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims. | An aircraft passenger seat having a seat bottom, a seat back, and right and left armrests. The arm rests include structural arm rest assemblies for attachment to the seat bottom, and arm rests for being removably-positioned on the structural arm rest panels. Upholstery shrouds are adapted for being positioned on and covering the right and left arm rests. The shrouds are easily removed and installed as needed. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the art of investment casting of metal or plastic objects by the lost wax process such as generally used in dentistry, jewelry, manufacture, and other fields; and more particularly the invention concerns an improved, elongated, tapered, sprue tube structure for spanning a long or wide casting investment, to make possible casting entire intricate dental bridge, jewelry article, artifact, work of art, or other object in one piece.
2. Description of the Prior Art
The conventional lost wax casting process generally used in industry and the arts involves fabricating a wax model or pattern of the article to be cast. Then one or more short sprue tubes are attached to the pattern; and both pattern and sprue tubes are embedded in a plaster investment. The entire assembly is then placed in an oven and heated to approximately 1800° F. for a period of time until the pattern is burned out of the investment cast. The pattern cavity is then filled with a fluid casting material such as molten metal or thermosetting plastic via the sprue passages while the plaster investment is whirled in the centrifuge. After the pattern cavity is filled the assembly is cooled down and the plaster investment is broken away to release the cast article.
Heretofore when a rather large intricate object such as a dental bridge had to be cast in metal or plastic, it was generally cast in several sections which were then soldered or fused together to make the complete object. This involved a great deal of hand work which had to be done by skilled artisans. The entire process was long, laborious, and expensive. Pieces were often made oversize and were then ground down to desired dimensions. It was not possible to cast thin walled sections directly. They had to be made thicker than required and then they had to be machined down to required thinness. Often pieces were broken or damaged in the lengthy hand work process. Often cast pieces had to be discarded because they were found to have porous walls.
SUMMARY OF THE INVENTION
According to the invention, one or more long span sprue tubes are provided for attachment to wax pattern of a rather large, intricate article such as an entire dental bridge. The casting of the article is accomplished by the lost wax process explained above. After the pattern and sprue tubes are embedded in the plaster investment and then burned or melted out, fluid casting material is passed through the long sprue passage or passages in the plaster investment to produce the desired article in its entirety. This contrasts with the prior situation where the short sprue tubes provide short sprue passages which enable casting only small pieces or small sections of large articles. Thereafter these small sections have to be soldered or fused together to make the desired complete article.
A sprue embodying the present invention has a long thick outer cylindrical section with a wide axial bore or passage. A short tapered section is integral with one end of the outer section. A long inner cylindrical section is integral with the narrow end of the tapered section. The inner section terminates in a tapered tip. Spaced from the tip is a hollow bulbous portion of the inner section. The entire sprue tube has an axial passage of narrow diameter extending through it from end to end. This structure makes possible long span direct spruing of investment castings without short sprues, gates, and other expedients heretofore used for indirect spruing. By direct spruing of the casting investment, rather large castings up to six inches in length and/or width, for example, can be made in one piece without requiring subsequent soldering or fusing together of small cast sections, as has been done heretofore.
These and other objects and many of the attendant advantages of this 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 in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a conventional short sprue tube known in the prior art, shown on a magnified scale;
FIG. 2 is a side elevational view of an elongated sprue tube embodying the invention, and shown on the same scale as that of FIG. 1;
FIG. 3 is an axial sectional view taken along line 3--3 of FIG. 2;
FIGS. 4 and 5 are cross sectional views on a further enlarged scale taken along lines 4--4 and 5--5 of FIG. 2;
FIG. 6 is an end elevational view taken along line 6--6 of FIG. 2 on the same scale as that of FIGS. 4 and 5;
FIG. 7 is a top view of a large wax pattern with a plurality of long span sprue tubes at a stage in an investment casting process;
FIG. 8 is a top sectional view of part of a plaster investment with pattern cavity and sprue passages made by means of the pattern and sprue tubes of FIG. 7; and
FIG. 9 is a side elevational view of an elongated sprue tube illustrating an alternate embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein like reference characters designate like or corresponding parts throughout, there is illustrated in FIG. 1, a short sprue tube designated generally by reference numeral 10, of a type known in the prior art and widely used in casting of articles by the conventional and well known lost wax process. In actual practice such as used in dentistry, the tube 10 may have overall length L ranging from one half of an inch to about one inch. A short tube has heretofore been considered desirable to minimize the length of the sprue passage through which the molten metal must travel through the plaster investment to fill the pattern cavity therein. The tube 10 has a long cylindrical section 12 terminating with a bulbous portion 18. Integral with the bulbous portion is a very short tapered tip 20. Inside the tube 10 is an axial bore or passage 14 extending the full length thereof. The tip 20 is generally about 1/8 of an inch long. The bore is 3/64 to 1/16 of an inch in diameter. The tube section 12 is about 1/4 to 1/2 inch long. The bulbous portion 18 is generally 3/16 to 1/4 of an inch long axially of the tube 10.
When the sprue tube 10 is to be used, the tip 20 of the tube 10 is attached to a wax pattern (not shown). This may be done by using melted wax or by heating the end of the tip 20 and slightly embedding it in the wax pattern. For most of its short length, the tip 20 will be embedded in the wax pattern so that it is not replicated as a cylindrical passage in the plaster investment. The bulbous portion 18 at this time will be disposed adjacent to the wax pattern. While the sprue tube 10 is being burned out, the axial passage 14 will facilitate release of air, vapor pressure, and wax. The sprue tube 10 will burn out completely with the wax pattern from the plaster investment, to leave a short sprue passage in the plaster investment communicating with a cavity left by the burned out wax pattern. The short sprue passage will have a size and shape corresponding to the negative of the tube 10 and the pattern cavity will have a shape corresponding to the negative of the wax pattern burned out. The sprue passage in the plaster investment will have a length equal to the length of tube section 12 plus the axial length of a chamber left by a bulbous portion 18. This chamber will be adjacent to the pattern cavity and is considered necessary because it fills with the molten casting metal and serves as a reservoir while the metal enters the pattern cavity during centrifuging. The reservoir chamber left by bulbous section 18 serves as an enlargement of the narrow sprue passage in the plaster investment for preventing withdrawal of the molten metal when the casting is being cooled. The chamber 18 has a drawback in that it materially reduces the pressure and velocity under which the fluid casting material is forced into the pattern cavity in the plaster investment. Since the pressure is reduced, many fine, narrow spaces in the pattern cavity do not fill properly. Very thin pattern walls having a thickness of about 0.2 to 0.5 of a millimeter cannot be cast at all. Undesired porosity in the resulting metal casting often results due to the reduced pressure and velocity under which the metal flows into the pattern cavity in the plaster investment. Because of these conditions, use of the short tube 10 shown in FIG. 1 has been limited to make very small cast articles, or small sections of a large article. The small cast sections have to be soldered together afterwards to make the whole article.
Turning now to FIGS. 2-7 which illustrate the new and improved long span sprue tube embodying the invention, there is shown a sprue tube designated generally by reference numeral 25 which has an outer cylindrical first section 26 of uniform diameter D1 and extending from a free outer end 28 to a wider end 29 of a tapered, frustoconical section 30 integral with section 26. The section 30 tapers down to a narrower end 31 where it is integral with a cylindrical third section 32 having a diameter D2 which is about one half of the diameter D1. The section 32 extends to a spherically curved or bulbous integral fourth section 34 which has a diameter slightly larger than diameter D1 of the section 26. Extending from the section 34 and integral therewith is a tapered fifth section or tip 36 whose free end 40 has a diameter which is at least half of the diameter D2. The tip 36 is substantially longer axially than tapered tip 20 of the sprue tube 10 shown in FIG. 1.
In a preferred form such as used in dental casting of bridges, the overall length L' of the tube 25 is at least two inches. The section 26 is at least 3/4 of an inch long; the tapered section 30 is about 1/4 of an inch long axially; the section 32 is about 1/2 of an inch long axially; the section 34 is about 1/4 of an inch long axially; section 36 (L1) is at least 1/4 of an inch long axially. The outside diameter D1 is about 3/8 of an inch and the diameter D2 is about 1/4 of an inch. As mentioned above, the length of the end section or tapered tip 36 is about 3/8 of an inch. This last dimension contrasts with the structure of the short tip 20 in the prior sprue tube 10, which is not more than 1/8 of an inch in axial length. The tube 25 has a narrow passage 42 extending entirely through the tube axially from end to end. The tube 25 is made of wax, a thermoplastic, or a combustible material, so that the tube 25 will melt and run out of a plaster investment, or will burn out completely when subjected to high temperature in an oven.
FIG. 7 illustrates one use of the invention. In one stage of the casting process two, three or more of the sprue tubes 25 are disposed in an angular or fanlike coplanar array. The outer ends 28 are disposed adjacent to each other. The tips 36 are stuck to a side 45 of a wax or plastic horseshoe shaped pattern 50. This may be accomplished by heating each tube tip 36 and then applying the end 40 to the pattern 50 at a desired point. Upon cooling, the tip 36 will adhere to the pattern 50 which may have a plurality of very thin sections 52, as thin as 0.2 of a millimeter. Thicker portions 54 may range up to 1/4 of an inch in thickness. The entire assembly of tubes 25 and the pattern 50 are then enclosed in a plaster investment 60 (indicated by dotted lines) leaving exposed the free ends 28 of all sprue tubes 25.
After the investment plaster has set hard, the assembly is placed in an oven and heated to a temperature as high as 1800° F. to cause the pattern 50 and the sprue tubes 25 to melt and/or burn out as indicated by dotted lines 62. This will leave the pattern cavity 50' and sprue channels or passages 25' in the plaster investment 60 as shown in FIG. 8. The pattern cavity 50' will be a precise negative of the pattern 50 and the sprue channels or passages 25' will be precise negatives of the portions of the tubes 25 which were embedded in the plaster investment 60. The passages 25' all communicate with the cavity 50' at openings 40'.
It will be noted that in each of the passages 25', there is an outer end section having an opening 28' through which molten casting metal or plastic can be injected into the passage 25'. The passage has two dimensional stages. The outer stage is defined by the passage portion 26' of larger diameter and the inner stage by passage or channel portions 32' and 36' of smaller diameter. Spherical chambers 34' located in the second stage portion serve as reservoirs for molten casting material and prevent discontinuities in the metal flow which could cause porosity in the final metal casting. The outer wider stage has a smooth transition to the narrower second stage via the tapered channel or passage portion 30'. This insures smoothness of metal flow without turbulence which could cause defects in the casting. When the molten casting material flows through the passages 25', the velocity and pressure and resultant driving force increases in the second stage due to the progressive narrowing of the passage. The velocity, driving force and pressure are further increased as the molten casting material passes the constricted opening 40'. The fine streams of molten material leaving the openings 40' rapidly penetrate to all points in the cavity 50' even to and through the most constricted or narrow spaces such as narrow spaces 52'. This two stage sprue channel or passage 25' produced by the novel shape of the sprue tube 25 is a critical feature of the invention and contrasts with the short sprue channel of the prior sprue tube 10 where enhanced or increased velocity of the casting metal does not occur. A further feature of the present invention is the long spacing of reservoir 34' from the opening 40' produced by the spacing of the bulbous section 34 from the tip 36 in the tube 25. In the use of the prior tube 10 the bulbous section 18 is disposed adjacent or against the wax pattern in the investment so that the sprue channel enlarges rather than constricts at the opening in the pattern cavity. Thus in the use of the prior tubes 10 reduced driving pressure and velocity of the casting metal, results in porosity in the castings, and makes impossible the production of castings having very thin spaces, interstices and details. The long span of the new sprue tube 25 makes possible direct long span sprue fabrication of castings without use of gates, bypasses, or other expedients heretofore used. The present invention makes it possible to cast an entire dental bridge at one time. This full mouth bridge will not have and will not require solder joints, seams or other means to join together several small cast sections as has heretofore been the practice. The present invention thus reduces the labor, time, and expense in casting an intricate article, and at the same time it produces a stronger, more long lasting, seamless, one-piece casting.
There is illustrated in FIG. 9 an alternate embodiment of the present invention comprising a sprue tube identical to the sprue tube illustrated in FIG. 2 and further including a short cylindrical section 37 inserted between the bulbous section 34 and the tapered section 36 to provide a smoother transition therebetween.
It should be understood that the foregoing relates to only a preferred embodiment of the invention which has been by way of example only, and that it is intended to cover all changes and modifications of the examples of the invention wherein chosen for the purpose of the disclosure, which do not constitute departures from the spirit and scope of the invention. | The tube is at least two inches long and has successive sections of progressively smaller diameters to produce a correspondingly shaped sprue passage communicating with a pattern cavity in a casting investment, so that fluid casting material passes with increasingly fluid velocity between an inlet and outlet of the sprue passage during the casting process. A bulbous portion of the tube is spaced from its free end, to form a reservoir chamber in the sprue passage, spaced sufficiently from the pattern cavity, so that casting material flowing through the sprue passage attains maximum velocity at the outlet of the passage entering the pattern cavity. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present application relates to apparatus and methods for assisting operators of vertical takeoff vehicles in landing operations within environments of low visual acuity. In particular although not exclusively the present application relates to a radar altimeter for assisting in landing operations of vertical takeoff vehicles.
[0003] 2. Related Art
[0004] Many incidents and accidents involving the use of vertical takeoff vehicles occur frequently during takeoff and landing operations. Given the complex mechanics of the vehicles involved, a wide array of variables can influence the success of these operations. Numerous accidents causing from minor damage or, at worst, destruction of the vehicle have resulted from environmental factors such as terrain type, wing and rotor clearance, etc.
[0005] One cause of accidents in landing operations is setting the vehicle down on steep or uneven terrain. From the air it can be difficult to sight imperfections in the landing area. Setting the craft down on steep or uneven surfaces can cause the craft to pitch and tip over. Another major factor in terms of the terrain type, which can affect landing and takeoff operations, is the composition of the landing/takeoff surface. For example in arid landing and takeoff environments sand, dust and other debris can be kicked up into the air by the down draft created by the vehicle. This situation is known as a “brownout”. In essence the debris that is kicked up into the air creates a cloud which can completely obscure the operators view to the landing zone and surrounding landmarks.
[0006] In the case of vehicles such as a helicopter, the increased turbulence created by the rotors (rotor wash) can create eddy currents within the particulate cloud. The swirling mass of particles can lead the pilot to experience the vection illusion, a form of spatial disorientation where the helicopter appears to be turning when it is actually in a level hover. A pilot not using the flight instruments for reference may instinctively try to level the aircraft, resulting in an accident.
[0007] The brownout problem has been keenly noted by the US military. Since 1991, there have been over 230 cases of aircraft damage and/or injury due to unsuccessful take-offs or landings in arid environments. Although the majority of the incidents occur during landing, there have been a significant number of incidents occurring during takeoff. Of the more than 50 brownout incidents occasioning damage reported during the period of 2001-2007, 80 percent were during landings and 20 percent during takeoffs. On average the number of brownout incidents occasioning damage costs the US military US$100 million per year.
[0008] In addition to the brownout problem, a large number of helicopter operations are carried out under the cover of darkness. Typically these operations require helicopters to minimize their presence by flying low and without lights. During such operations pilots become more dependent upon their instruments and limited information regarding terrain from night vision systems (if available).
[0009] One piece of equipment which can provide a pilot with valuable information in both brownout conditions and night time operations is a radar altimeter. The basic radar altimeter utilizes a radar ranging system which measures the time delay of the signal reflected from the nearest object within a single wide beam illuminating the ground. This wide-beam is intended to monitor aircraft height even when in a bank or flying near steep slopes.
[0010] One example of a radar altimeter is shown in U.S. Pat. No. 5,047,779 to Hager which is capable of tracking at least two targets. The altimeter of Hager information relating to the first target is captured via a first set of radar antennas and stored before the altimeter switches to a track and store information of the second target via a second set of radar antennas. U.S. Pat. No. 6,750,807 also to Hager et al., describes a similar scheme, but with a forward-looking scanning beam for obstacle warning. Both arrangements proposed in Hager patents simply provide range information to both targets and as such are generally useful in assisting a pilot with obstacle avoidance in flight. Neither of the altimeter Hager patents is capable of providing the pilot of any useful information regarding the tomography of the desired landing surface.
[0011] One approach to assisting pilots with obstacle avoidance in degraded visual conditions is discussed in U.S. Pat. No. 7,106,217 to Judge et al. The approach of Judge relies on merging data from a number of sensors to allow a display and fly-by-wire capability in poor visibility. While the system of Judge is capable of assisting a pilot with identifying the position of the aircraft relative to the select landing zone, and any obstacles within range of the aircraft, it does not provide the pilot any useful information regarding the topography of the desired landing surface.
[0012] Thus it would be advantageous to provide a system and method that would not only assist an operator of a vertical takeoff vehicle in identifying obstacles in flight and around a landing zone, but also provide the operator with information on the topography of the landing surface. It would also be advantageous to provide a system and method that is capable of producing accurate information regarding the topography of the landing surface in conditions of minimal visual acuity.
SUMMARY OF THE INVENTION
[0013] Accordingly, in one aspect of the present invention, there is provided a radar ranging system for imaging the topography of an area of interest; said system comprising at least one linear arrays of, for instance, 32 transmitter elements that transmit transmitter beams comprising a sequence of ranging signals phased to form a beam pattern covering part of the area of interest, the sequence phased to scan the beam pattern over an entire area of interest, at least one linear array of, for instance, 32 receiver elements arranged orthogonally to the transmitter linear arrays, e.g., as shown in FIG. 2A , 2 B or 2 D, wherein each receiver element receives a time sequence of the ranging signals reflected from variations on the ground as illuminated by the sequence of the ranging signals, the receiver elements each producing a receiver signal; and at least one processor adapted to process each receiver signal, wherein the at least one processor forms a multiplicity of receiver beams complementary to the transmitter beams such that the combination of the transmitter beams and the receiver beams form pencil beams which cover the entire area of interest in time sequence, wherein the at least one processor measures a time delay of a first reflection received in each of the formed pencil beams and converts the time delay into a range measure at each beam angle to form a topographic profile of the area of interest in range and beam angle coordinates. The at least one transmitter array may comprise two parallel transmitter sub-arrays of, for instance, 16 elements each operating at about 35 GHz and the at least one linear array of receiver elements may comprise two parallel receiver sub-arrays of 16 elements each. In this configuration, the spacing between the two parallel receiver sub-arrays should be equal to the length of each transmitter sub-array; likewise the spacing between the two parallel transmitter sub-arrays should be equal to the length of each receiver sub-array. The two pairs can be separated, such as shown, e.g., in FIG. 2E , or they can be in the form of a perimeter array, such as shown, e.g., in FIG. 2C , for a more compact arrangement. These arrangements of transmitter and receiver arrays, with a total of 32 transmitter elements and 32 receiver elements, and half wavelength spacing between the elements, forms 1024 pencil beams.
[0014] A time delay on the first return in each beam may be captured and scaled to a range measurement. The shortest range measured by all the beams may be displayed numerically as radar altitude.
[0015] The processor may be configured to process the topographic profile to display an image of the terrain topography in the area of interest and/or the processor may be configured to process the topographic profile in the area of interest to determine if the area of interest is safe for landing an aircraft. The processor may be configured to provide a warning signal if a hazard is present and configured to show a hazard and/or a safe area on a display. The display of the topographic profile may include a color display, a contour display, or a mesh plot display.
[0016] The display may be referenced to a vertical coordinate system and/or may be referenced to a coordinate system of a platform employing the imaging system. Moreover, the display may be presented as an artificial perspective of the ground as viewed looking forward from an aircraft platform.
[0017] The topographic profile may be compared with a threshold value denoting the slope, a level clearance, and a flatness according to pre-specified data to safely land an airborne vehicle within the area of interest and display suitable and unsuitable areas to an operator of the airborne vehicle. Moreover, the processor may be adapted to compare the topographic profile with pre-specified profiles needed for safe rotor and tail rotor clearance on approach to the area of interest and display suitable and unsuitable areas for landing.
[0018] The signal processor may form a guard channel to mitigate the effect of sidelobe leakage. This sets a detection threshold for all beams to ensure the signal detected in any beam has not entered through the sidelobes of its directional pattern. For this, for any one beam, the signal processor may weight the signals from all other beams according to the sidelobe pattern of the one beam and set the detection threshold above this by a suitable margin.
[0019] In one aspect, the processor may perform the Clean Algorithm on the data streams from all the beams to mitigate any effects caused by sidelobe leakage. This algorithm may sequentially subtract small proportions of the currently strongest beam signal from the signals in other beams, until the cross correlation, and hence the leakage, between signals from all the beams is minimized.
[0020] The radar ranging system may be mounted to look down, to assist operators make a vertical landing. The radar ranging system may be mounted to include a suitable forward look in the area of interest, to assist operators making a forward approach to the landing zone.
BRIEF DETAILS OF THE DRAWINGS
[0021] In order that this invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings, which illustrate preferred embodiments of the invention, and wherein:
[0022] FIG. 1 is a schematic diagram of a radar system according to principles of the invention;
[0023] FIG. 2A is a schematic diagram of an open array arrangement antenna which may be used in a radar altimeter, according to principles of the invention;
[0024] FIG. 2B is a schematic diagram of a T-shaped open antenna array which may be used in a radar altimeter, configured according to principles of the invention;
[0025] FIG. 2C is a schematic diagram of a perimeter antenna array which may be used in a radar altimeter, configured according to principles of the invention;
[0026] FIG. 2D is a schematic diagram of a spaced-apart T-shaped open antenna array which may be used in a radar altimeter, configured according to principles of the invention;
[0027] FIG. 2E is a schematic diagram of an antenna array showing sub-arrays arranged to form a generally parallel Tx and Rx pairs, with one pair adjacent to and spaced apart from the other pair, to form displaced pairs, configured according to principles of the invention;
[0028] FIG. 3 is a schematic diagram depicting landing area surveying operation performed by a radar altimeter, according to principles of the invention; and
[0029] FIG. 4 is a schematic diagram of an alternative arrangement of the at least one transmitter array and at least one receiver array forming a compact two dimensional array, according to principles of the invention.
DESCRIPTION OF THE INVENTION
[0030] The disclosure and the various features and advantageous details thereof are explained more fully with reference to the non-limiting examples that are described and/or illustrated in the accompanying drawings and detailed in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiments of the disclosure. The examples used herein are intended merely to facilitate an understanding of ways in which the disclosure may be practiced and to further enable those of skill in the art to practice the embodiments of the disclosure. Accordingly, the examples and embodiments herein should not be construed as limiting the scope of the disclosure. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.
[0031] A “processor”, as used in this disclosure, means any machine, device, circuit, component, or module, or any system of machines, devices, circuits, components, modules, or the like, which are capable of manipulating data according to one or more instructions, such as, for example, without limitation, a computer, a microprocessor, a central processing unit, a general purpose computer, a super computer, a personal computer, a laptop computer, a palmtop computer, a notebook computer, a desktop computer, a workstation computer, a server, or the like, or an array of processors, microprocessors, central processing units, general purpose computers, super computers, personal computers, laptop computers, palmtop computers, notebook computers, desktop computers, workstation computers, servers, or the like.
[0032] The terms “a”, “an”, and “the”, as used in this disclosure, means “one or more”, unless expressly specified otherwise.
[0033] Devices that are in communication with each other need not be in continuous communication with each other, unless expressly specified otherwise. In addition, devices that are in communication with each other may communicate directly or indirectly through one or more intermediaries.
[0034] Although process steps, method steps, algorithms, or the like, may be described in a sequential order, such processes, methods and algorithms may be configured to work in alternate orders. In other words, any sequence or order of steps that may be described does not necessarily indicate a requirement that the steps be performed in that order. The steps of the processes, methods or algorithms described herein may be performed in any practical order. Further, some steps may be performed simultaneously.
[0035] When a single device or article is described herein, it will be readily apparent that more than one device or article may be used in place of a single device or article. Similarly, where more than one device or article is described herein, it will be readily apparent that a single device or article may be used in place of the more than one device or article. The functionality or the features of a device may be alternatively embodied by one or more other devices which are not explicitly described as having such functionality or features.
[0036] Throughout the specification the term “comprising” shall be understood to have a broad meaning similar to the term “including” and will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. This definition also applies to variations on the term “comprising” such as “comprise” and “comprises”.
[0037] A “computer-readable medium”, as used in this disclosure, means any medium that participates in providing data (for example, instructions) which may be read by a computer. Such a medium may take many forms, including non-volatile media, volatile media, and transmission media. Non-volatile media may include, for example, optical or magnetic disks and other persistent memory. Volatile media may include dynamic random access memory (DRAM). Transmission media may include coaxial cables, copper wire and fiber optics, including the wires that comprise a system bus coupled to the processor. Transmission media may include or convey acoustic waves, light waves and electromagnetic emissions, such as those generated during radio frequency (RF) and infrared (IR) data communications. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, an EPROM, a FLASH-EEPROM, any other memory chip or cartridge, or any other medium from which a computer can read. A computer program product may be provided that stores software configured to, when read and executed by a processor, perform one or more steps of the processes described herein.
[0038] Various forms of computer readable media may be involved in carrying sequences of instructions to a computer. For example, sequences of instruction (i) may be delivered from a RAM to a processor, (ii) may be carried over a wireless transmission medium, and/or (iii) may be formatted according to numerous formats, standards or protocols, including, for example, WiFi, WiMAX, IEEE 802.11, DECT, 0G, 1G, 2G, 3G or 4G cellular standards, Bluetooth, or the like.
[0039] In order to produce a finely detail ground profile image via radar a multiplicity of beams is required. This conventionally requires a scanning dish antenna or phased array radar with many antenna elements and associated scanning electronics, making such systems complex and expensive.
[0040] An alternative approach to the formation of multiple beams is to utilize Multiple Input Multiple Output (MIMO) technique in association with orthogonal or near orthogonal transmitter and receiver antenna arrays. The MIMO technique makes use of the fact that the signal received from the far field with a bi-static transmitter receiver pair is identical to the signal which would be received by a single mono-static transmit/receive element placed at the mid point between the bi-static pair. For convenience, where the targets are in the far field, the image computation can be based on the geometry arising from a notional plurality of transient elements. The technique can also be used for signals from the nearer field, but additional processing by, e.g., a computer or processor, is required to account for an ellipsoidal co-phase surface with the bi-static elements at the foci. In the far field this ellipsoid tends to a spherical surface centered on a synthetic element at the mid-point.
[0041] The formation of multiple beams under MIMO processing is only possible where each receiver element is able to separate the return signals in order to match them to the corresponding signals transmitted from each transmitter element (i.e. a form of multi-static processing within the array itself). By transmitting separable signals from each of M transmitter elements, then capturing and processing the reflected signals from each of M transmitters in each of the N receiver elements, it is possible to form a number of beams equal to the product of the transmitter and receiver element numbers N×M. Typically this may be achieved by transmitting from each element in turn (time division multiplexing), or by simultaneously transmitting separable code sequences from each element (code division multiplexing), or by simultaneously transmitting differing frequency sequences (for instance orthogonal frequency division multiplexing). The code sequences required for signal separability can also serve the need for pulse compression.
[0042] The use of time division multiplexing, code division multiplexing, orthogonal frequency division multiplexing, combinations of these, and other coding techniques for applications in MIMO radar systems are discussed in the inventors earlier filed international applications PCT/AU2007/000033, PCT/AU2008/000628 and PCT/AU2008/001386 now assigned to the applicant all of which are incorporated herein by reference.
[0043] FIG. 1 illustrates the concept of synthesizing multiple beams under the MIMO technique. In this particular example the coding scheme is modulated onto a carrier 101 by encoders 102 a, 102 b, . . . , 102 M via mixers 103 a, 103 b, . . . , 103 M to produce a set of M discrete coded signal, before being transmitted toward the area of interest 105 from transmitting elements 104 a, 104 b, . . . , 104 M.
[0044] A set of reflected encoded signals is received by each receiver element 106 a, 106 b, . . . , 106 N, i.e., each receiver element captures reflected signals corresponding to the transmitted signals from each of the transmitter elements Tx 1 , Tx 2 , . . . , TxM. The received encoded signals are then decoded by applying a decode signal 107 a, 107 b, . . . , 107 M to each of the received signals captured ([Rx 11 , Rx 12 , . . . , Rx 1 M], [Rx 21 , Rx 22 , . . . , Rx 2 M], . . . , [RxN 1 , RxN 2 , . . . , RxNM]) by each of the receiver 106 a, 106 b, . . . , 106 N via banks of mixers 108 a, 108 b, . . . , 108 N. This produces a set of [1, 2, . . . , M ] received channels for each receiving element 106 a, 106 b, . . . , 106 N, which is then set to a beamforming unit 109 to produce M×N beams.
[0045] The proposed radar altimeter according to one embodiment of the present invention utilizes a downward looking MIMO phased array to form multiple beams, covering a relatively wide sector, +/−60 degrees or thereabouts. The distance to the ground is then measured in each beam allowing the ground profile to be formed. The beams may be tilted forward to cover from +90 degrees forward (horizontal) to 30 degrees behind nadir. The provision of such a forward tilt gives a greater degree of coverage in the direction of approach vector to the ground. This additional cover enables the altimeter to more accurately detect other vehicles in the proximity to the current approach vector of the vehicle to the desired landing zone. Such functionality is exceedingly desirable in instances where multiple vehicles are to be landed within a limited space, e.g., a deck of an aircraft carrier, etc.
[0046] A number of possible configurations of a suitable array 200 are illustrated in FIGS. 2A to 2E . FIG. 2A depicts an open array 200 arrangement which is formed from two sub-arrays 201 a, 201 b, one a transmitter array and one receiver array arranged substantially orthogonal to one another such that they form an L shape. An alternative open array construction 200 is shown in FIG. 2B in this case the sub-arrays 201 a, 201 b have been arranged to form a T shape. Again, the sub-arrays 201 a, 201 b are aligned substantially orthogonal to one another. FIG. 2D is similar to FIG. 2B in this case the sub-arrays 201 a, 201 b have been arranged to form a generally T shape. Sub-array 201 a is shown as 16 transmitters and sub-array 201 b is shown as 16 receivers, with the arrays spaced apart. FIG. 2E shows a broken-square format. In the case of FIG. 2E , the sub-arrays 201 a, 201 b have been arranged to form a generally parallel Tx and Rx pairs, with one pair adjacent to and spaced apart from the other pair, to form displaced pairs.
[0047] FIG. 2C depicts one possible configuration of a closed array 200 which is referred to as perimeter array. As shown, the array includes 32 transmitter elements and 32 receiver elements arranged into four sub-arrays. Two transmitter sub-arrays 201 a, 201 a ′ disposed on opposing sides of the array and orthogonal to the two receiver sub-arrays 201 b, 201 b′.
[0048] Each of the transmitter sub-arrays 201 a, 201 a ′ includes 16 antenna elements arranged in banks 203 of four antennas 205 . Each transmission bank 203 is coupled to a switching network 207 . The selection of which transmission elements 205 are active during the transmission cycle is determined by the switching network 207 which opens and closes the appropriate switches to activate the appropriate antenna element 203 based on the chosen multiplexing scheme.
[0049] As with the transmitter sub-arrays 201 a, 201 a ′, the receiver sub-arrays 202 b, 202 b ′ are arranged into banks 204 of four antenna elements 206 . Each receiver bank 204 is coupled to a switching network 208 which passes the signals received by the active receiver elements 206 to the back-end processing section.
[0050] Preferably, each of the antenna elements in the sub-arrays 201 a, 201 a ′ and 202 b, 202 b ′ have the same polarization. The antenna elements should also be selected to provide sufficient beam width (element directional pattern) to illuminate a sufficient area directly beneath and beyond the extremities of the vehicle e.g. +/−60 degrees in a long track and cross track. The spacing between the elements would need to be slightly greater than a half wavelength sufficient to synthesize 32 beams within the +/−60 degree element beam. While the array shown in FIG. 2C is a square parameter array, it will be appreciated by those skilled in the art that the array may be in the form of any suitable shape where multiple combinations of transmitter/receiver pairs allow the formation of a filled aperture. Such configurations might include a rectangle, a T or L shape, a circle, octagon or the like. Alternatively, a parallel pair of transmitters displaced from an orthogonal pair of parallel receiver arrays (i.e., formed as ∥=) can be used where it is desirable to minimize transmitter to receiver leakage.
[0051] FIG. 3 depicts the use of a MIMO array in a ground profiling operation in a radar altimeter according to one embodiment of the present invention. As shown, the aircraft 301 scans the desired landing zone 302 . The synthesized beams each form a narrow cone. Hence, the illuminated patch 302 is wide at higher altitudes. However, as the aircraft 301 descends smaller features of the ground profile can be resolved.
[0052] Each of the transmitter elements 203 in the array 200 radiate a sequence of M differing signals, the ground reflections from which are captured by each of the N receiver element 206 of the array. Each of the N receiver elements then separates out the M received ground reflections from the M transmitters to produce M×N differing received channels.
[0053] The channels are formed into M×N beams by co-phasing the data channels to remove the phase shifts associated with a particular angle of arrival and then summing. Then by suitably filtering the data in each beam, a set of range profiles is formed, thereby allowing the time delay of the return signal via the nearest point in each beam be measured and converted to a distance. These distance measures are then converted into a profile showing the ground and any obstacles 303 on the ground, allowing the suitability of a selected landing zone to be assessed.
[0054] In one aspect, separate transmitter and receiver elements may be formed where the transmitter array is electrically scanned and the receiver array forms a multiplicity of receiver channels such that the combined transmitter and receiver patterns form a set of pencil beams. These arrays may be mounted to, e.g., a helicopter, so that the scanning beams cover the sector below and forward of the helicopter. This has an advantage over conventional scanned phased array radar in that the set of scanning beams can complete a full scan of a sector much faster than a single scanning beam of a conventional phased array. The transmitter antenna 201 a may be a linear array of elements, such as shown in, e.g., FIG. 2A , 2 B or 2 D, forming a fan beam which is electronically scanned in the plane of the array. In this arrangement, the receiver array 201 b, e.g., FIG. 2A , 2 B or 2 D, is also a linear array mounted orthogonally to the transmitter array 201 a. Data from the elements of this receiver array 201 b may be processed with, for example, the Discrete Fourier Transform (DFT) to form a set of receiver fan beams. These are orthogonal to the scanning transmitter beam and intersect with it to form a set of scanning pencil beams. This is because the two way radar pattern is the product of the one way transmitter pattern and the one way receiver patterns.
[0055] In another arrangement, e.g., the configurations of FIGS. 2C and 2E which have transmitter and receiver elements arranged in parallel pairs forming a perimeter array (e.g., FIG. 2C ) or displaced pairs (e.g., FIG. 2E ), the two transmitter sub-arrays 201 a, 201 a ′ may form two fan beams with separate phase centers, the waveforms from the two transmitter fan beams is separately coded such that the two receiver sub-arrays 201 b, 201 b ′ can decode and apply phase correction for beam-forming. This is an adaption of a scanning fan beam technique but using MIMO techniques, and has the advantage of a smaller aperture for the same number of beams and the same beam-width.
[0056] In another form, as shown in FIG. 4 , the transmitter array 201 a may comprise four transmitters located at the corners of a compact two dimensional array of, for example, 32 receiver elements. The four transmitters each illuminates the whole scene of interest, with their well separate phase centers forming directional patterns which, when combined with the patterns of the receiver array in the processor, will form four times the number of beams, each half the width the receiver beam. These two-way radar beams can be formed in parallel by the processor using a two dimensional Fast Fourier Transform. Hence the range profiles from the whole scene can be collected from the returns from just four transmissions. The four transmitter waveforms can be in time sequence, in which case this is a form of MIMO radar with Time Division Multiplexing, alternatively the four transmissions can be orthogonal code sequences, giving a form of MIMO with for instance PCM or OFDM coding. In yet another form, four simultaneous in-phase transmissions will first illuminate the scene to form a fine grain interference pattern. This sharpens the resolving power of receiver beams phased to be coincident with the grating lobes of the transmitter interference pattern. Second, third and fourth transmissions then illuminate the scene, with pairs in opposite phase, to scan the grating lobes in four increments over the scene. For each transmission the receiver beams are formed to be on the peaks of the grating lobes. In this way the 32 range profiles from the sequence of four transmissions can be interleaved to give 128 higher resolution range profiles, and the first return in each located to form a 32 by 32 sample of the terrain profile.
[0057] To maintain a robust terrain profile, in the presence of the slow fades typically encountered by radar altimeters in hovering vehicles, a signal detector with a short sampling widow may be utilized. The signal detector measures the range to the nearest point in each beam with leading edge trackers which search out from zero range to detect the first return. The first return in each beam is then tracked with a suitable early-late gate or similar. If the signal fades the tracker stays locked for a short interval and if the signal has not returned in this interval the tracker repeatedly searches out from zero again until it can lock onto the return signal.
[0058] The resultant ground profile may be displayed to the pilot for assessment as a contour plot or as a mesh plot. This would allow the pilot to independently judge which regions within a surveyed area may be suitable landing sites. The altimeter may employ an algorithm to automatically determine the suitability of a surveyed area for landing. The algorithm may incorporate such considerations as whether there is adequate rotor/wing clearance, whether the ground slope is sufficiently parallel to the landing gear and determining the height at which any obstacles on the landing zone project above the landing surface, in order to decide which regions within a surveyed area are suitable for landing. Areas identified as suitable and unsuitable could then be displayed to the pilot via display unit to further assist the pilot in the selection of a landing zone. An audible warning may also be provided if the ground in view has a profile falling outside the specification for a safe landing. If a vertical reference is available the display could be referenced to this, otherwise the terrain display would be referenced to the pitch and roll of the vehicle. In this case the image of the ground profile would tilt according to the vehicle's angle with respect to the ground.
[0059] It should be noted that not only are the transmitted signals required to be readily separable to produce a useful image of the ground profile, they also need to have a sufficient bandwidth for a range resolution suited to the required height measuring accuracy. Typically a radar altimeter with a leading edge tracker can deliver the required accuracy (+/−2 ft) with a 20 ns pulse, but waveforms which can be time-compressed to that length (pulse compression) are also suitable.
[0060] The above discussion focuses on the use of the MIMO technique to produce a multi-beam radar altimeter capable of producing a highly accurate ground profile image. As mentioned above, one of the other major problems effecting landing and takeoff operations of vertical takeoff vehicles is that of brownout. Most radar altimeters can function under such conditions and their performance is not degraded due to the interference caused by the dust particles, etc. The selection of the type of transmission signal plays a significant role in overcoming such performance issues. Radar transmissions in the millimeter wavelength of the spectrum are capable of readily penetrating through dust, smoke or other such particulate clouds. Thus, by applying to each of the transmitter elements of the array, a short pulse of wavelength in the order of a few millimeters (e.g., 16.3 GHz or 35 GHz), the altimeter can readily image the terrain beneath the vehicle during a brownout, or similar events.
[0061] The MIMO technique described above for the formation of multiple beams typically requires the transmission of long orthogonal transmitter code sequences from each transmitter element and the need for the ground returns to stay coherent during the sequence may limit the use of radar at speeds above a few knots. Furthermore, the MIMO technique may require heavy signal processing burden with consequential high power consumption and a limited update rate. An alternative technique to the MIMO technique may use similar antenna structures as was used for the MIMO radar but with differing transmitter waveforms and signal processing. This technique takes advantage of the fact that:
Receiver arrays can form multiple beams at once by, for instance, applying the Discrete Fourier Transform to the data stream from the receiver elements. This enables very efficient beam-forming. The two-way radar directional patterns are formed as the product of the receiver directional patterns and the transmitter directional pattern Transmitter directional pattern can be scanned over the scene of interest from pulse to pulse, illuminating a wide footprint on the ground with each pulse, whilst the receiver arrays form multiple beams within the transmitter footprint. The wide transmitter footprint allows the entire area of interest to be covered with a few scans of the transmitter. Hence a suitable combination of transmitter and receiver two way patterns can scan a set of fine beam width directional patterns over the scene with a few transmissions. Typically the transmitter and receiver arrays will form fan beams orthogonal to each other where the intersection of transmitter and receiver fans form pencil beam.
[0068] In a simple first example to illustrate this technique, a linear transmitter array may be mounted orthogonal to a linear receiver array configured such as shown in FIG. 2A . A suitably timed sequence of wide band ranging signals is applied to the elements of the transmitter array 201 a with phase shifts such as to form fan beam directional patterns stepped in sequence over the area of interest. The timing of the transmissions must be long enough to allow all the reflections from the region of interest to die away before the transmission is repeated. The phase shifts must form a linear phase slope across the aperture for any one ranging signal (typically a pulse). A sequence of different phase slopes then scans a fan beam across the scene.
[0069] The signals reflected from the scene are collected by the elements of the receiver array 201 b and processed typically with a Discrete Fourier Transform (DFT). This synthesizes a set of receiver fan beam directional patterns aligned orthogonally to the transmitter fan beams. The intersection of the transmitter fan beam with the set of receiver fan beams forms a set of pencil beams. These are stepped over the scene as the transmitter fan beam is so stepped. The data streams received by these pencil beams are then processed to measure the time delay to the first return received in each pencil beam and this time delay is converted to a distance measure. The distance measured by each beam then defines a profile describing the topography seen by the radar in the beam angular coordinates. This ground profile may be displayed in suitable coordinates, and may be processed to determine if and where the topography is unsuitable for landing, showing such regions on the display.
[0070] This simple first example is based on a known scanning scheme, but has been adapted for a landing aid by measuring the ground topography, displaying an image of the topography, and giving a warning of unsafe conditions, which has not been previously provided.
[0071] In a second example, a new type of scanning technique is used. This offers an advantage over the first simple example, requiring an aperture which is half the size for a given performance (number of beams and beam-width) and with the same number of antenna elements. In this second example, two linear and parallel transmitter sub-arrays and two linear and parallel receiver sub-arrays are formed around the perimeter of a square such as shown in FIG. 2C . The two fan beams formed by the two transmitter sub-arrays (e.g., sub-arrays 201 a, 201 a ′) are stepped over the area of interest in synchronism, with the signals from the two sides transmitted simultaneously in the same phase and then in anti-phase at each pointing angle of the fan beams. The interference pattern so produced from the widely spaced transmitter arrays illuminates the ground with a row of narrow pencil beams within the fan beam footprint. These pencil beams will be spaced by twice their beam-width; hence the space between each beam needs to be filled. So, when the phase between the two fan beams is reversed the two fan beams will illuminate the ground again with a row of narrow pencil beams but interlaced between the co-phase pencil beams. In this way the area of interest is fully illuminated with rows of pencil beams in sequence as the fan beams are stepped over the area of interest.
[0072] At the receivers (e.g., receiver sub-arrays 201 b, 201 b ′) two sets of data may be received at each of the transmitter pointing angles: the set from the co-phase illumination, and the set from the anti-phase illumination. These are processed by first applying a DFT to the sum of these sets and then applying a DFT to the difference of these. This again forms two interlaced interference patterns, but orthogonal to the transmitter orthogonal patterns. A pencil beam as formed by the intersection of a transmitter and receiver fan beam now forms four pencil beams, doubling the resolving power in each dimension.
[0073] In order to achieve the maximum gain in each of these four beams the transmitter fan beam should be incremented in half beam-width steps across the scene and the receiver DFT should be interpolated to double the number of samples.
[0074] In one variation, the two transmitter sub arrays can be fired in sequence rather than simultaneously. The two interference patterns can then be formed in the receiver signal processing to complete the transmitter beam synthesis. This is a form of MIMO radar with simple time-division-multiplexing (TDM) providing orthogonal coding for the two transmitter sub-arrays only. However, with this variation, only half of the transmitters are used for any one burst, so halving the total energy available to illuminate the scene. In another variation, both transmitter arrays fire simultaneous to provide the full available energy. For this the two transmitter sub arrays each transmit a code sequence forming an orthogonal pair, using for instance phase code modulated or orthogonal frequency code (PCM or OFDM). The signal stream from the receiver array elements are then de-coded into the two channels representing the reflections from the scene as illuminated by the two transmitter fan beams with their displaced phase centers. The sum and differences output from these two fan-beams are then processed as with the TDM approach.
[0075] In yet another embodiment, the transmitter and receiver arrays can be in a square or rectangular format, for instance the arrangement in FIG. 4 , where a square array of receiver elements ( 201 a ) feeds a two dimensional Fast Fourier Transform (2D-DFT). This simultaneously synthesizes a set of receiver beams covering the scene from just one transmission. When the scene is illuminated with simultaneous waveforms from the four transmitter elements a two-dimensional interference pattern is formed illuminating the scene with an array of dark and light footprints. These bright footprints are narrower than the receiver beam footprints and the combined transmitter and receiver pattern spans a finer resolution area of the scene than the receiver beam alone. With appropriate element geometry the nulls in the receiver pattern will coincide with the remaining peaks of the transmitter interference pattern. The gaps in the transmitter interference pattern are filled stepping the transmitter interference across the scene with suitable phase shifts applied to the transmitter elements. For each of these transmissions the 2D FFT outputs are interleaved to form the higher resolution image.
[0076] The overall requirement for this and other variations is that:
the spatial convolution of the transmitter positions and the receiver positions forms a synthesized co-array of the form required to synthesize the desired directional patterns; and the receiver array simultaneously forms multiple receiver beams intersecting the scene illuminated by a single transmitter beam; and the transmitter beams complete the cover using MIMO or sequential scanning.
This combination offers faster sector cover than is possible with a single scanning beam or with the fully coded MIMO approach requiring long code sequences.
[0080] It is to be understood that the above examples have been provided only by way of exemplification of this invention, and that further modifications and improvements thereto, as would be apparent to persons skilled in the relevant art, are deemed to fall within the broad scope and ambit of the present invention described herein. | According to one aspect of the present invention, a radar system is provided which accurately measures the surface profile in a wide sector beneath and forward of a helicopter, to aid low level transit and landing in poor visibility. This uses an electronic beam synthesis technique to form multiple beams directed at the area of interest, each measuring the distance to the first reflected signal received by each beam. These distances represent the profile of the ground and any objects on the ground. A processor then compares the measured profile with the ideal ground profile for safe landing. If the deviations from straight and level exceed the specified requirement for safe landing, or if sufficient rotor clearance is not detected, then a warning is given to the operator. A display will show the measured ground profile highlighting the unsafe regions, allowing the operator to seek a safe region to land. The novelty lies in the way the beams are formed to measure and display the ground profile and provide a warning system. This beam-forming technique is simpler and more cost effective than with a conventional phased array radar. | 6 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention is directed to improvements in protective headgear. More particularly, the present invention is directed to a helmet which can be removed in an emergency situation without excessive movement of the wearer's head to avoid exacerbating possible head, neck or spinal injuries.
Protective headgear is worn by various athletes including but not limited to football players, race car drivers, motorcyclists, bikers, hockey players, skate boarders, and ski racers. In spite of efforts to protect the head of the wearer, occasionally a sports participant undergoes a head, neck or spinal injury. In such cases, it is extremely important that the head not be moved until the nature and extent of the injury can be diagnosed. Simultaneously, it is just as critical that the head gear be removed quickly should CPR be necessary and to enable the diagnosis to be carried out quickly so proper medical attention can be administered promptly. Conventional headgear requires the head of the wearer to be raised and an axial pull force, and associated frictional force, exerted to effect removal. Such movement of a patient's head is exactly the type of movement that could turn a relatively minor injury into a permanent disability.
Within the last several months, several severe injuries and, in some cases, deaths, have occurred due to head and/or spinal injuries to participants in sporting events. It is possible that one or more of the injuries may have been aggravated by the need to remove the wearer's helmet in order to administer first aid. The present invention provides a multiple-piece helmet design, the parts of which can be disassembled and removed from the head of its wearer while minimizing movement of the athlete's head and spinal column.
A first rigid portion is attached to a second rigid portion, preferably first and second halves, by a securing means that may be detached in the event of an emergency. The securing means can take any of a variety of forms including, but not limited to buckles, pronged fingers and recesses with fasteners, threaded fasteners alone, and a woven wire. The portions are most preferably a front half and a back half. In a medical emergency, the front half can be removed while the player is lying on her/his back, the patient fitted with a supporting collar and simply lifted out of the back half. In this way, cervical strain and range of motion (ROM) of the head, neck and spine to effect removal of the helmet are greatly reduced. While the present invention deals only with the external portions of the helmet, it will be understood that the internal liner will similarly need to be made in multiple pieces. These pieces can be most easily made separable through simply overlapping tapered soft liner portions. As an alternative, the liner may be equipped with VELCRO fasteners on the interface between the multiple pieces or two halves, as depicted in the drawings.
The securing means can take a variety of forms and several embodiments are shown. In a first embodiment, the securing means comprises a plurality of buckles, one section formed on each helmet portion, and one of the sections being relatively movable with respect to the helmet to permit the plurality of buckles to be affixed seriatim. A second embodiment depicts the securing means as a plurality of fasteners threaded directly into a layer from one of the helmet halves that underlies the other helmet half. A series of interdigitating fingers, pins in recesses, or a tongue-in-groove arrangement is provided to supply the needed alignment and joint reinforcement necessary.
A third and fourth embodiment of the present invention utilize a tension wire wound through interdigitating helmet portions which may include reinforcing steel pins. A first end of the wire is received in a recess and the opposite end is adjustable to remove the slack and adjust the tension in the wire as the tension in the wire, over time, produces stretching or creep. A fifth embodiment employs a latching between a series of pronged fingers on a first helmet half and a series of recesses or indentations on the second half, with fasteners insuring securement of the fingers in the indentations.
Other features, advantages and characteristics of the present invention will become apparent to a person of ordinary skill in the art following a reading of the following specification.
BRIEF DESCRIPTION OF THE DRAWING
The preferred embodiments are described in conjunction with the attached drawings, like elements bearing like reference numerals and, in which
FIG. 1 is a side view of a first embodiment of the two-piece helmet of the present invention;
FIG. 2 is a side view similar to FIG. 1 shown on a different style helmet with the dust covers removed;
FIG. 3 is a side view of the first embodiment with the two-halves disengaged;
FIG. 4 is a perspective view of the first embodiment with the halves disengaged;
FIG. 5 is a cross-sectional side view of the first embodiment as seen along line 5--5 in FIG. 3;
FIG. 6 is a top view of a second embodiment of the two-piece helmet of the present invention;
FIG. 7 is an exploded cross-sectional side view of the second embodiment as seen along line 7--7 in FIG. 6;
FIG. 8 is a top view with portions removed of a third embodiment of the present invention;
FIG. 8A is detailed cross-sectional side view of a first side of the third embodiment;
FIG. 8B is a detailed cross-sectional side view of a second side of the third embodiment;
FIG. 9 is a top view with portions removed of a fourth embodiment of the present invention,
FIG. 9A is a detailed cross-sectional side view of a side portion of the fourth embodiment;
FIG. 10 is a detailed perspective of a first variant of the present invention;
FIG. 11 is a side view of a detail of a second variant of the junction between the two helmet halves;
FIG. 12 is a side view of a detail of a third variant of the junction;
FIG. 13 is a perspective view of a fifth embodiment of the two-piece helmet of the present invention,
FIG. 14 is a sectional view of the fifth embodiment as seen along line 14--14 of FIG. 13;
FIG. 15A is a perspective of the back half of the helmet of the fifth embodiment; and
FIG. 15B is a perspective of the front half of the helmet of the fifth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first embodiment of the present invention is shown in FIGS. 1-4 generally at 20. Helmet 20 is comprised of first portion (or half) 22 and second portion 24. The two halves 22 and 24 engage along a seam which preferably extends across the wearer's head from ear to ear. Securing means 26, in this case a plurality of buckles consisting of first buckle half 28 secured to front half 22 and second buckle half 30 secured to rear half 24, are used to attach the two halves 22 and 24 together for conventional use and wear. Alternate buckle halves 28 are mounted on a track 29 (FIG. 5) to permit it to be slid toward and away from buckle half 30 to facilitate assembling and disassembling of the halves 22 and 24. The other alternate buckles 26 have the buckle half 30 movable to facilitate secure attachment (FIG. 3). The buckles are connected by pushing the arms 44 of a first buckle half into the recesses 46 of a second buckle half.
The principles of the invention are equally applicable to the race car style helmet depicted in FIG. 1 and the football helmet of FIG. 2. The buckles 26 are positioned in recesses 32 (FIG. 5) and enclosed by dust covers 34 which keep dirt, sod, and other material out of the recesses 32 where it could possibly foul the workings of the buckles 26. Dust covers 34 each have an annular protrusion 36 which snaps into a groove 38 extending about the periphery of recess 32. While any number of buckles 26 can be used, six have been depicted here. It is believed that the minimum number required would be three. As seen in FIG. 4, a plurality of extensions 40 are formed on front half 22 that are received in openings 42 in back half 24. Engagement between extensions 40 and openings 42 are needed to provide the structural rigidity needed to permit the helmet 20 to withstand the impact testing required for a helmet to be certified for use.
After the front (22) and rear (24) portions are assembled at the factory, the helmet 20 will be used as a conventional helmet, being slipped on and off with repeated uses. Should the helmet's wearer undergo a head, neck or spinal injury, s/he can be laid on her/his back, the dust covers 34 snapped off with a screw driver or other blunt instrument, the buckles 26 unfastened, and the front portion 22 removed by lifting it off the rear portion 24. This will provide those administering first aid access to the wearer's face and facilitate the attachment of a supportive neck brace, if necessary. Once the wearer's head has been stabilized, they can simply be lifted out of the rear portion and placed on a gurney for transport to the hospital. As an alternative, the wearer's head can remain in the rear portion 24 to help keep the head in a neutral position.
A second embodiment of the present invention is shown in FIGS. 6 and 7 generally at 20a. In this embodiment, a plurality of threaded fasteners 26a are positioned about the periphery of the helmet along the seam 50a. It is preferred that the fasteners 26a be spaced apart by about 11/2 to 2 inches. While seam 50a could be formed by overlapping flanges which are each 1/2 the thickness of the full helmet, in this embodiment, a tongue in groove configuration has been shown. A plurality of slots 52a are positioned in the front portion 22a of helmet 20a to permit it to be pried off the rear portion 24a by a screw driver, or the like. As seen in FIG. 7, tongue 54a on front portion 22a is received in groove 56a in rear portion 24a and secured there by screws 26a which thread into the lower flange of groove 56a to retain the two halves 22a, 24a together. The design could be simplified by having a half-thickness flange on one of the two halves 22a, 24a underlie a half thickness flange on the other. In the event of an emergency, the wearer can again be positioned on her/his back and the screws 26a removed using a cordless power screwdriver so that the front portion 22a can be quickly pried off the rear portion 24a and access gained to the wearer's face.
A third embodiment is depicted in FIGS. 8, 8A, and 8B generally at 20b. In this embodiment, seam 50b is formed by a first series of gear teeth 60b on helmet front portion 22b and a second series of gear teeth 62b on helmet rear portion 24b. These teeth 60b and 62b interdigitate as shown in FIG. 8. A recess 64b extends laterally through the teeth 60b, 62b and preferably, a tongue-and-groove engagement (not shown) of the type depicted in conjunction with the first embodiment occurs between the ends of gear teeth 60b, 62b and the corresponding recesses that receive them. A wire or cable 66b is threaded through recess 64b to secure front portion 22b to rear portion 24b. Once cable 66b is threaded, ball stop 70b will be affixed to the end 68b of cable 66b. This may be done by swaging or, more preferably, by threading. The opposite end 72b has an adjustment screw 74b attached by means of a swivel 76b. Adjustment screw 74b engages threads in enlarged opening 78b which can be directly formed in the plastic of the enlarged opening 78b or in a metallic insert (not shown) swaged into opening 78b. A screw driver can be inserted into a slot formed in the end of adjustment screw 74b to permit the cable 66bto be tensioned to properly attach the front portion 22b to the rear portion 24b even should the cable 66b stretch.
In this third embodiment, should an emergency occur, adjustment screw 74b can be fully loosened and swaged ball stop 70b snipped off the end or threaded ball 70b unscrewed. Then adjustment screw 74b can be completely backed out of opening 78b and the cable removed. Then, front portion 22b can be lifted off rear portion 24b to permit access to the wearer's face.
A fourth embodiment is depicted in FIGS. 9 and 9A generally at 20c. Cable 66c is wound around a plurality of steel pins 80c which extend between layers of plastic 61c and 63c which form gear teeth 60c and 62c. Again, an adjustment screw 74c which is mounted by means of swivel 76c allows the tension to be adjusted in cable 66c by pulling against a ball stop (not shown) to afford the proper retention force between helmet halves 22c and 24c. To assemble this embodiment, the cable 66c will be wound around the pins 80c with the two halves 22c, 24c slightly separated to afford access to the slots around the pins. Tongue-in-groove engagement between the bottom of the gear slots and the ends of the teeth will provide the reinforcement for stability as in the previous embodiment. Removal is effected by adjusting the screw 74c as was described above in conjunction with the other cable embodiment.
A first variant of the present invention is depicted in FIG. 10. Instead of having threaded fasteners extending radially inwardly through the layers of the two helmet halves as depicted in conjunction with FIGS. 6 and 7, a molded recess 82d could be formed in the rear half 24d of the helmet 20d and an apertured rib 84d formed on the front half 22d. In this way, the fasteners 26d extend circumferentially about the helmet 20d. It is preferred that the recess 82d be in the rear half 24d of the helmet so that the screws 26d can be removed while the wearer is lying on her/his back.
A second variant of the present invention is depicted in FIG. 11. Spherical protrusions 86e are received in spherical recesses 88e to provide the alignment of the two halves 22e and 24e, prevent rotational misalignment between the two halves and to provide the reinforcement needed to pass the structural integrity tests. Yet a third variant is depicted in FIG. 12 in which the protrusions 86f and recesses 88f are more intricately shaped and more resistant to slippage.
A fifth embodiment of the present invention is shown in FIGS. 13, 14, 15A and 15B generally at 20g. In this embodiment, a series of spring fingers 90g, with prongs 91g, extending from rear half 24g engage in a series of indentations 92g in the front half 22g and are secured there by screws 26g. A series of pins 40g in one half are received in holes 42g (FIGS. 15A, 15B) in the other to provide the alignment and reinforcing functions. To remove the helmet 20g in an emergency medical situation, screws 26g are removed using a cordless power tool and the fingers 90g pried outwardly to permit front half 22g to be lifted off rear half 24g.
Several embodiments of the present invention have been shown in which a two-piece helmet can be disassembled while on the wearer's head in order to avoid aggravating a possible head, neck or spinal injury. Various changes, alternatives and modifications will become apparent to one of ordinary skill in the art after a reading of the foregoing specification. It is intended that all such changes, alternatives and modifications as fall within the scope of the appended claims be considered part of the present invention. | A multiple-piece removable helmet can be disassembled on the wearer's head so that, in the event of a medical emergency, the front portion can be removed to afford access to the face of the wearer for administration of first aid and to facilitate the diagnosis of the extent of the injury. A neck brace can be attached and the injured can be lifted out of the back portion of the helmet. Apparatus for removably attaching the two halves include, in various embodiments, screws, adjustable tension cables, buckles, and spring fingers on one half engaging in indentations in the other with the fingers being secured in place by screws. | 0 |
BACKGROUND AND SUMMARY
[0001] The present application relates generally to an attachment system and more particularly to a solar panel attachment system for a roof of a building.
[0002] Conventional photovoltaic or solar panels are mounted to roofs of buildings through screw-in clips or the like. Examples of such conventional devices are disclosed in U.S. Patent Publication No. 2011/0088740 entitled “Photovoltaic Panel Clamp” which published to Mittan et al. on Apr. 21, 2011, and U.S. Pat. No. 6,672,018 entitled “Solar Module Mounting Method and Clip” which issued to Shingleton on Jan. 6, 2004, both of which are incorporated by reference herein. Such conventional methods cause the installer to juggle many loose fasteners while simultaneously holding heavy solar panels and/or roof mounting components, often on a tilted metal roof in unpleasant weather conditions. Furthermore, such traditional multi-piece screw or bolt arrangements take considerable time to install while also having inconsistent installation torque values, especially in the common situation where many of these solar panel mounting devices are required for each roof.
[0003] In accordance with the present invention, an attachment system is provided. In another aspect, a latching assembly is mounted to a building roof. Another aspect employs a moveable latch that removeably attaches an auxiliary component, such as a solar panel, to a building in a single motion and/or snap-in installation manner. A method of installing a latch assembly is additionally provided. Furthermore, a method of manufacturing a latch assembly is disclosed.
[0004] The present attachment system is advantagous over traditional devices. For example, in one aspect, a single motion installation is employed to engage an auxiliary roof component, such as a solar panel, for latch engagement without requiring tools. In an aspect of the present attachment system, an auxiliary roof component is quickly and easily secured to a building roof in a fast manner without requiring the installer to juggle multiple parts. In another aspect, a striker or protruding member is preassembled directly to a glass surface of a solar panel and a latch assembly is preassembled to a building roof via an easy to install roof clamp, prior to assembly of the solar panel to the latch assembly. Moreover, the auxiliary roof component can be easily detached from the latch assembly in an aspect of the present system. Another aspect allows for quick connect mounting of the auxiliary roof component to a latch assembly coupled to a tilted frame and/or by use of ballast on a horizontal surface. Another aspect of the present system is advantageous over conventional devices since this aspect uses lightweight and strong composite materials for various components of the attachment system. When installed, the latch assembly and roof clamp can optionally provide an electrical grounding path between the auxiliary roof component and the metal roof, or wires attached thereto. Additional advantageous and features of the present invention will become apparent in the following description and appended claims, taking in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view showing a first preferred embodiment attachment system securing solar panels to a building roof;
[0006] FIG. 2 is an exploded perspective view showing the first preferred embodiment attachment system;
[0007] FIG. 3 is a cross-sectional view, taken along line 3 - 3 of FIG. 4 , showing the first preferred embodiment attachment system;
[0008] FIG. 4 is a perspective view showing the first preferred embodiment attachment system;
[0009] FIG. 5 is a partially fragmented perspective view showing the first preferred embodiment attachment system;
[0010] FIG. 6 is a perspective view, generally opposite that of FIG. 4 , showing the first preferred embodiment attachment system;
[0011] FIG. 7 is a partially fragmented perspective view, like that of FIG. 5 , showing the first preferred embodiment attachment system;
[0012] FIG. 8 is a cross-sectional view, taken along line 8 - 8 of FIG. 7 , showing the first preferred embodiment attachment system;
[0013] FIG. 9 is a perspective view showing a second preferred embodiment attachment system; and
[0014] FIG. 10 is a partially exploded perspective view showing a third preferred embodiment attachment system.
DETAILED DESCRIPTION
[0015] FIG. 1 illustrates a building 21 having a tilted roof 23 , preferably made from sheet metal sections joined together at folded over, raised standing seams 25 . Auxiliary roof components, preferably multiple solar panel assemblies 27 , are secured to seams 25 by way of multiple attachment systems 29 . Each attachment system 29 includes a roof clamp 31 and a latch assembly 33 .
[0016] FIGS. 2 and 3 depict roof clamp 31 attached to seam 25 of roof 23 . Roof clamp 31 includes a saddle 41 , a roof seam-engaging wedge 43 , and an elongated shaft or securing member 45 . An optional part includes a retaining element 71 . Securing member 45 fits into and aligns saddle 41 with wedge 43 so that upon engaging securing member 45 , camming action of roof seam-engaging wedge 43 along saddle 41 secures roof clamp 31 to roof 23 . Notably the same securing member 45 that secures roof clamp 31 to roof 23 also secures an auxiliary-retaining device, such as latch assembly 33 , to roof 23 along a top surface of saddle 41 .
[0017] Saddle 41 further includes a saddle bore 51 , two side walls 53 , and a camming surface 55 located on each side wall 53 . Saddle 41 has an inverted U-shape or a bifurcated yoke body. Furthermore, the saddle top surface serves as the region through which securing member 45 is advanced or retracted so that the roof seam is engaged.
[0018] Saddle 41 defines a slot 61 which serves in part to engage seam 25 of roof 23 and also to serve as camming surface 55 . Slot 61 includes a substantially vertical access area and is adjacent camming surface 55 to facilitate trapping or clamping the roof seam in the roof clamp.
[0019] Roof seam-engaging wedge 43 includes a wedge bore which allows securing member 45 to pass through wedge 43 and into saddle 41 . This operates to secure roof clamp 31 on the roof seam and to also secure latch assembly 33 using the single securing member 45 and a nut fastener 63 secured to an upper end thereof. Wedge 43 includes at least one angled surface 65 that mates with camming surface 55 so that when securing member 45 is pulled by tightening nut 63 , wedge angled surface 65 moves along camming surface 55 of saddle 41 . A polygonal head of securing member 45 is prevented from rotation by a matching recess in a bottom of wedge 43 .
[0020] Retaining element 71 is disposed between an interior of saddle 41 and a top surface of wedge 43 . Protrusions on the inside of saddle 41 mate with retaining element 71 . This is either by a snap fit or interference fit to prevent retaining element 71 from becoming dislodged from saddle 41 prior to wedge 43 engaging the roof seam. In another construction, the retaining element can be replaced by a leaf spring secured to the saddle and/or wedge.
[0021] Saddle 41 , roof seam-engaging wedge 43 , securing member 45 , and optionally retaining element 71 , are pre-assembled prior to placing roof clamp 31 in the proximity of roof seam. “Pre-assembled” for the clamp refers to the components being aligned such that securing member 45 keeps them attached together. This can be achieved either on the ground at the work site, at a remote site, or at the factory at which roof clamp 32 is manufactured. When wedge 43 is retracted to trap seam 25 between an inner foot of the wedge and the inner slot edge of saddle 41 , a portion of securing member 45 extends beyond the top surface of saddle 43 such that proximal threaded end of member 45 also provides an attachment point for latch assembly 33 .
[0022] Referring now to FIGS. 2-7 , latch assembly 33 includes a stamped metal bracket 101 , a spring steel insert 103 and a pair of latches 105 and 107 . Bracket 101 has a generally U-end view shape defined by a generally flat bottom or base wall 111 and a pair of spaced apart and upstanding side walls 113 . Multiple slots 117 are provided in each side wall 113 which are openly accessible adjacent a top edge 119 thereof. An aperture 121 is provided in bottom wall 111 of bracket 101 to receive the threaded end of securing member 45 for nut attachment thereto.
[0023] Insert 103 is a stamped metal part including an outer ring 123 and a pair of tabs 125 diagonally projecting and biasing upwardly away from bottom wall 111 of bracket 101 . A generally horizontal turned flange 125 inwardly projects from each diagonal section of tab 123 within which is an internally slotted receptacle 127 . A central hole is also provided in insert 103 to receive member 45 therethrough.
[0024] Latches 105 and 107 are in mirrored symmetry to each other and have a generally hook-like shape defined by a somewhat radially extending engagement surface 141 . A pivot pin 143 projects laterally from each side wall 145 of latches 105 and 107 . The ends of each pin 143 have peripheral grooves therein for a compression fit into the side wall or for receiving circlips external to the side walls, such that pin is rotatably journaled within side walls 113 of bracket 101 to allow pin 143 to rotate with each associated latch. Alternately, the pivot pin can be stationarily affixed to bracket such that each latch rotates about the pin.
[0025] Furthermore, a central rib 147 extends from an internal ledge of each latch 105 and 107 , which is spaced apart from and between outer walls 145 in a generally parallel configuration. Alternately, each latch may be a single solid piece such that the peripheral surface continuously extends between walls 145 thereby subsuming central rib 147 . A peripheral camming surface 151 is provided on walls 145 and 147 such that each tab 123 acts as a cam follower by riding against and controlling motion of camming surface 151 for at least central wall 147 , and optionally outer walls 145 , of each latch. This camming action serves to urge each latch to either its unlatched position (as shown for latch 107 ) or its latched position (as shown for latch 105 ). The latches are preferably made by compressing sintered powder metal, but may alternately be cast metal which is thereafter machined.
[0026] A striker arm 201 protrudes from each auxiliary roof component, preferably solar panel 27 , for engagement by latch assembly 33 . More specifically, each striker 201 includes a generally cylindrical rod 203 bordered by laterally enlarged and generally circular abutment stops 205 and 207 . A curved neck 209 ends with a generally flat pad 211 which is adhesively bonded directly to a bottom surface 213 of the glass solar panel with a suitable adhesive, such as that obtained from A. Raybond Sarl as Techbond™ brand polyurethane adhesive. Thus, an expensive and heavy peripheral frame is not required to mount the solar panels 27 to the building roof 23 . The strikers 201 are preferably made by compressing sintered powder metal in the present system, but may alternately be cast metal or extruded and then cold head compression formed for the pads.
[0027] Each striker 201 is preassembled to the associated solar panel 27 either at the solar panel manufacturing plant or on the ground at the job site. Moreover, roof clamp 31 is preassembled onto the roof seam 25 and thereafter, latch assembly 33 is assembled to roof clamp 31 using a single securing member 45 in a top-only access manner. Subsequently, the solar panel assembly, including the preassembled striker 201 , is manually lowered by the installer through the associated slots 117 of bracket 101 . This single linear motion causes rod 203 of striker 201 to manually rotate latch 107 about pin 143 from its unlatched position to its latched position. In the latched position, a pawl 221 (see FIGS. 3 and 8 ) protrudes into receptacle slot 127 of spring tab 123 , thereby providing a locking function to secure the latch in its latching position. Hence, rod 203 of striker 201 is trapped between latch engaging surface 141 and edges of the bracket side walls defining slots 117 . This is done in a quick connect or snap-in manner without requiring tools or threaded fastener engagement.
[0028] When it is desired to service or remove solar panels 27 , the user can install an elongated tool, such as a flat bladed screw driver, within a gap 223 (see FIG. 6 ) between solar panels 27 . The screw driver is then pushed against an extending end of tab 125 between latches 105 and 107 . This tab depression unlocks pawl 221 which allows the user to then manually pull up on the solar panel which, in turn, causes counter rotation of the associated latch toward its unlatched position.
[0029] FIG. 9 illustrates another configuration of the latch assembly 301 . The bracket 101 , insert 103 (not shown), latches 105 and 107 , and strikers 201 are the same as the prior embodiment. However, an elongated rail 303 is employed instead of a roof clamp. The bracket and latches are secured within an upper section of rail 303 and upwardly accessible access slots are additionally provided in side walls of rail 303 to match those in bracket 101 . Rail 303 has a generally H-end view shape with a bottom flange 305 laterally extending therefrom. A polarity of holes 307 are located in flange 305 such that screws 309 , rivets or other fasteners can be inserted therein for attachment to a structural rack or frame 311 . Frame 311 is provided with an offset angled configuration relative to a flat or tilted building roof, building side wall, or even on the ground.
[0030] Referring now to FIG. 10 , another embodiment attachment system 351 includes a latch assembly 33 like that of the first embodiment discussed hereinabove. An elongated rail 353 , however, secures bracket 101 therein and includes a laterally extending lower flange 355 . Heavy weighted ballast members 357 , such as cement blocks, are positioned on flange 355 to hold attachment system 351 onto a flat roof surface 359 without the need for other fasteners or clamps. Additionally, a solar panel or other auxiliary roof component 361 , such as a snow guard, pipe, wire conduit, ladder, or the like, can be adhered or otherwise attached onto strikers 201 .
[0031] It is alternately envisioned that rails 303 and 353 , or even bracket 101 , are made from a composite material including one or more sheets of long strand (e.g., longer than one inch) fiberglass or carbon fiber, either of a woven or random fiber orientation, in polymeric resin such as epoxy. In one version, a pultrusion process is employed to make this composite material prior to its molding, extruding or shaping into the desired configurations. The edges and slots are cut from the sheets before or after curing, and before or after molding. This process and material advantageously provides a lightweight and very durable component for the attachment system. In another alternate configuration, rails 303 and 353 have a single upstanding wall in the upper segment upon which bracket 101 is clamped between a downwardly open slot edge of the bracket and a camming wedge similar to wedge 43 ; this would eliminate the need to cut the slots in the pultruded rails.
[0032] While various aspects of the present attachment system have been disclosed, it should be appreciated that modifications can be made. For example, the present accessory mounting brackets can be secured to conventional roof clamps such as those disclosed in the following U.S. Pat. Nos. 7,758,011 entitled “Adjustable Mounting Assembly for Standing Seam Panels” which issued to Haddock on Jul. 20, 2010; 7,386,922 entitled “Snow-Guard Clamping Unit” which issued to Taylor et al. on Jun. 17, 2008; and 5,715,640 entitled “Mounting Device for Controlling Uplift of a Metal Roof” which issued to Haddock on Feb. 10, 1998; except many of the present advantages will not be realized. These patents are incorporated by reference herein. Moreover, more or less latches can be attached to a single bracket. It is also envisioned that the attachment system is attachable to an exterior side of a building, although various advantages may not be achieved. Furthermore, the latches can have differing camming and/or striker engaging surfaces, such as internally elongated slots, however, various advantages may not be obtained. The striker can also have different shapes, such as a U-shape, although certain advantages may not be observed. In an alternate embodiment, bracket 101 is integrated into saddle 41 as a single piece. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the present invention. | An attachment system is provided. In another aspect, a latching assembly is mounted to a building roof. Another aspect employs a moveable latch that removeably attaches an auxiliary component, such as a solar panel, to a building in a single motion and/or snap-in installation manner. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This non-provisional application claims the benefit of previously filed provisional application No. 60/868,916 first filed on Dec. 6, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates in general to key control systems. More particularly, the invention comprises a key trapping, modular, access control system and panel.
[0004] 2. Description of the Related Art
[0005] Access control systems for securing master and other keys are well-known in the art. These systems are used in office buildings, hospitals, apartment complexes, and other structures which require master key and other key security. Examples of master key panels that prevent the removal of keys in a keyway can be found in U.S. Pat. Nos. 5,505,066, 4,641,509, 5,970,761 and in systems such as those found in http://www.keywatcher.com/keywatcher/ where a master key panel with a plurality of keys is attached to the panel through the use of a circular ring. Embodiments such as those found at http://www.kewatcher.com/keywatcher/ can be programmed via an onboard console to release the applicable key and has the added feature of an indicator light to point the person using the key as to which key they need.
[0006] However, the problem with existing master key systems is that systems such as those of the KeyWatcher system use rings to secure the keys. Rings have been a huge problem in this field since they are easily cut with portable tools. Further, and more problematic, there is no way for the access control system to verify that the appropriate key has been replaced with the appropriate ring. What commonly results are that keys are often misplaced resulting in lost keys, delay in services, and money spent on locksmiths to replace lost or misplaced keys.
[0007] Other systems used in key prevention devices are those found in lockers and post office boxes that prevent the removal of keys once they have been inserted into their associated keyway. Examples of these are found in U.S. Patent Pub. No. 2001/0039819, 2001/0039819, 2004/0007032, and U.S. Pat. Nos. 7,051,563, 7,021,095, and 4,641,509. Yet, the problem with these devices that utilize key retention locks do so as a single access system (One user and key per lock) and are not controlled by a master control unit or access system. Further, these locks require the user to manually turn the key back to the trapped position.
[0008] Another class of locks is dedicated for use with doors (E.g., hospital doors) that utilize programmable magnetic cards capable of being swiped through card readers on the doors thereby allowing selective entry. Examples of these types of locks are found in U.S. Pat. Nos. 5,2917,66, 3,954,460, 6,840,071, 7,080,533, and German Patent Nos. 4002085, 4002093, and 4002085. Yet, in each of these cases, the cards enable access entry only for a selected user(s) to a room and the card is the key as opposed to comprising a master key system.
[0009] Another problem with current systems is their inability to adapt to scale and conformity with various locks, most particularly cylinder locks. Building administrators often wish to change the types of locks and add or subtract the number of keyed users that exist on the system. Currently, it is impossible to change the types of locks used without eliminating the entire key system since once a system is purchased, the purchaser is locked into the key locks of that system and the fixed scale imposed by the key system.
[0010] What is needed is a key system whereby a key panel houses keys that are retained in their keyway when not in use, automatically returns those keys to their trapped position when reinserted, is selectively controlled by a master control unit engaging the key panel to release those keys to specified users, and can validate that the appropriate key has been properly replaced. What is also needed is a truly modular access control system to allow for the scaling up or down of a key panel to allow for the addition or subtraction of key locks, and one that can adjust to varying length locks.
SUMMARY OF THE INVENTION
[0011] An automatic key trapping lock comprising a lock housing; a lock removable from the lock housing and further comprising a core with an internal lock assembly for trapping and releasing a key when a key is turned in a specified direction; a cam assembly comprising a cam member rotatably engaging the lock; a return spring biasing the cam member towards a key trapped position; said cam member operatively engages a locking and releasing solenoid with a plunger for locking and unlocking the cam member; and the locking and releasing solenoid is actuated by one or more control means operatively engaging the locking solenoid for locking or unlocking the cam.
[0012] It is a further object of the present invention to provide an automatic key trapping lock of with a lock arm moveably engaging the solenoid plunger, a return spring arm engaging the cam assembly and the return spring, and a portion of the lock arm is formed to allow the return spring arm to bias into a locked position and prevent the lock arm from returning to an unlocked position; a receiving means for removably receiving and securing the solenoid plunger for locking and unlocking the cam; a control device for reading one or more magnetically readable and programmable cards or biometric data and, operatively engaging one or more card readers or biometric readers; or one or more indicators operatively engaging the one or more control devices.
[0013] It is another object of the present invention to provide an adjustable key panel assembly having an adjustable cam for accommodating variable length locks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic overview of a key trapping key panel with a plurality of key trapping locks operatively engaging a reader and network for controlling access to keys.
[0015] FIG. 2 is a rear view of a solenoid activated arm release for removing a trapped key from a lock with a return spring arm in an unlocked position.
[0016] FIG. 3 is a front view of a solenoid activated arm release for removing a trapped key from a lock with a key in an unlocked position.
[0017] FIG. 4 is a rear view of a solenoid activated arm release for removing a trapped key from a lock with a solenoid plunger extended to place the return spring arm into a locked position.
[0018] FIG. 5 is a front view of a solenoid activated arm release for removing a trapped key from a lock with a key in a locked position.
[0019] FIG. 6 is a rear perspective view of a cylinder from a cylinder lock exposing spring bias mechanisms for biasing the cylinder in a vertical position in a cylinder lock barrel.
[0020] FIG. 7 is a schematic of an access relay system connecting one or more key trapping locks to an access controller.
[0021] FIG. 8 is a side view of a removable proximity solenoid actuated key trapping lock in a retaining tube.
[0022] FIG. 9 a is a side cross-sectional view of a proximity solenoid and sensors engaging one or more key trapping locks.
[0023] FIG. 9 b is a front view of a proximity solenoid and sensors engaging one or more key trapping locks
[0024] FIG. 10 is an electrical diagram showing a proximity solenoid for trapping a key in a lock on a key panel.
[0025] FIG. 11 is an exploded view of a spring biased automatic key trapping lock utilizing a solenoid plunger directly engaging a cam and having an adjustable lock shaft.
[0026] FIG. 12 a is a top view of a spring biased automatic key trapping lock utilizing a solenoid plunger directly engaging a cam and having an adjustable lock shaft and illustrating movement B-B.
[0027] FIG. 12 b is a cross-sectional view of a spring biased automatic key trapping lock utilizing a solenoid plunger directly engaging a cam and having an adjustable lock shaft and having key movement Section B-B.
[0028] FIG. 13 is a top view of a spring biased automatic key trapping lock utilizing a solenoid plunger directly engaging a cam and having an adjustable lock shaft.
[0029] FIG. 14 is a side view of a spring biased automatic key trapping lock utilizing a solenoid plunger directly engaging a cam and having an adjustable lock shaft.
[0030] FIG. 15 is a front view of a spring biased automatic key trapping lock utilizing a solenoid plunger directly engaging a cam and having an adjustable lock shaft.
[0031] FIG. 16 is a bottom view of a spring biased automatic key trapping lock utilizing a solenoid plunger directly engaging a cam and having an adjustable lock shaft.
[0032] FIG. 17 is a rear view of a spring biased automatic key trapping lock utilizing a solenoid plunger directly engaging a cam and having an adjustable lock shaft.
[0033] FIG. 18 is an elevated perspective view of a spring biased automatic key trapping lock utilizing a solenoid plunger directly engaging a cam, having an adjustable lock shaft, and having a locking lever for locking a lock housing onto a key panel.
[0034] It should be understood that although these examples may describe some of the more specific features of the invention, they are given only for the purpose of illustration and the invention should not be construed as limited thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] A complete understanding of this invention can be gained through reference to the drawings in conjunction with a thorough review of the disclosures herein.
Key Access System
[0036] The present invention provides a novel key access system for automatically securing and releasing keys through key retention. In general, and as a system, the preferred embodiment as shown in FIG. 1 contains a central key panel or board 1 with one or more key trapping locks 2 engaged by a reader 3 preferably connected to an access control system 31 having an intelligent control software and hardware. The reader assembly 3 can be any known mechanism for reading data to identify a user. In a preferred embodiment a magnetic card (not shown) is programmed through a central access control system 31 that is connected to the reader assembly 3 through a network 23 . For example, in an embodiment using a magnetic card, software and hardware interfaces of the access control system 31 can program a magnetic card with a variety of user information, send the data to the reader assembly 3 on the key panel 1 so that when a card engages the reader assembly 3 signals can be sent to locks 2 through leads engaging locks 2 for releasing one or more trapped keys based on user data.
[0037] There are a number of vendors who provide central access control system software and hardware for key access systems. These units are adaptable and configurable to meet existing security needs for the present invention. For purposes of the present invention, existing central access systems such as Kantech, Hirsch, Northern, Keri, Rosslare, Visonic, IEI, can be adapted and used with a key trapping key panel as disclosed herein. Therefore, much of the hardware and software benefits of these systems will naturally extend to the novelty of the present invention.
[0038] Typically, modern access control systems such as the ones just mentioned are mated with existing network systems to accommodate a broader range of security services such as sensors for monitoring open doors, surveillance cameras, and—specific to the present invention—master key systems. FIG. 1 shows a typical network topology working in conjunction with the present invention wherein a network 23 engages an access controller 31 , an audio visual component 38 , and a reader 3 and key trapping lock system 1 . Alternately, the network topology can be configured in any known way, such as remote or wireless access to key panels, and engage any number of components in addition to audio visual components, such as door locking sensors and etc. In this way, programmable data can be entered at a central or remote location and sent to a reader onboard or in proximity to and engaging a key panel 1 .
[0039] Further, there are a number of different ways in which a programmable interface of an access control system can be implemented. For example, instead of using a magnetic card and reader, known techniques for performing biometric scans (eyes, fingers, etc) can also be used. In this way, all programmable features can be accessed by a biometric reader for access by a user with the appropriate biometric data.
[0040] In its simplest embodiment, and as illustrated in FIG. 7 , only one key retention lock is situated on a single key panel 1 . Yet, because most buildings have many keys, and because those numbers of keys can grow, the capability to support a plurality of keys becomes critical. For that reason, a key panel 1 of the present invention also provides for scalable architecture as to the locks. This may be accomplished by adapting the scale of the key panel through input 17 and output 19 boards of varying size to accommodate desired scale.
[0041] FIG. 1 , for example, illustrates how a key panel 1 can be outfitted with slots for accepting one or more key retention locks and FIG. 8 illustrates how each lock can be interchangeably fitted into separate housing channels.
[0042] As will be discussed in more detail below, individual lock housings may also be constructed to fit the varying lengths of standard cylinder locks by creating locks with slide adjustments. As such, key control system administrators can expand existing systems, replace broken lock housings within the system, or upgrade to different lock technologies.
Automatic Key Trapping
[0043] One novel aspect of the present invention is its ability to automatically trap keys when they are reinserted into a lock keyway. Currently, keys are trapped by inserting a key into a lock and then manually rotating the key to release or engage a lock attached to the key cylinder. When the key is in the locked position, either a flange in the cylinder or tumblers will prevent the key from removal or counter-rotation. (See, U.S. Publication 2001/0039819 to McCurry) and an uneven sheer line “traps” the key preventing removal. However, to avoid the problem of requiring manual rotation of the key in the slot to lock the key, (rotation into a key trapped and locked position) this problem is overcome by incorporating a biased return spring. This may be accomplished in several ways: first, by coupling the return spring to an arm joined to a key cylinder to automate the key-trapping function; using a cam that directly engages a solenoid plunger; or through a proximity solenoid that senses the removal and insertion of a key.
[0044] The present invention adds to standard cylinder lock technology. A cylinder lock typically uses tumblers 16 with a spring biased against an internal keyway 24 of the cylinder. When a properly bitted (cylinder conforming) key is inserted into the keyway, the corresponding and matching ridges of the key bias against spring-biased tumblers to form a sheer line. Once the sheer line is formed and tumblers are aligned, a cylinder 14 can be rotated inside a barrel to engage known locking mechanisms. (E.g., a cam for turning a deadbolt) Beyond standard cylinder locks there are also provided key trapping locks which will lock the key in place when a cylinder 14 (See FIG. 6 ) is turned to a non-vertical or other devised position. However, for these locks to trap a key, a person re-inserting the key must manually turn the key to engage the locking mechanism or else the key will be able to be removed because the sheer line (in a cylinder lock) will remain intact and the locking flange (or other locking mechanisms) will not engage the lock.
[0045] This problem is overcome in several ways, ( FIGS. 2-5 ; FIGS. 6-9 b ; and FIGS. 11-12 ). In a first of these embodiments, ( FIGS. 2-5 ) the present invention incorporates the use of a return spring 10 that biases a return spring arm 27 or cam 60 mounted to a rotating cylinder 14 of a cylinder lock 14 to bias arm 27 and rotating cylinder 14 toward a horizontal or “locked” position. Automatic biasing is accomplished through an automatic return spring function, whereby an optional cylinder lock screw 15 ( FIG. 5 ) may be biased against external door and lock components such that when key tumblers form a sheer line keeping cylinder 14 is prevented from rotating to a horizontal position when the key 13 is removed or, in assisting in keeping the sheer line intact once a key 13 is reinserted. Once key 13 is replaced however, the tension of cylinder lock screw 15 can be released and the biased tension created by return spring 10 and return spring arm 27 turns cylinder 14 to a locked position. When return spring arm 27 is biased downward, it slides below the slope of a lock arm 6 preventing a key from turning cylinder 14 back toward a vertical or unlocked position. FIGS. 1 and 2 show a key 13 and return spring arm 27 simultaneously biased horizontally. Lock arm 6 prevents return spring arm 27 from being turned by key 13 to a vertical position.
[0046] To remove key 13 , lock arm 6 can be mounted to an arm support pivot 7 so that lock arm 6 can be rotated to allow return spring arm 27 and cylinder 14 to be rotated back toward a vertical, unlocked position. Lock arm 6 is automatically rotated by a plunger 28 connected to a solenoid 5 . When solenoid 5 is actuated, plunger 28 is forced against lock arm 6 , partially rotating it around pivot 7 to allow return spring arm 27 to be rotated back to the unlocked position. Solenoid 5 can be actuated by many known manual or access control systems. In a preferred embodiment, a card reader assembly 3 is mounted to a key panel 1 so that a programmable magnetic card can be “swiped” across or through the assembly thereby activating lock arm solenoid 5 .
[0047] Alternatively, and as shown in FIGS. 11-17 , instead of a plunger engaging a sloped lock arm 6 that is separate from the cam and spring locking assembly, a rotating cam member 60 with an aperture 61 (Or, in the alternative, a groove, recess or magnet, clamp) sufficient to accommodate a spring biased 282 solenoid plunger 280 that directly engages the cam member 60 when a solenoid 281 is actuated. Starting from a key 130 trapped position (which for the purposes of illustration is parallel to the ground), key 130 is trapped—unable to be removed—due to an uneven shear line internal to the cylinder lock—and cannot be rotated to a position perpendicular to the ground because the solenoid plunger 280 is in a locked position and extended into aperture 61 of cam member 60 . To remove key 130 , solenoid 281 is actuated through a control mechanism (E.g., magnetic card reader or biometric scanner programmed to release keys based on selected criteria) thereby retracting plunger 280 and freeing cam member 60 to rotate key 130 to a perpendicular and unlocked position (as shown) created by an even sheer line and allowing removal of key 13 . Plunger 280 is spring biased and rides on cam surface after the initial activation and will extend into aperture 61 when proper rotation is achieved. Actuation of plunger 280 can be timed to extend back through action of spring 282 after a specific period of time.
[0048] When key 130 is removed, as in the other embodiments, an uneven sheer line is created preventing a spring bias from rotating a cam back to a locked and trapped position. When key 130 is reinserted cylinder 280 rotates back toward a key trapped position and plunger 280 reinserts into cam aperture 61 .
[0049] In another exemplary embodiment, each lock 2 can be associated with input 18 and output 19 controls that feed into an access control unit 31 . This can be accomplished either through various types of sensors 8 284 on the panel 1 to each lock 2 or, through separate sensors 8 284 associated with each lock 2 in a multiple lock embodiment. For example, exemplary embodiments include using single pull double throw switches to control LED and key contact internal to a lock to effect numerous status messages or indicators either on the front of the lock itself or as signals sent remotely or to a remote location. In this way, and in view of the embodiment incorporating a return spring arm, status indicators 30 joined to the sensors 8 284 can create an interface (lights, alarms, and etc.) on the panel, adjacent to the appropriate lock, on a lock faceplate 285 , or otherwise capable of indicating various status' to the user when each sensor 8 284 or its relative status indicator 30 is engaged, directly or indirectly. Indicators 30 can include LED's or other illuminating or digital elements onboard panel 1 , faceplate 285 or, can include leads back to central access control software of access controller 31 that can then notify appropriate persons through various electronic techniques available in the art and novel in light of the present invention.
[0050] For example, and as shown in FIGS. 1 and 3 , status indicator 8 can be connected (wired or otherwise) to an access control system. Status indicator 8 can also engage and sense a position of return spring arm 27 or whether a key is in cylinder 14 to indicate to a user interface whether a key is in a locked or unlocked position. This can be done by return spring arm 27 engaging a status indicator directly or through the use of the return spring arm engaging a switch. (not shown) In this way, when a user activates a reader 3 on a panel 1 to return a key 13 , an appropriate indicator (E.g., LED) is illuminated, sounded, or other electronic signal sent to a central access system. If a key is inserted and if the key is not inserted properly or there is a malfunction whereby the status switch has not been engaged by the return spring arm, the indicator light can continue to be illuminated acting as a warning to ensure the proper return of the key. Further, a separate indicator light (also not shown) can be illuminated; or an alarm can be activated indicating to the user or a remote system that a key is not properly inserted.
[0051] Alarms and notifications will vary with each access system design. Most access systems have alarm and notification capabilities (E.g., email or alarm outputs that trigger outside sounders) It can also be hooked up to an alarm system and monitored by a central station that would notify those responsible for monitoring the access control system.
[0052] Alternatively, if a key is not resubmitted to an appropriate lock on the panel within a specified period of time, an alarm with a timing mechanism and engaging the status indicator can sound either a physical alarm or even a software alarm of the intelligent control system. Those in the art will readily appreciate the number of different embodiments possible. Typically, key access software has timers built into the software for events such as propped door times, door unlock times and etc. In a preferred embodiment, the present invention would extend standard time from seconds to hours. Therefore, if a key is not returned within the time period the access system will send a programmed response to status indicators 30 or to the access software itself.
[0053] In another preferred embodiment for trapping locked keys and as shown in FIGS. 8 , 9 a , and 9 b , a return spring solenoid 32 is actuated by a circuit completed by the insertion of a key 13 engaging a cylinder lock 2 . Similar to the return spring embodiment described above, a proximity solenoid 32 is mounted to a panel 1 with a proximity solenoid plunger 33 engaging a proximity solenoid lock arm 37 . When a key is returned to a keyway, it leads to solenoid 32 to complete a circuit and a plunger is extended, releasing lock arm 37 , thereby allowing the key cylinder to rotate. Once rotated, it is prevented from counter-rotation through the lock arm and not released from the trapped position until a reader is activated.
[0054] Further, it is also desirable to have a single solenoid act as both a lock and proximity solenoid engage and disengage a single lock arm to trap and un-trap a key in a lock. When a key is locked in a keyway of a cylinder lock, a lock arm 6 prevents return arm 27 from being returned to create a sheer line and allow release of a key. Then once a card or other biometric member is swiped or scanned, lock arm 6 is released and a second arm 37 pivotally engaged with a second plunger on proximity (or circuit) solenoid 32 and return spring arm 27 locks return spring arm 27 in place to prevent it from instantly returning to a trapped position and the key can be removed from its cylinder. When a key or conductor then touches the key cylinder, a circuit ( FIG. 8 , leads 289 from the cylinder to the solenoid and panel component) is completed causing proximity solenoid 32 to actuate a proximity solenoid plunger 33 to move second arm 37 away from return spring arm 27 allowing it to move to the trapped position when the proper key is inserted creating a sheer line and allowing the cylinder to turn in the barrel. In this way, any optional flanges or nipples biased against the panel components to prevent the barrel from rotating are unnecessary. Vice versa, solenoids and plungers can act in opposing ways to achieve the same result.
[0055] In another preferred embodiment for trapping automatically trapping keys and as shown in FIGS. 9 a and 9 b , a spring lock solenoid 50 and spring arm 51 engages a lock bushing 53 that releasably engages a lock channel 56 on the bushing. The lock bushing 53 also engages a pivotal arm 54 that is biased toward a sensor 55 by a proximity solenoid 58 when a key is removed from a keyway of the lock. In this position the position is shorted and a plunger 59 in constant engagement with the arm 54 remains extended so that arm 54 remains in contact with a sensor 60 connected to I/O contacts 61 for determining key status. When a key is reinserted into the keyway, a circuit is completed and plunger 59 is retracted rotating the arm 54 back towards the spring arm 51 which once the channel 56 rotates sufficiently toward the spring arm 54 , the spring biases the end of the arm into the channel and locks or traps the key in place until another scan or read of a card is made.
[0056] FIG. 9 b shows a bushing 64 and groove into which a shaft 630 can extend. The lock can then be inserted into a lock housing 650 and then locked in place. By having a rotatable shaft 53 , its rotating motion and that of the cylinder is transferred to a return spring arm allowing it to turn to a trapped or un-trapped position. The shaft can be detachable from the cylinder and the panel to allow for interchangeability and easy removal of the lock. However, to avoid unwanted solenoid activation through inadvertent touching of other parts of the panel, non-conductive bushings (plastic, and etc) can be fitted around the shaft portion that fits into the locking groove 640 (or, the structure of the groove can be formed of a non-conductive material) and in the same way a non-conductive bushing 660 can be formed around the interior of the key lock housing to prevent the key housing from contacting any conductive components of the panel.
Scalable Architecture
[0057] Another benefit of the present invention is its ability to provide for scalability. This can be accomplished through a modular key panel design whereby either key locks or key panels can be removed from the key panel. In this way, locks can be replaced quickly, easily, and without having to purchase and upgrade to an entirely new key system and, whole panels can provide for added scalability and can be added to accommodate two or more locks.
[0058] A modular design with the capability of having interchangeable locks is illustrated in FIGS. 11 and 12 . A cam shaft 63 is preferably rotatably joined to a cam 60 and that can be adjusted through manual sliding of the cam and a cam drive 110 a rear tap screw 69 and then secured in place through a set screw 67 engaging a d-slot 105 on or attached to cam shaft 63 . Adjustment is accomplished by releasing set screw 67 and adjusting cam shaft 63 to accommodate various length cylinder locks resting in cylinder lock housing 70 71 comprised of either a single frame or, a multi-frame assembly as is shown in FIG. 11 . Frame assembly in FIG. 11 illustrates rear housing member 70 and front housing member 71 that can be adjusted or formed to accommodate the longest cylinder housing available. Likewise, cam shaft 63 can also be specified to accommodate any desired length so that it can adjust to desired cylinder lengths.
[0059] As alternative method for adjusting cam shaft 63 , external threading on cam shaft 63 and internal threading in drive 110 can be used to allow for the adjustment of cam shaft 63 through a rear tap screw adjustable from the back of the lock assembly. To prevent cam shaft 63 from rotating when a key is turned in cylinder 283 , a counter-locking nut can be fitted on the cam shaft 63 .
[0060] To accommodate all the various manufacturers of locks, specifically, cylinder locks, a universal b-tail cam 112 can be fitted onto the back of cylinder 283 thereby allowing cam assembly to rotatably secure to any cylinder lock through a mated cam fitting 113 using the novel cam approach of the present invention.
[0061] To enable interchangeable lock housing, a panel may be constructed to lock in a plurality of lock housings of the various embodiments described above. This is generally accomplished by incorporating a locking lever 100 that mates with a locking knob 102 engaging a lock housing solenoid 101 and as illustrated in FIG. 18 . Similar to the solenoid actuation of locking solenoid 280 and 5 disclosed above, solenoid 101 can either be independently actuated or programmed into a magnetic key card, biometric scanner, or other control device, and in addition to features described above.
[0062] The above disclosures and drawings are merely illustrative of the present invention and do not claim to represent all of its numerous embodiments. Those skilled in the art will appreciate many other ancillary embodiments that flow from the novelty of the present invention contained herein. | An automatic key trapping lock comprising a lock housing; a lock removable from the lock housing and further comprising a core with an internal lock assembly for trapping and releasing a key when a key is turned in a specified direction; a cam assembly comprising a cam member rotatably engaging the lock; a return spring biasing the cam member towards a key trapped position; said cam member operatively engages a locking and releasing solenoid with a plunger for locking and unlocking the cam member; and the locking and releasing solenoid is actuated by one or more control means operatively engaging the locking solenoid for locking or unlocking the cam. It is another object of the present invention to provide an adjustable key panel assembly having an adjustable cam for accommodating variable length locks. | 4 |
BACKGROUND OF THE INVENTION
Major household appliances, such as automatic clothes washers, clothes dryers and refrigerators for example, typically include some mechanism for leveling the appliance housing so that it will operate optimally, even though the floor on which it is mounted is not level. In addition, some appliances, particularly automatic clothes washers, include mechanisms to adjust the mounting of the machine in response to unbalanced or non-symmetric loads, such as when the washer is centrifugally extracting water from an unbalanced load.
Clothes washers typically have adjustable mounts or feet adjacent their front corners and an unbalance compensating mechanism at their rear. Typically the unbalance compensating mechanism includes a strap, bar or rod which is connected to mounting feet with a degree of freedom so that the strap can move relative to the feet or to the housing to compensate for the unbalance.
Such assemblies and mechanisms present a number of problems in the manufacture and use of such appliances. For example it is desirable to assemble the mounts or feet to the housing at the factory. However, if they are attached early in the manufacturing process, they are subject to damage and inhibit the use of traditional conveyor systems for subsequent manufacturing steps.
It is desirable that the mounts be easily and quickly assembled to the unbalance compensating mechanism, preferably by merely snapping them into place.
Typically the front mounts are rotatable relative to the housing base to adjust their height when the appliance is installed. It is desirable that the mounts be easily installed at the factory using normal factory equipment and, at the same time, be adjustable at appliance installation, using only normal hand tools such as a wrench.
Typically the front mounts and the mounts or feet used with the unbalance compensating mechanism are significantly different. In some highly automatic manufacturing processes, it is advantageous to use a single design mount for all locations, even though each mount includes features that are not needed in any particular individual location.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention an appliance leveling assembly includes an appliance housing with a base. An opening is provided in the base adjacent each front corner of the housing, surrounded by a helical thread with a pair of axially projecting detents. An unbalance mechanism at the rear of the housing includes a strap extending across the base, with a transverse cross member adjacent each of its ends. A mount is provided for each opening and each end of the strap. Each mount includes a head with a bottom to support the appliance from a floor and an elongated shaft extending from the top of the head. The shaft includes an external helical thread which mates with a corresponding helical thread in the base. The mount is molded from a plastic material which will cold flow sufficiently for the shaft thread to conform to the detents on the housing thread. The distal end of the shaft remote from the head includes a pair of mutually perpendicular openings which receive one end of the strap and the associated cross member. A pad is bonded to the bottom of the head and engages the floor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified, perspective view of an automatic clothes washer, partly broken away, incorporating a mounting system constructed in accordance with the principals of the present invention.
FIG. 2 is a fragmentary exploded perspective view of the lower right front corner portion of the washer of FIG. 1, illustrating certain aspects of the housing and front leveling mounts.
FIG. 3 is a fragmentary cross section view as seen along line 3--3 in FIG. 2, but with the mount assembled to the housing.
FIG. 4 is a fragmentary exploded perspective view of the lower right rear corner portion of the machine of FIG. 1, illustrating certain aspects of the unbalance compensating mechanism and rear mounts.
FIG. 5 is a cross section view of the mechanism of FIG. 4, but with the mount assembled to the unbalance compensating mechanism.
FIG. 6 is a perspective view of another mount usable in the machine of FIG. 1.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a top loading automatic clothes washer or washing machine 10 with a top 11 having a door 12 providing access to the interior of the machine for loading and unloading items to be washed. A backsplash 13 contains various controls for user control of the operation of the machine. The machine 10 has a hollow, rectangular, box like housing with a front panel 14, side panels 15 and a rear panel 16. The housing includes a base joining the various vertical panels 14-16. In the illustrative machine 10, the housing base includes a front brace 17, which extends between the side panels 15 just inside the front panel 14, and a rear brace 18, which extends between the side panels 15 just inside the rear panel 16.
The operating components of washer 10 are not part of the present invention and have been omitted for the sake of simplicity. However it will be understood that, when machine 10 is operated to wash a load of fabrics, forces are generated and transferred to the floor on which the machine is mounted. This is particularly true when the machine spins the fabric containing tub (not shown) at high speed to centrifugally extract liquid from the fabrics. If the machine is not level or the weight distribution is non-symmetric, these forces often will cause the machine to "walk", that is to move across the floor on which it is mounted.
There are two aspects to leveling the housing. First mounts or feet are mounted to the base adjacent the front corners of the housing. These mounts are vertically adjustable to level the housing. Second, an unbalance compensating mechanism normally is provided at the rear of the machine to enable the rear of the machine to move relative to the rear mounts in response to unbalanced forces generated during operations, particularly during extraction.
Referring now to FIGS. 2 and 3, there is illustrated the right front mount and its connection to the base of the housing of the illustrative machine 10. In particular a mount 20, positioned adjacent the right front corner of the machine, and its connection to or mounting on the front brace 17 is illustrated. It will be understood that an identical mount is connected to the front brace 17 adjacent the left front corner of the housing. Preferably the mount 20 is molded form a suitable plastic material such as polypropylene. The mount 20 includes a head 21 with a pad 22 overlying its bottom. Preferably the pad is formed from a suitable plastic material, such as sontoprene. Preferably the pad is placed in the mold for the mount before the mount is formed and bonds to the mount 20 during the molding process. The pad 22 serves two purposes. First it provides an anti-skid surface to inhibit the machine from sliding across the floor on which it is mounted. Second, it isolates vibrations of the machine from the floor.
A shaft 23 projects perpendicularly from the top of the head 21 and includes a helical thread 24 along its outer surface. A mating helical thread 25 with an interruption 26 is formed in the front brace 17 and defines a central opening 27. The mount 20 is mounted on the brace 17 by inserting the distal end 27 of the shaft 23 into the opening 26 and then rotating the shaft to engage the thread 24 with the thread 27. The length of the shaft 23 below the brace 17, and thus the distance from the bottom of machine 10 to the bottom of pad 22, is adjusted by screwing the shaft into and out of the brace. For this purpose the bottom of the head 21 is formed with a polygonal recess 29 to receive a power tool for mounting and adjusting the position of the mount 20 during manufacture of the machine 10. A polygonal collar 30 is formed on the outer surface of shaft 23 next to the head 21. This provides a drive surface for a tool, such as an open end wrench for example, to adjust the height of the mount 20 when the machine is installed. In this way, during and after the machine is installed, the mount can be adjusted with the machine sitting upright in its normal operating orientation. Preferably both the recess 29 and the collar 30 are hexagonal to fit typical tools. Conveniently the mount 20 at each front corner of the machine 10 is essentially fully seated in the brace 17 during manufacture to minimize the possibility of damage during shipment. When the machine is installed, each mount 10 is then adjusted to level the machine.
Once the machine is leveled at installation, it is important that the front mounts 10 do not accidentally move relative to the front brace 17. The thread 25 includes a pair of detents 31 which project axially downward on diametrically opposite sides of the thread 25. The detents 31 are forced against the upper surface 32 of the thread 24 by the weight of the machine. The material of the shaft, polypropylene in the exemplification, will cold flow under this pressure sufficiently that the upper surface 32 will form indentations 33 which conform to the detents. The detents 31 and indentations 33 in the thread 24 form stops which deter the mounts 20 from accidentally moving relative to the brace 17. However, once someone deliberately moves a mount 20 slightly, its indentations 33 no longer hold the conforming detents 31 and the mount can easily be adjusted to another shaft height or length.
The weight of operational components of washing machines often is not distributed evenly. In addition the floor on which the machine is mounted may be uneven. This may result from the floor sagging under the weight of the machine, faulty floor construction or any of a number of other reasons. This tends to add to the non-symmetrical weight distribution of the machine and the machine may vibrate excessively and "walk" across the floor. Typically washing machines include an unbalance compensating mechanism or assembly to compensate for such non-symmetric weight distribution. Such mechanisms typically include a cross member, in the form of strap or rod, which extends across the rear of the machine and is mounted to the rear mounts or feet. Either the connections of the cross member to the feet or to the housing is vertically adjustable under the influence of the non-symmetrical weight distribution to compensate for such non-symmetry. One such system or assembly is disclosed in U.S. Pat. No. 3,304,032, issued to Roy K. Yates and assigned to General Electric Company, assignee of the present invention; which patent is hereby incorporated herein by reference.
Referring now to FIGS. 4 and 5, there is shown a part of the non-symmetrical weight or unbalance compensating assembly of the illustrative machine 10. The rear brace 18 includes a horizontal bottom wall 36 and a vertical side wall 37. A vertical tab 38 is lanced from the bottom wall 36 and bent upwardly to extend parallel to the side wall 37. Ears 39,40 are lanced form the side wall 37 and tab 38 respectively and bent outwardly. The ears are angled to provide angled slots 41,42 respectively. It will be seen that the tops of the slots and ears are closer to the side wall 15 than are their bottoms. While not shown, it will be understood that mirror image ears and slots are formed adjacent the other end of the rear brace 18. In this way the slots and ears at the ends of the brace converge from top to bottom. A strap 44 extends across the rear of the housing and has its ends generally aligned with the slot and ear arrangement adjacent each end of brace 18. A cross member 45 is mounted adjacent each end of the strap 44 and projects perpendicularly to each side of the strap. Conveniently the cross members are in the form of circular cross section cylindrical pins which are tightly received in circular openings 46 in the strap 44. Each cross member projects through the slots 41,42 and the weight of the machine causes the ears 39,40 to engage the cross members. Non-symmetric weight of or forces generated by the machine will cause the strap and cross members to shift relative to the machine. That is, one end of the strap will move downwardly relative to the corresponding ears and slots while, the other end of the strap will move upward relative to the corresponding ears and slots.
The mount 20 is designed for use with such non-symmetry or unbalance compensating or self-leveling mechanisms. More particularly the distal end of shaft 23, remote from head 21 is formed with mutually perpendicular slots 48 and 49 which extend axially into the shaft from its end and project transversely completely across shaft. The mount 20 is inserted about the junction of the strap 44 and cross member 45 with the strap 44 fitting closely in slot 48 and cross member 45 fitting closely in slot 49. The friction between shaft 23, on the one hand, and the strap 44 and cross member 45, on the other hand, maintains the mount on the strap.
FIG. 6 illustrates a mount 50 of slightly different construction than mount 20 The mount 50 has a head 51 and a shaft 53 with threads 54, a polygonal collar 56 and a distal end 57. The head also has a polygonal recess, not shown, in its bottom and a pad 52 is bonded to the bottom. The distal end 57 of shaft 53 includes one slot 58, which extends across the shaft and projects into the shaft from its end. A cylindrical hole or bore 59 extends through the shaft perpendicular to slot 58. Mount 50 is placed on the end of strap 44, with the strap tightly received in the slot 58 and with the opening 46 aligned with the bore 59, before the cross member is attached. Then the cross member 45 is inserted through the opening 46 and bore 59. Thus it will be recognized that mount 50 is more securely mounted on the strap 44 than mount 20 but the assembly process is slightly more complicated.
The mounts 20 and 50 have composite configurations. That is a single mount configuration can be used at both the front and back corners of a machine. This enables a manufacturer to stock only one part. It will be recognized that, if desired, the mounts can be modified to provide different configurations tailored to front and rear usage. On the one hand, mounts tailored for the front would not have either the crossed slots or the slot and bore arrangement at the distal end of the shaft. On the other hand mounts tailored for the rear would not have the thread, the polygonal collar on the lower portion of the shaft or the polygonal recess in the bottom of the head.
While specific embodiments of the invention have been illustrated and described herein, it is realized that modifications and changes will occur to those skilled in the art to which the invention pertains. 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. | An assembly to mount an appliance on a floor includes a pair of openings in the appliance base, each surrounded by a helical thread. The thread includes a pair of downwardly projecting detents. A mount for each opening includes a head with a shaft extending from the top thereof and received in the opening. The shaft includes an external helical thread mating with the appliance base thread. The mount is made of plastic which cold flows sufficiently for the shaft thread to conform to the detents. An unbalance responsive mechanism includes a strap extending across the housing with a transverse pin adjacent each end. A mount for each end of the strap includes a head with a shaft extending from the top thereof. The distal end of the shaft includes transverse openings to receive an end portion of the strap and the corresponding transverse pin. Non-skid, insulating pads are bonded to the bottom of the heads. | 5 |
BACKGROUND OF THE INVENTION
Field of Invention This invention relates to a fastening system for attaching panels of one material to a panel of a dissimilar material.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Subject matter disclosed herein is disclosed in the following copending applications filed contemporaneously herewith and assigned to the assignee of the present invention:
[0002] Fastening System for Assembling Panels of Dissimilar Materials (CN-1003);
[0003] Wall Panels of Dissimilar Materials (CN-1101); and
[0004] Method for Assembling Panels of Dissimilar Materials (CN-1103).
BACKGROUND OF THE INVENTION
[0005] It is known to attach panels of dissimilar materials together by using adhesive bonding, such as silicone adhesives. Adhesive bonding is problematic in that typical adhesives have low static load strengths, leading to adhesive failure and separation of the panels. Typical adhesives used in the building industry have a modulus of elasticity which allows unacceptable movement between panels. Simple mechanical fasteners do not allow for movement due to differential expansion and contraction between panels of dissimilar materials.
[0006] There is a need for a fastening system to fasten two panels of dissimilar materials, e.g., aluminum and filled acrylic composite, in such a way that differential growth of one panel relative to the other does not cause warping of either panel. There is also a need for a fastening system that can be assembled with access to only the backside of one panel.
SUMMARY OF THE INVENTION
[0007] An embodiment of the invention is a fastening system for panels of dissimilar materials, which comprises a threaded fastener, a captive nut with a through hole which is formed from a flat body with a first face; a shoulder protruding from the first face; a polygonal extension protruding from the shoulder; and a captive washer comprising a washer body; and a polygonal cutout sized to fit the said polygonal extension.
[0008] In another embodiment, slotted holes in a first panel allow both panels to expand and contract relative to each other while maintaining rectangular alignment.
[0009] In another embodiment, a wall panel is constructed from the assembly of an aesthetic panel and a carrier panel fastened together by the fastening system for panels of dissimilar materials.
[0010] In another embodiment, a building is constructed with wall panels constructed from the assembly of an aesthetic panel and a carrier panel fastened together by the fastening system for panels of dissimilar materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows an exploded view of the fastening system.
[0012] FIG. 2A shows a wall panel assembled with the fastening system and two panels of dissimilar materials.
[0013] FIG. 2B shows a wall panel assembled with the fastening system and two panels of dissimilar materials employing an optional anchor.
[0014] FIG. 3A shows a carrier panel with through holes.
[0015] FIG. 3B shows a carrier panel with through holes and slots.
DETAILED DESCRIPTION
[0016] The present invention is not limited to fastening any specific type of panels to one another for any specific application. The fastening system of the present invention may be used for panels of such materials as wood, stone, metal or plastic. It is found to be especially useful for fastening panels of an aesthetic material to a support panel for use as building cladding. For purposes of illustration, one panel will be called an aesthetic panel ( 600 ), and the other will be called a carrier panel ( 700 ).
Panel Fastening System
[0017] The panel fastening system ( 500 ) is comprised of three components, a captive nut ( 100 ), a captive washer ( 200 ), and a threaded fastener ( 300 ). The components may be made of metal, or some other suitably strong and durable material, using standard manufacturing methods. Preferred materials are aluminum or an engineering plastic.
Captive Nut
[0018] The captive nut ( 100 ) comprises four integral components, a main body ( 105 ), a shoulder ( 110 ), an extension ( 120 ), and a through hole ( 130 ). In a preferred embodiment, the captive nut will be a unitary member machined from one piece of material, wherein each component will extend out from one side of the main body ( 105 ), i.e., the shoulder will commence at the face of the main body and extend therefrom, and the polygonal extension will commence at the shoulder and extend therefrom. However, the captive nut components may be manufactured individually and then assembled to form the captive nut as shown in FIG. 1 . The four components share a centerline ( 400 ).
[0019] The main body ( 105 ) may be formed in any shape that allows an installer to hold it in a manner to prevent rotation during installation. In general, the main body will be a flat shape that can be grasped by a handtool, such as a pliers or wrench. FIG. 1 illustrates the main body of the captive nut with an outer surface in the shape of a hexagon, which is the preferred shape. The hexagon shape allows the captive nut to be held with a conventional wrench. The other integral components of the captive nut will not rotate when the main body is held captive.
[0020] The shoulder ( 110 ) on the captive nut establishes a controlled-dimension gap between the captive nut and captive washer ( 200 ) when they are assembled to fasten to a carrier panel ( 700 ). The gap dimension is selected to be a slip fit for the carrier panel held between the captive nut and captive washer. The shoulder extends from a face of the main body.
[0021] The polygonal extension ( 120 ) is a polygonal shape that extends from the shoulder ( 110 ). It is sized to fit into the cutout ( 230 ) in the captive washer ( 200 ), to be discussed below. The extension may be of any polygonal shape that will not rotate inside of a correspondingly shaped hole. The polygon may be formed from straight sides, curvilinear sides, or a combination thereof. When the extension of the captive nut is mated with the cutout of the captive washer both the captive washer and the captive nut are prevented from rotation when the main body is held captured by a wrench. This allows the fastening system to be assembled with access to only the backside of the carrier panel ( 700 ). For purposes of illustration, a hexagon shaped extension and cutout are used.
[0022] A through hole ( 130 ) commences on a face of the captive nut opposite that from which the shoulder and polygonal extension extend, and runs through the entirety of the combined main body, shoulder, and polygonal extension. The through hole provides a means for a threaded fastener ( 300 ) to pass through the captive nut and fasten to a panel ( 600 ).
[0000] Captive Washer A captive washer ( 200 ) comprises a washer body ( 210 ), and a polygonal cutout ( 230 ). A function of the captive washer, along with the captive nut, is to form a gap that is a slip fit for a carrier panel ( 700 ) held between the captive nut and captive washer. The captive washer also establishes a space between the two panels, which lowers friction between them and allows free movement due to differential expansion and contraction.
[0023] A purpose of the washer body ( 210 ) is to distribute the pressure of the threaded fastener ( 300 ) evenly over the carrier panel ( 700 ), reducing the chance of damage thereto. The shape of the washer body is not critical. A generally annular shape is preferred.
[0024] The cutout ( 230 ) is a polygonal-shaped through hole in the washer body. The shape and size is a sliding fit for the extension ( 120 ). It is critical that the cutout matches the extension and be of a geometry that prevents the extension from rotating inside the cutout.
[0025] Optionally, a resilient washer ( 220 ) that serves as a spring while the threaded fastener ( 300 ) is being tightened may be employed. Any resilient washer, such as, split washers, Bellville washers, wavy washer, and star washers may be used. Preferably, a foam washer may be used between the face of the washer body ( 210 ) and the panel ( 600 ). In a preferred embodiment, the foam washer is adhesively bonded to the washer body ( 210 ) for ease of installation.
Threaded Fastener
[0026] Any threaded fastener ( 300 ) suitable for the panel ( 600 ) into which the threaded fastener will be driven may be used. In embodiments where the panel does not readily accept a threaded fastener, an anchor ( 302 ) may be used. An example of suitable anchors are those supplied by Fischer Fastening Systems of Auburn Hills, Mich., and the undercut anchors supplied by KEIL Befestigungstechnik GmbH of Engelskirchen, Germany.
Optional Slots in Carrier Panel
[0027] The present invention requires through holes ( 710 ) in the carrier panel to allow the threaded fastener to penetrate through the carrier panel into the aesthetic panel. There is no limitation on the size, shape, or number of through holes used. It is found useful to use a combination of circular holes and oblong slots to allow controlled movement between the dissimilar panels while maintaining rectangular alignment. As illustrated in FIG. 3 , through holes of different sizes, and slots may be included in carrier panel ( 700 ) at locations where threaded fasteners will pass through the carrier panel. At one point a reference hole ( 710 ) is sized to fit close around the outer diameter of a captive nut shoulder ( 110 ). This point connection becomes a fixed connection point between the panels.
[0028] Panel slots ( 720 , 730 , 740 a ) are used at the corners of the carrier panel. The panel slots are elongated in the direction coincident with the slot's position from the reference hole. Consequently, as the aesthetic panel expands or contracts relative to the carrier panel the slots will allow unconstrained linear movement between the dissimilar panels. Optionally, a larger diameter hole ( 740 b ) may be used at the corner diametrically opposite the reference hole. The combination of through holes and panel slots allow the panels to move relative to each other while maintaining alignment.
Fastening System Installation
[0029] The present invention is not limited to fastening any specific type of panels to one another for any specific application. For purposes of illustrating the installation of the fastening system, a first panel known as an aesthetic panel ( 600 ), will be fastened to a second panel known as a carrier panel ( 700 ). Through holes ( 710 ) are provided in the carrier panel to allow the threaded fastener ( 300 ) to fasten the aesthetic panel to the carrier panel.
[0030] As a first step in installing the fastening system, provision is made for the threaded fastener ( 300 ) to thread into the aesthetic panel ( 600 ). The threaded fastener may be driven directly into the aesthetic panel in situations where the material of the aesthetic panel readily accepts screw threads. In situations where the material of the aesthetic panel may crack, a blind pilot hole may be drilled into the back surface ( 600 b ) of the aesthetic panel. When simple threaded fasteners are either impractical or ineffective, a screw anchor ( 302 ) may be used. The screw anchor is installed into the back surface of the aesthetic panel ( 600 b ) according to the manufacturer's instructions and specifications. Threaded fasteners should not penetrate through the front surface of the aesthetic panel ( 600 a ) so as to maintain the aesthetic appeal of the panel.
[0031] The captive washer ( 200 ) is positioned on the aesthetic panel with the cutout ( 230 ) aligned with the point on the carrier panel where the threaded fastener ( 300 ) will be driven. The carrier panel ( 700 ) is positioned opposite the aesthetic panel in a position where a through hole in the carrier panel ( 710 ) is aligned with the captive washer. A captive nut ( 100 ) is inserted into the through hole in a manner which mates the polygonal extension ( 120 ) and the cutout ( 230 ). The threaded fastener ( 300 ) is inserted through the through hole ( 130 ) in the captive nut ( 100 ). A wrench is placed on the main body ( 105 ) to prevent the fastening system from spinning and the threaded fastener is driven into the aesthetic panel.
Application in Building Construction
[0032] The present invention is not limited to fastening any one specific type of panel to any other type of panel, for any specific application. The fastening system of the present invention may be used for any combination of panels of such materials as wood, stone, metal or plastic. For purposes of illustration it is found to be especially useful for fastening a first panel of an aesthetic material to a second, supporting, carrier panel for use as building cladding. The carrier panel is typically a structural metal wall panel. An example of a structural metal wall panel is the Dri-design Wall Panel System from Dri-Design of Holland, Mich. Two or more holes are drilled into a structural metal wall panel that are utilized as the carrier panel ( 700 ). A threaded fastener ( 300 ) is fit through a captive nut ( 100 ), and then through a hole in the carrier panel. A captive washer is placed on the threaded fastener on the opposite side of the carrier panel and assembled to the captive nut by mating the extension ( 120 ) on the captive nut to the cutout ( 230 ) on the captive washer. The threaded fastener is then driven into the aesthetic panel to fasten the carrier panel to the aesthetic panel to form a wall panel. It is found useful to prevent the captive nut and captive washer from spinning while the threaded fastener is driven into the aesthetic panel by holding the main body ( 105 ) with a wrench.
[0033] It is found that an aesthetic panel of solid surface material will give a pleasing appearance and good weathering characteristics. Corian® solid surface from DuPont of Wilmington, Del. is an example of an acceptable solid surface material.
[0034] Numerous wall panels, formed from aesthetic panels fastened to carrier panels, are assembled to the exterior structure of a building to create walls.
[0035] The following examples further illustrate the invention.
EXAMPLE
[0036] An aesthetic panel made of Corian® solid surface material was placed on a workbench surface with the finished side face-down on the work surface. The Corian® panel had previously had undercut holes for Keil anchors machined into the back face. Consequently, these undercut holes were exposed on the backside of the Corian® panel. Keil anchors were inserted in each of the undercut holes.
[0037] Captive washers were positioned on each Keil anchor with the cutout in the captive washers capturing the extension of the Keil anchor. The captive washers were positioned so the resilient washer adhered to one face of the captive washers was between the captive washers and the backside of the Corian® panel. The resilient washer was made of foam.
[0038] A mating Dri-Design aluminum carrier panel was then placed on top of the captive washers, with the holes and slots in the carrier panel aligned with the through holes in the captive washers.
[0039] A captive nut was then inserted through the single small diameter reference hole in the carrier panel with the captive nut extension inserted into the cutout in the captive washer. The position of the carrier panel was then slightly adjusted so the shoulder feature diameter of the captive nut was aligned with the carrier panel hole diameter so the captive nut shoulder was inserted into the panel hole and the shoulder face came into contact with the surface of the captive washers.
[0040] Captive nuts were then inserted through the carrier panel slots with captive nut extensions inserted into the cutouts in the captive washers. The position of the carrier panel was slightly rotated around the captive nut previously placed in the small diameter reference hole so the shoulder feature diameter of the captive nuts were aligned with the Dri-Design panel slot edges so the captive nut shoulders were inserted into the panel slots and the shoulder faces came into contact with the surface of the captive washers. Captive nuts were similarly inserted and aligned in all the slots along the two perpendicular axes of slots to complete the alignment of the two dissimilar panels
[0041] Captive nuts were then inserted through the remaining large diameter carrier panel hole, with captive nut extensions inserted into the cutouts in the captive washers.
[0042] Bolts with a proper length to span the distance between the Keil anchors and the back face of the carrier panel were then dropped into the through holes of each captive nut. Each bolt was then threaded into the mating Keil anchor and tightened to the proper torque value, while holding the main body of the captive nut with a wrench. | A fastening system for attaching cladding panels to a carrier panel and allowing for differential thermal expansion. The system fastens the two panels together at points in the direction perpendicular to the panel planes. A combination of different carrier panel hole sizes and slots fix the panels together at one point and allow the panels to expand and contract relative to each other while maintaining rectangular alignment. Wall panels and buildings constructed using the fastener are disclosed. | 4 |
BACKGROUND OF THE INVENTION
The field of the present invention is shredding machinery, particularly shredding machinery for converting paper, cardboard and other materials into a shredded form. While the structure disclosed and described hereinafter is primarily concerned with paper products and the like, similar structure of appropriate strength materials could be used for shredding metal or similar materials.
In previous U.S. Pat. Nos. 3,685,437 and 2,894,697, machinery is disclosed for the shredding of paper products and the like which is similar to that which is envisioned for use in connection with a shredder as hereinafter disclosed. In such a system, waste paper products are moved by a plurality of upwardly inclined successively overlapping conveyors each succeeding conveyor operating at a higher rate of speed than the one preceding it so as to cause the waste paper to be spacially dispersed in a longitudinal axial direction relative to the conveyor surface.
Although substantial spacial dispersion of waste paper products is accomplished in this fashion, the products tend to reaccumulate in the shredder to some extent and this is especially true when glops or wads of such products get conveyed into the shredder. The greater the potential exposure of the waste paper products to moisture becomes as the result of acquiring, storing and transporting it to the shredder, the more likely it is that glops or wads will form. The result may be that the shredder forcibly slows or jams and the shredding apparatus which includes electromechanically rotated shredding structure is inhibited in or prevented from operating. Several serious results can result from this phenomenon. First, resistance can build up in the electric motor driving the apparatus or in the control system for the motor or both and if safety shut offs are not installed or if installed are not quickly functional, either the motor or controls or both may burn out. If safety shut off controls operate or the motor or controls burn out delays of the shredding operation result for potentially substantial periods of time. Second, journal and bearing structure for one or more shafts involved in the operation of the structure may be severely damaged resulting in even longer periods of machine shut down time while repairs are made.
Since the shredded material is simply being baled for shipment to a center for reprocessing, it is not that critical that every glop or wad be that thoroughly shredded and some may even pass through the shredder virtually unscathed and still be included in the bale. One important reason for this is that the shredded material is often reprocessed into paper or cardboard by being dumped into vats where water and chemicals are added to further break the waste down in the reprocessing process.
It is desirable, therefore, to provide in structure of the character described, a shredder constructed and controlled to eliminate the problems above described.
SUMMARY OF THE INVENTION
The present invention is an improved shredding machine for waste products which includes a waste material receiving entryway and a discharge aperture and electro-mechanically driven shredding mechanism intermediate the entryway and discharge aperture for shredding waste products passing therethrough. The electro-mechanical mechanism includes control structure for sensing resistance increases resulting from slowing or jamming of the shredding structure and, which in response to the sensing, operates hydraulic ram means. The shredding mechanism includes wall and gate structure defining a chamber within which the waste material is shredded and the gate being a part of or disposed for pivital movement within and generally parallel to one wall and coupled to the hydraulic ram means. The gate, in an original selected position, constricts the chamber to assist in directing the flow of the waste material into shreddable relationship with shredding knives or teeth disposed on rotatable means journaled in the wall structure. The sensing mechanism operates to activate the ram means to reposition the gate to one of a plurality of alternate positions other than the originally selected position to increase the chamber volume and thereby enable glops or wads to be discharged from or drop by gravity and centrifugal force through the chamber in partially shredded or unshredded condition freeing the shredding mechanism from its jammed or slowed state to return to normal speed.
A general object, therefore, of the present invention is to provide in a device of the character above described, a shredding machine for waste products, including a plurality of shredder walls interconnected to define an elongated waste material shredding chamber having margins defining a waste material inlet at one end and margins defining a waste material discharge aperture at the end remote from the waste material inlet, a rotatable shredder structure journaled in walls of the machine for rotational movement within the chamber, a gate mounted for pivotal movement within the chamber disposed in spaced relationship to one wall to diverge from a point adjacent to the one wall to a point substantially spaced from the one wall in an originally selected position thereby constricting the latitudinal cross-sectional area of the chamber progressively from material inlet to material discharge aperture thus assisting to direct the flow of waste material from the inlet to the discharge over and about the rotatable shredder structure, the gate being pivotally movable to a plurality of alternate positions expanding the latitudinal cross-sectional area of the chamber and therefore its volume such that waste material may flow more freely therethrough.
Another object of the present invention is to provide in structure of the character above described a plurality of alternate gate positions which progressively increase the latitudinal cross-sectional area and thus the volume of the chamber.
Yet another object of the invention is to provide in structure of the character above described hydraulic ram means coupled to the gate and machine for pivotally moving the gate between the original selected position and the plurality of progressive alternate positions.
A further object of the present invention is to provide in structure of the character above described electronic controls for operating the machine, including means for sensing increase of resistance or voltage to the operation of the rotatable shredder structure, and in response to the increase, activating the hydraulic ram means to pivot the gate from the original selected position to one of the plurality of progressive alternate positions.
The foregoing and other objects and advantages of the invention will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown by way of illustration a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention, however, and reference is made therefore to the claims herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a shredding machine embodying the present invention;
FIG. 2 is an end elevational view of the structure shown in FIG. 1 as viewed from the left;
FIG. 3 is a view partly in side elevation and partly in vertical cross-section through side elevation of the structure shown in FIG. 1 from the opposite side relative to FIG. 1 and exposing internal machine structure required to explain the present invention;
FIG. 4 is an end elevation of ram mounting structure at the left of FIG. 3, with one piece shown in cross section;
FIG. 5 is a top plan view of a portion of the structure shown at the extreme left of FIG. 3;
FIG. 6 is a partial top plan of a portion of the structure shown in FIG. 4;
FIG. 7 is a vertical cross-section through a portion of structure shown in FIG. 3, taken along line 7--7 of FIG. 3 looking in the direction of the arrows;
FIG. 8 is a vertical cross-section through a portion of structure shown in FIG. 3, taken along line 8--8 of FIG. 3 looking in the direction of the arrows;
FIG. 9 is a flow chart to aid in explanation of the flow of the operation of the novel concept of the present invention; and
FIG. 10 is a schematic representation of electronic and pneumatic structure included in the novel concept of the presnt invention to aid in explanation of the machine operations.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particularly to FIG. 1, a shredding machine is shown generally identified by the numeral 20. Machine 20 includes a base generally identified by the numeral 22 and a superstructure generally identified by the numeral 24 affixed to the base 22.
Also mounted on base 22 is an electric motor 44 of the conventional heavy duty variety. Superstructure 24 includes four elongated spaced walls 26, 28, 30 and 32 suitably joined together at their side margins to form an elongated shredding machine chamber 34. The overall vertical length of walls 26, 28, 30 and 32 is the same. It is required to view FIGS. 2 and 3 of the drawings to see all of the sides 26, 28, 30 and 32.
Referring to FIGS. 1, 2 and 3 of the drawings, it can be readily seen that base 22 is comprised of a pair of horizontally spaced, parallel I-beams 36 and 38, to which a superstructure platform 40 consisting of several sections is joined in vertically spaced, parallel relationship by a plurality of spacer-joiners 42. Secured to one section of platform 40 is electric motor 44 having an output drive shaft 46. A pulley 48 is mounted on shaft 46 as desired in a conventional manner such as by a key and keyway (not shown). While either a pulley 48 or a gear may be used, a pulley is disclosed in the preferred embodiment.
Attention is again directed to FIGS. 1, 2 and 3 of the drawings but most specifically to FIG. 3 which discloses rotatable shredding means generally identified by the numeral 50.
Shredding means 50 includes an elongated rotor shaft 52 journaled in any suitable manner in walls 30 and 32. A rotor 54 is mounted in a fixed manner on shaft 52 to rotate therewith within chamber 34. Rotor 54 is provided with ripper teeth 56 spaced helically-longitudinally about the exterior of rotor 54 relative to the longitudinal centerline axis of rotor 54 and shaft 52. Shaft 52 extends beyond wall 30 terminating exteriorly of chamber 34 and is provided with a rotor shaft pulley 58 in the same vertical plane as pulley 48 such that the two may be interconnected by a V-belt 60. The pulley 58 may be mounted to shaft 52 in any conventional manner such as a key and keyway (not shown) to rotate with shaft 52. The entire structure including belt 60, pulley 48, pulley 58 and the ends of shafts 46 and 52 are enclosed for safety and appearance purposes within a belt and pulley housing 62.
It can now be easily shown that when electric power from a source (not shown) is supplied to motor 44, drive shaft 46 and drive pulley 48 will through belt 60, drive rotor shaft pulley 58 and shaft 52 thereby rotating rotor 54 within chamber 34. In the instant disclosure, this drive is in a counterclockwise direction as viewed in FIG. 3 of the drawings.
Reference to FIGS. 1, 2 and 3 of the drawings will disclose that elongated wall 28 consists of upper channel section 64, middle channel section 66 and lower channel section 68 suitably secured together in vertically stacked relationship by any suitable removable fastener (not shown). This is to allow removal of middle channel section 66 which acts as an access window or door to chamber 34.
Continuing reference to FIGS. 1, 2 and 3 will show that chamber 34 has a pair of vertically elongated chamber restricting inner side walls spaced axially relative to shaft 52 and numbered 70 and 72 respectively. Chamber restricting walls 70 and 72 are provided with apertures (not shown) for shaft 52 to pass through in rotatable relationship thereto. Walls 70 and 72 are bolted in place in the preferred construction but could be fastened in any other suitable manner. Walls 70 and 72 extend laterally from elongated wall 26 to elongated wall 28.
Note that an angle baffle 74 is mounted on the interior surface of upper channel section 28 and extends laterally from wall 70 to 72. Baffle 74 is positioned to have its angle extremity or apex 76 slightly greater in radial distance from shaft 52 than the radially outward most extremity relative to shaft 52 of teeth 56. Note that chamber restricting inner side walls 70 and 72 and angle baffle 74 are three-fourths of structure to channel waste material entering chamber 34 over rotatable shredding means 50. The upper margin 78 of inner wall 70 and upper margin 80 of inner wall 72 together with the upper extremity margin 82 of elongated wall 28 and the upper extremity margin 84 of wall 26 define a generally rectangular aperture for receiving in telescoping relationship therein entryway chute 86. Chute 86 is provided with a circumscribing lip flange 88 to overlay the margins 78 and 80 and upper extremity margins 84 and 86 of walls 28 and 26 respectively. To prevent vibration rattling a gasket (not shown) may be inserted between the underside of lip flange 88 and the margins 78, 80, 84 and 86.
Platform 40 is disclosed in FIG. 3 as though it were a unitized platform, however, it is actually comprised of a motor platform section 88 and a ripper gate platform section 90.
As can be seen from FIGS. 1, 2 and 3 of the drawings, lower inner side wall margins 92 and 94 of walls 70 and 72 together with lower side wall margin 96 of side wall 26 and lower side wall margin 98 of side wall 28 cooperate to form a discharge aperture at the bottom of chamber 34 into which a discharge chute 100 is telescopingly inserted and fixedly mounted in any suitable fashion (not shown). This joinder could be either welding or through the use of conventional removable fasteners.
Referring now most particularly to FIGS. 1 and 3 of the drawings vertically elongated gate means are disclosed and generally identified by the numeral 102. Gate means 102 include a laterally, arcuately pivotable ripper gate 104 fixedly mounted at one end to a gate link 106 on one side at the upper extremity of chamber 34. Gate link 106 is fixedly mounted on ripper gate pivot shaft 108 for lateral arcuate pivoting of gate 104 within chamber 34, said pivoting action structure disposed externally of chamber 34 which in turn is mounted for rotational movement to inner walls 70 and 72 adjacent their respective upper margins 78 and 80.
The end of gate link 106 remote from gate 104 is pivotally connected to an end connector of first ram 112. A first ram shaft 110 protrudes axially from the end of first ram 112 remote from gate link 106. The end of ram shaft 110 remote from gate link 106 is pivotally connected to pivot link 114. Ram 112 is in the preferred embodiment a pneumatic ram but could be any form of hydraulic ram. Ram 112 is portrayed in FIGS. 1 and 3 in its so-called normal position when it is not activated. The ram is connected to a source of air (fluid) under pressure (not shown) but schematically illustrated in FIG. 10 of the drawings and is provided with an electrically operated solenoid valve of a well known variety (not shown) but schematically illustrated in FIG. 10 of the drawings easily available on the market. When activated, the solenoid ports air (fluid) under pressure to the lower end of ram 112 driving the piston upwardly as viewed in the drawing. When the solenoid is not activated, the ram shaft 110 returns to its normal position as shown in the drawings urged by spring or other suitable biasing means in the upper end of ram 112 and gravity porting the air to atmosphere.
The end of ripper gate 104 remote from gate link 106 is generally V-shaped in vertical cross section as viewed in FIG. 3 of the drawing. The interior angle of the V-shaped end of gate 104 faces toward rotor 54 and is sufficiently obtuse an angle so as to generally circumscribe an arcuate portion of shredding means 50 radially spaced from shaft 52 a sufficient distance so as to clear ripper teeth 56.
Rotor 54 is provided with a plurality of circular parallel axially spaced ripper teeth mounting rings 116 protruding radially from the exterior of rotor 54, thereby defining intervening grooves between the rings 116.
Each leg of the V-shaped end of ripper gate 104 is provided with a plurality of combs 118 fixedly mounted to the gate 104 and protruding therefrom toward rotor 54. Combs 118 are axially spaced relative to shaft 52 such that they protrude into the grooves defined by rings 116 so that when material in the process of shredding lodges in the grooves defined by rings 116 the combs clean out the lodged material so that it falls via gravity and centrifugal force toward the discharge aperture and discharge chute 100. The lowermost extremity of gate 104 is provided with a pivot block flange 120 protruding toward side wall 26 to which is fixedly mounted a first pivot block 122. The end of pivot link 114 remote from the coupling of first ram shaft 110 and link 114 is pivotally connected to first pivot block 122 as is clearly shown in FIG. 7 of the drawings. Wall 26 is provided with a suitable aperture to permit link 114 to move arcuately therethrough as will be hereinafter described.
Referring again to FIGS. 1 and 3 of the drawings, additional structure forming a part of gate means 122 will be hereinafter described. Details of that structure will be shown in FIGS. 4, 5 and 8 to assist in understanding of the manner in which the structure functions.
At the extreme right of FIG. 1 and the extreme left of FIG. 3 of the drawings a channel mount 124 is shown fixedly mounted to ripper gate platform section 90 upon which a ram mounting bracket 126 is fixedly mounted. A second ram 128 having a second ram shaft 130 extending outwardly axially from one end is mounted to have bracket mounting tab 134 at one end of ram 128 fixedly connected to bracket 126 and the end of shaft 130 pivotally connected to a bell crank detent link 132 intermediate the extremities thereof.
At the end of first ram shaft 110 remote from ram 112 a pivot link connector 136 joins shaft 110 to pivot link 114 in a pivotal fashion and is greater in overall horizontal dimension therethrough than shaft 110 so that a shoulder 138 is formed for purposes that hereinafter will become obvious.
Intermediate channel mount 124 and superstructure 24 on platform section 90 a first channel member 140 and a second channel member 142 are fixedly mounted in spaced parallel relationship the space being bridged by a block plate 144 the undersurface of which is fixed to the members 140 and 142 and the upper surface of which supports a second pivot block 144. Note that the members 140 and 142 are set in place on one leg thereof such that plate 144 is in a plane spaced parallel and above the plane of the upper surface of channel mount 124 but horizontally offset from channel mount 124.
A second pivot block 146 is fixed to the top surface of plate 144. Second block pivot link 148 is pivotally connected at one end to second pivot block 146 such that the pivotal connection of second block pivot link 148 to pivot link 114 is spaced and parallel to but directly below the connection of pivot link connector 136 with pivot link 114, the longitudinal axis of the two said connections lying in the same vertical plane as is shown in FIG. 8 of the drawings.
Along the uppermost edge of bell crank detent link 132 is a pivot link connector stop 150 which is bifurcated to slidably receive and allow vertical axial movement of shaft 110. However, shaft 110 can only move axially upwardly until pivot link connector shoulder 138 is stopped by the lower surface of the bifurcated portion of pivot link connector stop 150. The extremity of bell crank detent link furthest remote from the bifurcated end of pivot link connector stop 150 is pivotally connected to second pivot block 146 separately from second pivot block link 148.
FIGS. 4, 5 and 6 show various slotted slidable mounting means not novel and of general knowledge to permit adjustment in the mounting of the structure described to prevent binding of the shafts 110 and 130 and the various linkages.
Similarly, FIGS. 7 and 8 show details of the pivot connections including bearing structure, pivot pins and pin retaining rings to aid in understanding of the pivotal connections, however, pivot connections herein described are well known in the art.
Referring now most specifically to FIGS. 9 and 10 of the drawings when the shredding machinery is in operation a flow of waste material is being received into entryway chute 86 and falls by gravitation force into chamber 34 defined by chamber walls 70 and 72, ripper gate 104 and the inside of wall 28. Such waste material is further guided or directed by angle baffle 74. Thus, it can be seen that the material is guided over the rotating shredding means 50 where it is shredded by ripper teeth 56 after which it is directed by gravity and centrifugal force to fall through discharge chute 100 after which it will be baled or otherwise processed in operations which form no part of the present invention.
From time to time, the waste materials such as paper, corrugated board and other absorbent products have taken on sufficient moisture to form glops or wads of waste material causing a build-up and back-up of waste products in chamber 34 which ultimately severely impede the rotational movement of shredding means 50, particularly rotor 54 and shaft 52. Such action could cause belt 60 to burn, cause bearing wear of failure at the locations that shaft 52 is rotatably journaled and could cause burn out of various points of the electric and electronic structure which provides the operating power of the machine and at the same time meshes the machine operations in a sequential fashion with the operations of conveyors, compactors, bale making structure and other satellite equipment. It is undesirable and uneconomical to shut the equipment down to clear it and since the presence of some partially shredded or unshredded glops or wads in the shredded material may be easily accommodated this invention describes an alternate method of dealing with the situation.
In the electric circuit for operation of the motor 44, there has been installed a sensing means 152 which may be a resistor, capacitor, or other means for sensing resistance or voltage increases from blockages which slow the normal rotational movement of shaft 52 and rotor 54.
Sensing means 152 activates a first solenoid valve 154 which is operably coupled to a source of pneumatic pressure 156 by a fluid flow line 158. Solenoid 154 has a pneumatic connection to ram 112 which is normally blocked by a solenoid operated valve. As air under pressure is delivered to ram 112 by solenoid valve 154, the piston is biased causing shaft 110 to move upwardly along its longitudinal centerline axis until shoulder 138 of pivot link connector 136 engages the under surface of the bifurcated extremity of pivot link connection stop 150. Thus, links 148 and 114 pivot relative to first pivot block 122 and second pivot block 148 causing ripper gate 104 to pivot arcuately away from rotor 54, teeth 56, rings 116 and shaft 52 allowing wads, glops and accumulated materials to pass easily over and around rotor 54 and drop by gravity into discharge chute 100. At the same time, the rotational speed of rotor 54 will usually return to normal or increase toward normal adding centrifugal force to the discharge of the wads or glops. If the sensing means senses a return to normal operational conditions, solenoid valve 154 will return to its original position blocking air under pressure to ram 112 and venting ram 112 to atmosphere. A biasing means such as a spring 160 will then axially return shaft 110 to its original positioning reversing the pivot process previously described.
Should sensing means 152 sense a continuation of resistance increases or voltage increases, a second solenoid valve 162 will be operated to port air under pressure through second fluid flow line 164 and the valve part of second solenoid valve 162 to ram 128 with which it is coupled to deliver air under pressure. This will cause shaft 130 to move along its longitudinal centerline axis toward ram 128 pulling bell crank detent link to pivot on second pivot block 146 withdrawing the bifurcated extremity of pivot link connector stop 150 from engagement with shoulder 138 of link 136. Removal of stop 150 in this fashion permits shaft 110 to move further axially upwardly arcuately moving ripper gate 104 increasing the volume of chamber 34 that rotor 54 and shaft 52 can virtually spin freely until gravity and centrifugal force clear the chamber.
When the resistance or voltage drops and both solenoid valves 154 and 162 are deactivated blocking air pressure to both rams and venting the air pressure in the rams. Biasing means 160 in ram 112 and second biasing means 166 of ram 128 reverse the pivoting action of both sets of linkages restoring all structure to its starting position.
While the flow chart of FIG. 9 and schematic diagram of FIG. 10 are simplistic, they serve to show the manner in which the structure of the present invention operates to accomplish all of the objectives previously set forth herein. | Improved shredding machine shredding mechanism having elongated wall and gate structure defining a chamber. The chamber walls have margins defining a material entryway at one common end and margins defining a material discharge aperture at the remote end of the chamber from the entryway. An electrically driven rotatable shredder journaled in the wall structure intermediate the entryway and discharge aperture. The gate pivotally mounted externally of the chamber for movement within the chamber at the entryway and extending from a point adjacent to one of the walls divergingly relative to the wall and terminating remote from the pivotal mounting and from the wall defining a progressively constricting chamber as to area of the chamber in latitudinal cross-sectional dimension from entryway to discharge aperture in a selected position of the gate. Electronic sensing means for the motor for rotating the shredder to sense resistance increases to the rotation of the shredder and coupled with hydraulic rams interconnecting the gate and the machine for pivoting the gate from the selected position to a plurality of additional positions progressively increasing the cross-sectional dimension of the chamber thereby increasing the volume thereof. In the selected position the gate assists in guiding material through the chamber. The gate has a plurality of combs for cleaning out between the shredding teeth when the gate is in the selected position. | 1 |
This is a divisional of copending application(s) Ser. No. 08/032,441 filed Mar. 16, 1993, now allowed Mar. 4, 1994 which is a continuation of Ser. No. 07/616,060, filed on Nov. 20, 1990, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to spherical resin particles in micron order with a narrow particle diameter distribution, to methods for the production thereof and to uses thereof. Specifically, this invention relates to resin particles which have been widely used as matting agents, blocking-preventive materials, carriers for chromatography, carriers for medicaments, powder paints and varnishes, gap-adjusting materials, toners for electrophotography, cosmetics, and the like.
In recent years, polymer beads have been put into wide use as matting agents, blocking-preventive materials, organic pigments, carriers for chromatography, carriers for medicaments, powder paints and varnishes, gap-adjusting materials, toners, and the like. Polymer beads used for such purposes are required to have a particle diameter ranging from 0.1 to 100 μm, a narrow particle diameter distribution and a spherical shape.
As examples of the resin particles hitherto usable for the above-mentioned purposes, mention can be made of resin particles which are prepared by a polymerization granulation method. Polymerization granulation methods are generally classified into emulsion polymerization method, suspension polymerization method, seed polymerization method and dispersion polymerization method, which are discussed hereunder.
EMULSION, POLYMERIZATION METHOD
In this method, resin particles are obtained by polymerization in the micelles of polymerizable monomers stabilized by surfactants in water.
According to the emulsion polymerization method, particles having a sharp particle diameter distribution can be obtained. However, the particle diameters are decided by the size of the micelles existing stably, confining the diameter range to from about 0.01 to about 0.5 μm, and it is not possible to prepare particles having a particle diameter of about 1 μm or more. Besides, surfactants essential for stabilization of the micelles remain on the surface of the particles prepared, which also limits the applicable use of the obtained resin particles.
SUSPENSION POLYMERIZATION METHOD
According to this method, polymerizable monomers are polymerized to afford particles in a suspension system obtainable by mechanically stirring a mixture of water and the polymerizable monomers.
In the suspension polymerization method, it is not easy to polymerize in a stable system. In addition, it is difficult to obtain fine polymer particles having a uniform particle diameter distribution, since the particle sizes depend on the mechanical stirring.
For this reason, a suspension-stabilizing agent is used in suspension polymerization to prevent particles from coalescence and to stabilize the polymerization. As such suspension-stabilizing agents, use is generally made of sparingly soluble inorganic compounds, for example, sparingly soluble salts such as barium sulfate, calcium sulfate, magnesium carbonate, barium carbonate, calcium carbonate and calcium phosphate; metal oxides such as silica, calcia, magnesia, titanium oxide; minerals such as diatomaceous earth, talc, clay and kaolin; and their mixtures or water-soluble mixtures, such as polyvinyl alcohol, gelatin and starches.
Actually, even when said suspension-stabilizing agents are used, the particle diameters of the particles obtained by the suspension polymerization method are about several dozens μm or more and the particle diameter distribution thereof is broad, which gives rise to the classification after polymerization.
SEED POLYMERIZATION METHOD
The seed polymerization method has been proposed to solve the above-mentioned problems. Therein, particles obtained by another method are used as seed particles, and are imbibed with solvents and a polymerizable monomer. The thus-obtained particles are allowed to grow by polymerization within the imbibed seed particles.
In the seed polymerization method, it is, in principle, possible to obtain particles having a sharp particle diameter distribution by selecting suitable seed particles, and the particle diameters con be controlled according to the imbibition ratios of the seed particles and polymerizable monomers.
The seed polymerization method was originally devised for the purpose of producing particles having a particle diameter between 0.01-0.5 μm obtainable by the emulsion polymerization method and several dozens μm or more obtainable by the swelling polymerization method. Accordingly, as a matter of fact, the particles usable as seed particles in the industrial seed polymerization are often limited to particles obtainable by the emulsion polymerization method, namely, vinyl polymer particles. However, it is difficult to imbibe vinyl polymer particles using polymerizable monomers. The imbibition ratio is decided by the interaction of the polymer composing the seed particles with the monomer used for imbibition and by a balance with a surface tension of the imbibed particles, and thus the imbibition ratio is actually limited to 2-10 times at most.
Alternatively, the imbibition ratio cannot be increased extremely, since the particle diameters which can be enlarged at one time is limited. Ten times the particle diameter corresponds to 1,000 folds the volume, and extreme imbibition necessitates repeated seed polymerization.
TWO-STEP IMBIBITION SEED POLYMERIZATION METHOD
This method was devised For the purpose of increasing the imbibition ratio of seed particles. In the 2-step imbibition seed polymerization method, seed particles are imbibed with an oligomer or a sparingly soluble lower molecular substance (a imbibing agent), etc., whereafter particles are further imbibed with a polymerizable monomer. By this method, the imbibition ratio of the seed particles can be increased to several thousand folds. However, the imbibing agent remains in the particles obtained by the 2-step imbibition seed polymerization method, and another step for removing this imbibing agent is requisite.
Though the seed polymerization method is excellent in that the resin particles in micron order having a sharp particle diameter distribution can be prepared, the foregoing problems prevent the seed polymerization method from being industrially employed.
DISPERSION POLYMERIZATION METHOD
In this method, a polymerizable monomer, an initiator and stabilizer are dissolved in an organic solvent, whereby initiating the polymerization, and the polymer particles insoluble in the organic solvent are made to grow with coalescence the oligomer produced in the first stage of the polymerization as the particle cores.
Though the dispersion polymerization method is excellent for preparing resin particles in micron order having a sharp particle diameter distribution, realization of mass-production by this method is difficult, due to the use of an organic solvent as a medium, which disqualifies the dispersion polymerization method as an industrial method for producing spherical resin particles.
As mentioned above, the particle diameter range of resin particles is limited in the emulsion polymerization method and the suspension polymerization method, and besides, only resin particles having a broad particle diameter distribution can be obtained by these methods. It is possible to obtain resin particles having a sharp particle diameter distribution by the seed polymerization method and the dispersion polymerization method. However, it is in effect impossible to produce spherical resin particles at a low cost, since realization of mass-production by these methods is unavailable.
Moreover, as mentioned above, resin particles produced by the polymerization-granulation methods, i.e., emulsion polymerization, suspension polymerization, seed polymerization and dispersion polymerization, are in most eases limited to vinyl polymers, as is self-evident from the production steps therefor. Thus, the resin particles of the condensation polymers of the present invention cannot be obtained by the "polymerization-granulation" method.
On the other hand, particles of polyester resins, polyamide resins, polyurethane resins and other condensation type resins cannot be formed by a suspension polymerization means. As an alternative means, resins are dissolved in a solvent and this solution is added dropwise to a precipitating agent for solidification, but it is difficult to form substantially spherical particles by this way, and a step for recovering the solvent is required.
SUMMARY OF THE INVENTION
An object of this invention is to provide substantially spherical resin particles comprising, as the main polymer component, a condensation polymer having an optional particle diameter and a narrow particle diameter distribution, and methods for the industrial production thereof.
Another object of the invention is to provide uses of said resin particles.
That is, this invention relates to resin particles comprising a condensation polymer containing an ionic groups as the main component, wherein the average particle diameter (D) ranges from 0.1 to 100 μm; at least 70% by weight of the particles have a particle diameter between 0.5 and 2.0; and at least 70%, by number average, of the particles have a sphereness (ratio of the short diameter to the long diameter) of not less than 0.7. More preferably, said resin particles comprise an ionic group-containing condensation polymer as the main component, and a counter ionic group containing vinyl addition polymer as the sub-component, still more preferably, the equivalent ratio of the ionic group (B) contained in the vinyl addition polymer to the ionic group (A) contained in the condensation polymer, i.e., B/A, is less than 1.0; and the average particle diameter (D) ranges from 0.1 to 100 μm.
As the methods for producing the resin particles of the present invention, the following method can be proposed.
(1) The method for producing resin particles, characterized by comprising at least steps of preparing a liquid microdispersion of a condensation polymer capable of microdispersion therein at an average diameter (d) of not more than 1.0 μm and allowing said micro-dispersed particles to coalesce by keeping the amount of the ions on the surface of the micro-dispersed particles in the dispersion system uniform by addition of compounds having counter ions of electrolytes, whereby producing substantially spherical particles of average diameters ranging from 0.1 to 100 μm, which comprise a condensation polymer as the main component.
The preferred embodiment of this method is as follows:
(2) In this method, at least the following steps are comprised. That is, an ionic group-containing condensation polymer is dispersed (i.e., microdispersed) in a water dispersion medium containing at least 50% by weight of water, preferably 5-45% by weight, more preferably 10-40% by weight, at an average diameter of not more than 1.0 μm, preferably 0.5 μm, and the aforesaid micro-dispersed condensation polymer is coalesced by addition of a monomer containing ionic groups (B') constituting counter ions to the ionic groups (A') contained in said condensation polymer and a polymerizable double bond in the molecular, followed by polymerization of the monomer to produce substantially spherical resin particles of average particle diameters ranging from 0.1 to 100 μm, preferably 0.5-50 μm, more preferably 1.0-20 μm, which comprise the condensation polymer as the main component. The resin particles of the present invention is preferably applied, for example, to toners for electrophotography as the main component thereof.
DETAILED DESCRIPTION OF THE INVENTION
The condensation polymers in this invention are polymers as opposed to the addition polymers produced by cleavage of unsaturated double bonds, which are exemplified by polyester polymers, polyamide polymers, polyimide polymers, polypeptide polymers, polyamino polymers, polycarbonate polymers, polyurethane polymers, natural polymers such as celluloses and chitins, and the like, their derivatives and their modified polymers. Preferable polymers among the before-mentioned polymers are polyester polymers and polyurethane polymers.
The expression "the main component" in the present invention means the component contained in the resin particles in a proportion of not less than 70% by weight, preferably not less than 80% by weight among the components composing the resin particles, and the expression "the sub-component" means the component contained in a proportion of not more than 30% by weight, preferably not more than 20% by weight including 0%.
The gist of this invention lies in obtaining substantially spherical particles in micron order which have a sharp particle diameter distribution, by micro-dispersion of a condensation polymer in a dispersion medium and coalescence of the micro-dispersed particles.
There are known methods which comprise dissolving a polymer uniformly and then precipitating the once-dissolved polymer as micro-particles caused by the change of solubility by pH adjustment, etc. (salting method); methods which comprise dispersing a polymer in the form of the solid microparticles in a liquid medium and making the irregularly-shaped micro-dispersed polymer spherical by warming the entire system to a temperature higher than the softening point of the polymer; and methods which comprise (adding and) mixing a liquid of fluxed (melt) polymer under stirring in the absence or a solvent to make the polymer spherical.
However, limitation of these methods is that it is extremely difficult to produce spherical particles in micron order having a sharp particle diameter distribution industrially in a large amount, since especially in case of condensation polymers, melting points or softening points are high or the solvents to be used need special care, which is disadvantageous in handling.
The state of the "micro-dispersion" in "a liquid", especially in a water medium, in the present invention means the state of dispersion caused by formation of stable micelles resulting from formation of electric bilayer and generally means dispersion in a state of an emulsion, a colloid, or the like. The average diameters of the dispersed particles are preferably not more than 1.0 μm, preferably 0.5 μm.
While there is no special limitation to said condensation polymers capable of micro-dispersion in a liquid, especially in water, examples thereof include condensation polymers having ionic groups, condensation polymers admixed with particular surfactants such as an anionic dispersant, a cationic dispersant or a nonionic dispersant, natural macropolymers such as chitins and celluloses, in which the substitution degree of hydrophobic groups and hydrophilic groups and the molecular weight are controlled. Moreover, solvents and inflating agents may be additionally used to obtain such micro-dispersions.
Preferably, use can be made of condensation polymers containing ionic groups, chitin/chitosan in which the substitution degree of acotamide groups by amine groups is adjusted, carboxymethyl celluloses in which the degree or substitution is adjusted, and the like.
Of these polymers, particularly preferred are condensation polymers containing ionic groups in the molecular.
According to the present invention, by addition of an ionic group (B') having counter ions to the ions of the micro-dispersed condensation polymer (A') to, and addition polymerization of a monomer having polymerizable double bonds in molecules, namely, a vinyl monomer in the dispersion system of the aforesaid micro-dispersed condensation polymer at a temperature not less than 40° C., preferably not more than 100° C., the ions on the surface layer of the micro-dispersed particles are neutralized and the particles coalesce to form spherical particles having the particle diameters in the range of about 0.1-100 μm, which results in surprisingly sharp particle diameter distribution of the particles obtained. The preferable particle diameters can be attained by selecting the reaction conditions. When preferable particle diameters are obtained by particle coalescence, the temperature of the system is lowered to room temperature or a lower temperature (0°-30° C.) and the particles are separated and dried, whereby the objective particles can be efficiently obtained. While the particles obtained according to the present invention can be directly used without classification as mentioned above, classification may be performed when necessary.
There is no particular limitation to the ionic groups in the present invention, and preferable examples thereof include sulfonic acid group (--SO 3 H), groups of metal salts of sulfonic acid (--SO 3 M; M=metal), carboxylic acid group (--COOH), groups of metal or ammonium salts of carboxylic acid (--COOX; X=metal or ammonium), amine group, ammonium group, phosphoric acid group (--PO 4 H 2 ), groups of metal or ammonium salts of phosphoric acid (--PO 4 XY; X,Y=hydrogen, metal or ammonium), acid residues containing phosphorous atom (e.g. --PO 3 H 2 , --PO 2 H 2 , --POH 2 , --PO 3 XY or --PO 2 HX; X,Y=hydrogen, metal or ammonium), or the like.
The methods for allowing condensation polymers to contain aforesaid ionic groups for micro-dispersion include methods of adding them as the surfactant, methods of copolymerization with the condensation polymer and methods of adding ionic groups to the modified condensation polymer.
As the surfactants, there can be mentioned, for example, anionic surfactants such as fatty acids represented by RCOOM, alcohol sulfuric acid esters represented by ROSO 3 M, fatty alcohol phosphoric acid ester salts represented by ROP(OM) 2 and alkylarylsulfonic acid salts represented by R--Ar--SO 3 M; and cationic surfactants such as aliphatic amine salts represented by R 1 N(R 2 ,R 3 ).X and quaternary ammonium salts represented by (R 1 ,R 2 , R 3 ,R 4 )N.X where M stands for an alkali metal, specifically Na, respectively. As the methods for copolymerization with the condensation polymers, use can be made of, but not limited to, methods comprising forming, for example, polyethyleneterephthalate.isophthalate copolymer in which 5-sodium sulfo-isophthalic acid is copolymerized, polyethylene terephthalate-isophthalate copolymer in which a glycol having a tertiary amine of HOCH 2 CH 2 N (CH 2 CH 2 NR 1 R 2 ) (CH 2 CH 2 OH) (wherein R 1 and R 2 are hydrogen or methyl) is copolymerized, polyhexamethylene adipate copolymers in which a diamine having a tertiary amine of H 2 N--CH 2 CH 2 CH 2 N (CH 2 CH 2 CH 2 NR 1 R 2 ) CH 2 CH 2 CH 2 NH 2 (wherein R 1 and R 2 are as defined above) is copolymerized, known polyurethane copolymers in which a diol or a diamine having a tertiary amine as mentioned above is copolymerized, and the like.
Examples of methods for introducing ionic groups by modification of the condensation polymers include methods of neutralizing carboxyl groups of polyamic acids which are precursors of polyimides with ammonia or an organic base and methods of adding trimellitic anhydride to hydroxyl group at the terminals of the polyesters or copolymers of polyesters, followed by exchanging the carboxyl group subjected to addition with a metal ion or ammonia ion.
To be specific about the polyester polymers which are preferably applied as the condensation polymers in the present invention, both of saturated polyester resins and unsaturated polyester resins can be used as the polyester resins. The polyester resins in this invention include, for example, polyesters composed of dicarboxylic acid resin and glycol components.
As the dicarboxylic acid components, use can be made of, for example, aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, orthophthalic acid and 1,5-naphthalic acid; aromatic hydroxy carboxylic acids such as p-hydroxybenzoic acid and p-(hydroxyethoxy) benzoic acid; and unsaturated aliphatic dicarboxylic acids and alicyclic dicarboxylic acids such as succinic acids, adipic acid, maleic acid, itaconic acid, hexahydrophthalic acid, tetrahydrophthalic acid; and the like. As the acid components, a small amount of tri- and tetracarboxylic acids such as trimellitic acid, trimesic acid and pyromellitic acid may be contained, if necessary.
As the glycol components, use can be made of, for example, diols such as ethylene glycol, propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, neopentyl glycol, diethylene glycol, dipropylene glycol, 2,2,4-trimethyl-1,4-phenylene glycol, ethylene oxide addict of 1,4-phenylene glycol, polyethylene glycol, polypropylene glycol, polytetra methylene glycol; ethylene oxide addict and propylene oxide addict of bisphenol A; ethylene oxide addict and propylene oxide addict of bisphenol A, hydride; and the like.
In addition to the foregoing, there may be contained, if necessary, a small amount of triols and tetraols such as trimethylol ethane, trimethylol propane, glycerine and pentaerythritol. There may be also contained lactone polyester polyols which can be obtained by ring-opening polymerization of lactones such as ε-caprolactones, as polyester polyols.
Particularly in case where dye coloring is conducted, polyester resins containing terephthalic acid, isoterephthalic acid and 5-sodium sulfoisophthalic acid are preferably used as the acid components, among other polyester resins.
The "monomers containing counter ionic groups and polymerizable double bonds in molecules" used as the subcomponent in the present invention mean vinyl monomers containing ionic groups opposite to the ionic groups contained in the condensation polymer, the main component (when the ionic groups contained in the condensation polymer are anionic groups, the counter ionic groups are cationic groups and when cationic groups are contained in the condensation polymer, the counter ionic groups are anionic groups).
As for the amount of the counter ionic groups, the equivalent ratio of the amount of the counter ionic groups in the vinyl monomer to that of the ionic groups in the condensation polymer is in the range of not less than 0.5, preferably 0.5-10.0, more preferably 0.8-2.0.
As the vinyl monomers containing cationic groups, there can be mentioned, for example, 2-aminoethyl(meth)acrylate, 2-N,N-dimethylaminoethyl (meth)acrylate, 2-N,N-diethylaminoethyl(meth)acrylate, 2-N,N-dipropylamino(meth)acrylate, 2-N, t-butylaminoethyl(meth)acrylate, 2-(4-morpholino)ethyl(meth)acrylate, 2-vinylpyridine, 4-vinylpyridine, aminostylene, etc.
As the vinyl monomers containing anionic groups, there can be mentioned, for example, monomers containing carboxyl group such as (meth)acrylic acid, itaconic acid, crotonic acid, maleic acid, fumaric acid or a salt thereof; monomers containing sulfonic acid, group such as styrenesulfonic acid, vinyltoluenesulfonic acid, vinylethylbenzenesulfonic acid, isopropenylbenzenesulfonic acid, vinyloxybenzenesulfonic acid, vinylsulfonic acid, sulfoethyl or sulfopropyl ester of (meth)acrylic acid, and 2-acrylamide-2-methylpropenesulfonic acid or a salt thereof; and monomers containing phosphoric acid group such as azidophosphoxyethyl (meth)acrylate, azido-phosphoxypropyl (meth)acrylate, 3-chloro-2-azidophosphoxypropylmethacrylate, bis(meth)acryloxyethyl phosphate, vinyl phosphate or a salt thereof; and the like.
The polymerized ones of the aforesaid ionic group-containing vinyl monomers are the vinyl polymers, namely, the sub-component in the present invention. The aforementioned monomers are used singly or as a mixture, and the polymers include homopolymers and copolymers.
A combination of an anionic group-containing resin (A) with a cationic monomer is preferable for attaining the object of the present invention. Also, a co-use of a known nonionic monomer as appropriate is acceptable.
By the foregoing steps, there can be industrially produced resin particles having an optional particle diameter (D) within the range from 0.1 to 100 μm in which not less than 70% of the particles have the particle diameters within the range of 0.5-2.0. The particle diameters can be easily controlled by the equivalent ratio of the amount of the counter ionic groups to the vinyl polymer (B) against the amount of the ionic groups of the resin (A), polymerization temperature, polymerization time and other factors. For example, the resin particles can be magnified by increasing the equivalent ratio within the range between 0.1 and 10, by raising the polymerization temperature, by prolonging the aging time, or by other means. The average particle diameters are preferably 1-30 μm, most preferably 1-10 μm.
From the aspect of industrial polymerization conditions or the vinyl monomer (b), the resins (A) having Tg within the range from 30° to 90° C. are desirable, and in terms of improvement of the sphereness of the particles and shortening of the aging time, the polymerization temperature is desirably set to Tg+10° C. or higher. By this way, there can be formed resin particles in which not less than 70%, by number average, of the particles have a sphereness of not less than 0.7. The sphereness is preferably 0.8, more preferably 0.9.
There is no special limitation to the initiators usable for polymerizing the vinyl monomers (b), and examples thereof include, for example, organic peroxides such as benzoyl peroxide and acetyl peroxide; azo compounds such as 2,2'-azobisisobutylonitrile and 2,2'-azobis(2,4-dimethylvaleronitrile); inorganic peroxides such as persulfates, hydrogen peroxide salts and permanganates; and water soluble redox initiators such as combinations of the aforesaid inorganic peroxides with reductants such as sulfites, bisulfites, metasulfite, hydrosulfite, thiosulfate, iron salts, and oxalic acid. From the viewpoint of safety and industrial feasibility, water soluble redox initiators are desirable. The amount of the polymerization initiators to be used ranges in general from 0.1 to 3% by weight relative to the amount of the vinyl monomers (b).
By using solvents and plasticizers for the resin (A) additionally, it is possible to lower the apparent Tg (or minimum membrane-forming temperature) of the resin (A) and thus polimerize at a temperature higher than the temperature mentioned above. There is no limitation to the solvents and plasticizers to be used as long as they do not interfere with the polymerization, and suitable ones are selected from those known depending on the species of the resin (A).
While other polymerization conditions can be adopted in accordance with conventional methods, the step of adding the vinyl monomer (b) to an aqueous dispersion of the microparticles of the resin (A) in advance, followed by dropwise addition of a polymerization initiator is preferable in that it involves no rapid coalescence and aggregation of the microparticles of the resin (A).
The thus-obtained aqueous dispersion of the resin particles can be formulated into dried powders in accordance with conventional methods such as filtration, lyophilization and spray drying.
The above-mentioned methods of adding the counter ion-containing vinyl monomer to the system of micro-dispersion of the ionic group-containing condensation polymer, followed by polymerization work successfully due to the following mechanisms, while some aspects are left unclarified.
That is, the ionic groups of the ionic group-containing polymer dissociate and form stable micelles covered with electric bilayer, whereby an aqueous micro-dispersion is formed.
Though the polymerizable monomer containing the counter ionic group to the ion contained in the polymer exists in the system in dissolution in water, it fails to form a salt with the ionic group (in dissociation) of the polymer. However, once the counter ionic group-containing polymerizable monomer polymerizes, the ionic groups of the polymer are covered by the polyion complex. Since the polymerization proceeds extremely slowly, covering of the ionic groups occurs partially on the individual surface of the micro-dispersed particles. The micro-dispersed particles which have partially lost the electric bilayer become unstable and coalesce with other particles also having lost the electric bilayer partially, whereby wrapping inside the unstabilized surface thereof and reducing the total surface area by the coalescence, which results in re-stabilization of the particles. As mild polymerization proceeds in the system, the system remains extremely uniform macroscopically. Therefore, coalescence of particles occurs with even probability, and thus, the particle diameter distribution of the particles obtained is extremely sharp.
Examples of other concrete methods for producing the resin particles of the present invention include methods of mildly decomposing a compound which produces an acid or an alkali in an aqueous micro-dispersion of the condensation polymer having ionic groups, the dissociation of which can be controlled by changing the pH.
As the compounds which produce an acid or an alkali through decomposition, there can be mentioned, for example, peroxodisulfates (persulfates) and bicarbonates which can be decomposed by heating and triazines which can be decomposed by light radiation.
Among the peroxodisulfates, alkali metal salts and ammonium salts are preferably used. Among the bicarbonates also, alkali metal salts and ammonium salts are preferably used.
The peroxodisulfates and the bicarbonates can be gradually decomposed by heating an aqueous solution thereof at 40° C. or higher, and the former changes the pH of the solution to acidic and the latter changes the pH of the solution to alkaline.
As mentioned above, the polymer having ionic groups forms micelles stabilized by electric bilayer resulting from dissociation of the other ionic groups therein, whereby forming an aqueous micro-dispersion. If the state of dissociation of the ionic groups is changed to the state of non-dissociation by adjusting the pH or the temperature, or both, while the entire system is kept homogeneous, the stable micro-dispersion becomes slightly unstabilized, which gives rise to mild cohesion of particles.
If homogeneity of the system (microscopically) is maintained, coalescence of particles occurs in equal probability, and the obtained particle diameter distribution becomes extremely sharp. The adjustment of pH while the homogeneity of the system is maintained is impossible by conventional methods such that an acid or an alkali is added to the system, followed by mixing. This method, while based on the principle of salting, is characterized in that the homogeneity of the system is maintained.
As other concrete methods for producing resin particles of the present invention, there can be mentioned, for example, a method in which the ionic groups are cleaved by heating of the aqueous micro-dispersion of the condensation polymer having sulfonic acid group, group of metal salts of sulfonic acid, carboxylic acid group, group of metal or ammonium salts of carboxylic acid, amine group, ammonium group, phosphoric acid group, group of metal or ammonium salts of phosphoric acid, whereby the micro-dispersion is unstabilized, resulting in coalescence and granulation of particles. The heating is preferably conducted with the pH of the aqueous micro-dispersion being 7.0 or above. As the method for making the pH 7.0 or above, there can be mentioned a method wherein NaOH, Na 2 CO 3 , KOH, K 2 CO 3 , ammonia, ammonium compounds of cation group-containing water-soluble compounds, etc. are added to an aqueous micro-dispersion, with preference given to a method wherein ammonia or ammonium compounds are added.
As other concrete methods for producing resin particles of the present invention, there can be mentioned, for example, a method in which the ionic groups are cleaved by light-irradiation of the aqueous micro-dispersion of the condensation polymer having phosphoric acid group, sulfonic acid group, carbonic acid group or hydroxy amino group, whereby the micro-dispersion is unstabilized, resulting in coalescence and granulation of particles.
An embodiment of the present invention includes the process wherein the resin particles obtained in accordance with the present invention are separated from the liquid medium, and dried by a specially devised drying process for affording perfectly dried particles. Such specially devised drying processes include rapidly elevating the temperature in the same manner as in hitherto-known methods for ballooning microparticles thermally expandable, to obtain hollow spherical particles having substantial specific gravity of 0.1-1.2. Alternatively, hollow particles of the present invention with thermal expansion suppressed by a slight degree may be immersed in a blowing agent, so that the blowing agent is contained mainly in the hollow space thereof to make thermally expandable micro-particles.
Another embodiment of the present invention involves the process wherein a small amount of an amphoteric polar solvent is added to an aqueous dispersion of the resin particles comprising the condensation polymer of the present invention as the main component, followed by stirring; the temperature is elevated to 70°-100° C. and thereafter rapidly cooled to give porous particles; and the particles obtained are separated from the medium and dried under usual (mild) conditions to yield substantially spherical porous resin particles (comprising particles of a sphereness of not less than 0.7 in a proportion of 70% by number average) having substantial specific gravity of 0.1-1.2 and a sharp particle diameter distribution.
Still another embodiment of the present invention involves the process wherein after an aqueous dispersion of the resin particles comprising the condensation polymer of the present invention as the main component has been kept at 70°-100° C. at a pH not more than 7 for a long time, it is cooled and dried to yield potato-shaped particles having a number of convexes and concaves (craters or dimples) of not more than 0.1 Do wherein Do means the average particle diameter, on the particle surface.
The resin particles of the present invention are particularly useful as toners for electrophotography, such as toners used as the photographic developer for eletrophotographic copiers, laser printer, etc. The present invention thus also provides toners for electrophotography.
The methods for coloring the toners for electrophotography of the present invention are not particularly limited, and conventionally available pigments, dyes or carbon blacks known per se can be used. Specifically from the viewpoint of spectral transmission characteristics, dyes are preferred.
As the pigments, there can be used lake pigments, rhodamine pigments, quinacridone pigments, anthraquinone pigments, monoazo pigments, disazo pigments, phthalocyanine pigments and the like.
Particularly, anthraquinone pigments and disazo pigments are preferred as the yellow pigments. Disazo pigments having benzidine as the basic skeleton are further preferable. Concrete examples of the disazo yellow pigments having benzidine as the basic skeleton include
C.I. pigment yellow 12,
C.I. pigment yellow 13,
C.I. pigment yellow 14,
C.I. pigment yellow 15,
C.I. pigment yellow 16,
C.I. pigment yellow 17,
C.I. pigment yellow 63,
C.I. pigment yellow 77, and the like.
Especially, anthraquinone pigments and quinacridone pigments are preferred as the magenta pigments. Examples of such quinacridone pigments include
C.I. pigment violet 19,
C.I. pigment violet 30,
C.I. pigment red 122, and the like.
Especially, phthalocyanine pigments are preferred as the cyan pigments. Examples of such phthalocyanine pigments include
C.I. pigment blue 15,
C.I. pigment blue 15:1,
C.I. pigment blue 15:2,
C.I. pigment blue 15:3,
C.I. pigment blue 15:4,
C.I. pigment blue 16,
C.I. pigment blue 17,
C.I. pigment blue 17:1,
C.I. pigment green 7,
C.I. pigment green 13,
C.I. pigment green 25,
C.I. pigment green 36,
C.I. pigment green 37, and the like.
The amount of the pigments to be contained is 0.1-25% by weight. As the methods for incorporating and dispersing the pigments in the resin particles, there can be mentioned, inter alia, methods of incorporating the pigments by kneading in the resin in advance, methods of co-dispersing the pigments in the aqueous dispersion in the course of coalescence and growth of microparticles, to permit the pigments to be incorporated in the particles concurrently with the coalescence of the microparticles, methods of coating the pigments mechanically on the particle surface after granulation, and other methods, which are not limitative.
As the dyes, there may be used disperse dyes, vat dyes, metallized dyes, acidic dyes, basic dyes, cation dyes, reactive dyes, and the like. Dispersion dyes and cation dyes are preferably used.
As the carbon blacks, there can be used thermal black, acetylene black, channel black, furnace black, lamp black, and the like. The amount of the carbon blacks to be contained is 0.1-25% by weight.
In the present invention, the carbon blacks can be used singly or, if necessary, in combination. If necessary, other coloring agents such as pigments and dyes can be additionally used.
The carbon blacks can be, for example, absorbed by particles, covered with particles or hit mechanically into the particle surface, for example, by dry process. As the methods for producing carbon black-containing particles with the carbon blacks dispersed in particles, there can be mentioned, for example, methods of dispersing carbon blacks in particles, followed by granulation and methods of permitting the carbon blacks to be incorporated in the particles during coalescence and granulation by allowing an aqueous dispersion of the carbon blacks to coexist in granulation.
In the present invention, silica micropowders can be contained for controlling surface characteristics, flowability and electrification characteristics. Such silica micropowders exist preferably in the surface layers of toners or in the vicinity of the surface layer.
More specifically, it is preferable that silica micropowders attach to the surface layers of the polyester resin, cover the surface layers or are partly imbedded in the surface of the polyester particles.
Preferably, the silica microparticles cover not less than 25%, more desirably not less than 40% of the surface of the polyester particles, and are partly imbedded in the polyester particle surface.
The silica microparticles are preferably incorporated in such a way that the amount of silica contained in the area of 0.05 D in depth from the particle surface wherein D means the average particle diameter of the polyester particles is not less than 10% by weight. The silica micropowders to be used in the present invention have preferably an average particle diameter of not more than 1 μm the preferably spherical. These silica micropowders can be adsorbed in the particles, for example, by wet or dry method or anchored after adsorption.
In the present invention, electrical charge controlling agents can be used in ease where friction-electrification characteristics need control. As such electrical charge controlling agents, there can be used pigments, resin particles having an average particle diameter of not more than 2μ and inorganic particles.
As the pigment type electrical charge controlling agents capable of giving positive electrical charge to toners by friction with earlier particles, there can be mentioned, for example, Ca, Ba and other metal titanates or carbonates, alkoxy amines, polyamide resins such as nylons, pigments having positive zeta potential exemplified by phthalocyanine blue, quinacridone red and azo metal complex green, azine compounds, azine compounds modified by stearic acid, azine compounds modified by oleic acid, azine pigments such as nigrosin and quaternary ammonium compounds.
As the pigment type electrical charge controlling agents capable of giving negative charge to toners through friction with earlier particles, there may be mentioned, for example, carbon blacks, pigments having negative zeta potential such as halogenophthalocyanine green, flavanthrone yellow and perylene red, metallized azo compounds of copper, zinc, lead, iron, etc.
As the resin particles having an average particle diameter of not more than 2μ, there can be mentioned, for example, polyamide resins such as nylons, urethane resins and polymethyl methacrylate resins.
As the inorganic particles, there can be used micro powders of minerals such as talc, mica, kaolin and clay, and micropowders of metal oxides such as silica, titanium oxide, magnesia, calcia and alumina.
The electrical charge controlling agents exist preferably at least in the surface layers or in the vicinity of the surface layers of toners. More specifically, it is preferable that these agents be incorporated in a coating on the surface layers of the polyester particles or imbedded in the surface layer.
While the electrical charge controlling agents can be adsorbed in the particles, for example, by wet or dry methods, or anchored after adsorption, the methods of treating the particles with these agents by a mechanofusion method, a dry method, are preferable.
In the present invention, the resin particles may be covered with a thermoplastic polymer of the constituent component different from that with the condensation polymer as the main constituent component, for controlling surface characteristics, flowability and electrification characteristics of the particles. Preferably, not less than 30% by weight of the thermoplastic resins are contained in the area of 0.05D in depth from the surface of the resin particles wherein D means the average particle diameter of the resin particles.
As the thermoplastic resins, there can be used polymers such as polyethylene resins, vinyl chloride resins, polypropylene resins, rubbers, nylon resins, urethane resins, acryl resins, polymethyl methacrylate resins, fluorine resins and silicon resins. The preferred resins in the present invention are urethane resins and resins containing methacrylate as the main component.
There is no particular limitation imposed on the methods for covering the surface of the resin particles with the thermoplastic resins, and conventionally-known treatment methods can be used, whether they are wet methods or dry methods.
In the present invention, magnetic powders can be contained in the resin particles if it is necessary to impart the resin particles with magnetism. As the magnetic powders, there can be used, for example, iron, cobalt, nickel or their alloys comprising those as the main clement, or oxides of magnesium or ferrite, or the like. Particularly, magnetic powders of oxides with ferrite as the main element are preferably used. These may be used singly or as a mixture. These magnetic powders may be, if necessary, treated with silane coupling agents, titanate coupling agents, phosphoric acid coupling agents, surfactants, and the like. The amount of the magnetic powders to be contained is preferably 10-70% by weight, more preferably 15-50% by weight.
EXAMPLES
Hereafter the present invention is described in further detail by the following examples, which are not limitative to the scope of the invention.
"Part" and "percentage" shown in the following examples are by weight unless specified otherwise. The average particle diameters were measured by an automatic particle diameter distribution measuring apparatus type CAPA700 manufactured by Shimazu Corporation, and the sphereness was decided by measuring long diameters and short diameters from the projected images by an optical microscope and taking the ratio of the short diameter to the long diameter. The particles having a sphereness of 1.0 are regarded as true spheres, and below 1.0 as deformed spheres. The molecular weights were measured by a molecular weight measuring apparatus type 115 manufactured by Hitachi, Ltd., and the particle diameters of the dispersions were measured by a grind meter and an optical microscope.
In Examples 12-14 and Comparative Example 3, the resins and the resin particles used have the following physical properties:
Melting point and glass transition point:
measured with the temperature raising rate at 10° C. /minute by the differential scanning calorimeter (manufactured by Shimazu Corporation).
Softening point:
measured in accordance with JIS K2351.
Number average molecular weight (steam pressure method):
measured by the molecular weight-measuring apparatus (manufactured by Hitachi, Ltd.)
Average particle diameter:
measured by the automatic particle diameter distribution-measuring apparatus type CAPA700 manufactured by Shimazu Corporation.
Sphereness:
calculated as the ratio of the short diameter to the long diameter measured from the projected image of the sphere with the use of optical microscopes; 1.0 being a true sphere and below 1.0 being a deformed sphere.
EXAMPLES 1-5 AND COMPARATIVE EXAMPLES 1-2
Production of aqueous dispersions of polyester resin particles
The reactor was charged with 95 parts of dimethyl terephthalate, 95 parts of dimethyl isoterephthalate, 68 parts of ethylene glycol, 114 parts of neopentyl glycol and 0.1 part of zinc acetate, and ester interchange reaction was conducted at 140° C.-220° C. for 3 hours, followed by addition of 5.4 parts of 5-sodium sulfoisophthalic acid and further 1 hour's ester interchange reaction at 220°-260° C. Thereafter, 1 hour's polycondensation reaction was conducted under reduced pressure (10-0.2 mmHg) at 200°-260° C. to afford a polyester resin having the molecular weight of 2700 and Tg of 55° C. (sodium sulfonate base amount: 104 equivalent/10 6 g) as (A) resin.
After the mixture of 34 parts of the obtained polyester resin and 10 parts of butyl cellusolve was stirred at 100° C., 56 parts of water at 80° C. was added to give an aqueous dispersion (I) of the polyester having the average particle diameter of 0.1μ.
After 1000 parts of the aqueous dispersion (I) was put in a distilling flask, distillation was conducted until the fraction temperature became 100° C., followed by cooling and addition of 250 parts of deionized water, to give the aqueous dispersion (II) with 34% by weight solid.
Production of resin particles and evaluation thereof
In a four-mouthed 1 l-separable flask equipped with a thermometer, a condenser and a stirrer were put 834 parts of the aqueous dispersion (I), 35 parts of deionized water and the cationic monomer (b) as shown in Table 1, and the temperature was raised to the polymerization temperature as shown in Table 1, respectively. After 100 parts of an aqueous solution containing 0.2 part of ammonium persulfate was added over 40 minutes, polymerization was conducted and the reaction mixture was kept at said temperature for the aging time as shown in Table 1. The dispersion was subjected to spray drying to give resin particles. The evaluation results of the shape, particle diameter, and the like of the particles are also shown in Table 1.
From Table 1, it is evident that the spherical resin particles having a narrow particle diameter distribution and an optional average particle diameter can be obtained by controlling the equivalent amount of the cationic groups, the polymerization temperature and the aging time.
TABLE 1__________________________________________________________________________ Comparative The present invention Examples 1 2 3 4 5 1 2__________________________________________________________________________Species of aqueous dispersion I I I I II I IISpecies of monomer (b) DAM DAM DAM DAM/MMA DAM DAM MMAAmount of monomer (b) (part) 13 26 26 16/24 13 13 100Equivalent ratio of cation/anion 2.8 5.6 5.6 3.5 2.8 2.8 *Polymerization temperatue (°C.) 70 70 80 80 80 15 80Aging time (min.) 60 90 90 120 240 240 240Average particle diameter (D: μm) 7.6 28.6 45.5 98 7.0 0.1 0.1Occupation percentage of particles 90 87 91 85 91 -- --of 0.5 D-2.0 D (%)Occupation percentage of particles 90 86 84 82 96 -- --having sphereness of not less than0.7 (%)__________________________________________________________________________ Note: (-) means that no microspheres were obtained *: Free from cationic group DAM: Dimethylaminoethyl methacrylate MMA: Methyl methacrylate
EXAMPLE 6
In a four-mouthed 1 l-separable flask equipped with a thermometer, a condenser and a stirrer was put 250 parts by weight (with 34% by weight solid) of the aqueous dispersion (I) of the copolyester as obtained in Example 1, and the temperature of the mixture was raised to 70° C. while stirring. Thereto was added dropwise over 40 minutes 26 parts by weight of deionized water with 1.2 parts by weight of dimethylamine dissolved therein, and the mixture was stirred at 70° C. for 180 minutes, whereby the particles of the copolymer having a particle diameter in submicron order occurring in the aqueous dispersion thereof grew to yield the polyester particles having the average particle diameter D of 5.2 μm in which the occupation percentage (by weight) of the particles having a particle diameter ranging from 0.5D to 2.0D was 89% and the occupation percentage (by number) of the particles having a sphereness of not less than 0.7 was 95%.
EXAMPLE 7
In a four-mouthed 1 l-separable flask equipped with a thermometer, a condenser and a stirrer were put 250 parts by weight (with 34% by weight solid) of the aqueous dispersion (I) of the copolyester as obtained in Example 1 and 1.2 parts by weight of dimethylamine, and the temperature was raised to 70° C. under stirring, whereby the copolymer having a particle diameter in submicron order existing in the aqueous dispersion of the copolyester grew in size, and there were produced the polyester particles having the average particle diameter D of 5.2 μm in which the occupation percentage (by weight) of the particles having a particle diameter ranging from 0.5D to 2.0D was 89% and the occupation percentage (by number) of the particles having a sphereness of not less than 0.7 was 95%.
EXAMPLE 8
In a four-mouthed 1 l-separable flask equipped with a thermometer, a condenser and a stirrer were put 250 parts by weight (with 34% by weight solid) of the aqueous dispersion (I) of the copolyester as obtained in Example 1 and 8 parts by weight of acrylic acid/sodium styrenesulfonate copolymer, and the temperature was raised to 70° C. under stirring. Thereto was added dropwise over 40 minutes 26 parts by weight of deionized water with 1.55 parts by weight of sodium chloride dissolved therein, and the mixture was stirred at 70° C. for 180 minutes. Thereby the particles of the copolymer having a particle diameter in submicron order existing in the aqueous dispersion of the copolyester grew in size, and there were obtained the polyester particles having the average particle diameter D of 6.5 μm in which the occupation percentage (by weight) of the particles having a particle diameter ranging from 0.5D to 2.0D was 89% and the occupation percentage (by number) of the particles having a sphereness of not less than 0.7 was 95%.
EXAMPLE 9
In a four-mouthed 1 l-separable flask equipped with a thermometer, a condenser and a stirrer were put 250 parts by weight (with 34% by weight solid) of the aqueous dispersion (I) of the copolyester as obtained in Example 1 and 8 parts by weight of formalin condensate of sodium naphthalene sulfate, and the temperature was raised to 70° C. under stirring. Thereto was added dropwise over 40 minutes 26 parts by weight of deionized water with 1.55 parts by weight of sodium chloride dissolved therein, followed by 180 minutes' stirring at 70° C. Thereby the particles of the copolymer having a particle diameter in submicron order existing in the aqueous dispersion of the copolyester grew in size, and there were obtained the polyester particles having the average particle diameter D of 6.5 μm in which the occupation percentage (by weight) of the particles having a particle diameter ranging from 0.5D to 2.0D was 84% and the occupation percentage (by number) of the particles having a sphereness of not less than 0.7 was 95%.
EXAMPLE 10
In a four-mouthed 1 l-separable flask equipped with a thermometer, a condenser and a stirrer was put 250 parts by weight (with 34% by weight solid) of the aqueous dispersion (I) of the copolyester as obtained in Example 1, and the temperature was raised to 70° C. under stirring. Thereto was added dropwise over 40 minutes 26 parts by weight of deionized water with 1.55 parts by weight of sodium chloride dissolved therein, followed by 180 minutes' stirring at 70° C. Thereby the particles of the copolymer having a particle diameter in submicron order existing in the aqueous dispersion of the copolyester grew in size, and there were obtained the polyester particles having the average particle diameter D of 4.8 μm in which the occupation percentage (by weight) of the particles having a particle diameter ranging from 0.5D to 2.0D was 72% and the occupation percentage (by number) of the particles having a sphereness of not less than 0.7 was 98%.
EXAMPLE 11
1 Preparation of polyester polyol
In an autoclave equipped with a thermometer and a stirrer were put 392 parts by weight of dimethyl terephthalate, 392 parts by weight of dimethyl isophthalate, 310 parts by weight of ethylene glycol and 520 parts by weight of neopentyl glycol, and the mixture was reacted by heating at 200° C. under stirring for 360 minutes until the methanol fraction became 252 parts by weight. Thereafter, the reaction mixture was cooled to 120° C., and 292 parts by weight of adipic acid was added. After the temperature was again raised to 200° C., the mixture was reacted for 480 minutes to afford the polyester polyol.
2 Urethanation and preparation of aqueous dispersion of polyurethane
Dehydration of 100 parts by weight of the obtained polyester polyol was conducted at 120° C. under reduced pressure, and the product was cooled to 80° C., followed by addition of 100 parts by weight of methyl ethyl ketone and stirring of the mixture for dissolution. Thereafter, 65.3 parts by weight of tolylene 2,4-diisocyanate and 17.7 parts by weight of 2,2-dimethylol propionate as a chain extender were added, and the mixture was reacted at 70° C. for 10 hours. After completion of the reaction, the reaction mixture was cooled to 40° C., and 12.3 parts by weight of piperazine and 13.3 parts by weight of triethylamine were added for chain extension and neutralization, followed by addition of 500 parts by weight of water under stirring to afford the aqueous dispersion of polyurethane.
3 Production of polyurethane particles
In a four-mouthed 5 g-separable flask equipped with a thermometer, a condenser and a stirrer were put 800 parts by weight of the obtained aqueous dispersion of the polyurethane, 800 parts by weight of deionized water and 25 parts by weight of dimethylaminoethyl methacrylate, and the temperature was raised to 70° C. After 100 parts by weight of an aqueous solution containing 0.2 part by weight of ammonium persulfate was added dropwise over 30 minutes, the mixture was reacted at 70° C. for further 20 minutes. Thereby, the micro-dispersed particles having a particle diameter in submicron order existing in the aqueous dispersion of the polyurethane coalesced and grew in size to yield the polyurethane particles having the average particle diameter D of 7.5 μm in which the occupation percentage (by weight) of the particles having a particle diameter ranging from 0.5D to 2.0 D was 92% and the occupation percentage (by number) of the particles having a sphereness of not less than 0.7 was 95%.
EXAMPLE 12
In an autoclave equipped with a thermometer and a stirrer were put 94 parts by weight of dimethyl terephthalate, 95 parts by weight of dimethyl isophthalate, 89 parts by weight of ethylene glycol, 80 parts by weight of neopentyl glycol and 0.1 part by weight of zinc acetate, and ester interchange reaction was conducted by heating at 120°-230° C. for 120 minutes. Thereto was added 6.7 parts by weight of 5-sodium sulfoisophthalic acid, and the mixture was reacted at 220°-230° C. for 60 minutes. After the temperature was raised to 250° C., the reaction was conducted with the system pressure reduced to 1-10 mmHg for 60 minutes to give the copolyester (A1).
The obtained copolyester (A1) had the molecular weight of 2700 and the amount of the sulfonic acid metal salt group was 118 equivalent/1000000 g. The amount of the sulfonic acid metal salt group was decided by measuring the concentration of sulfur of the copolyester. From the results of NMR analysis, the copolyester (A1) contained 48.5 mol % of terephthalic acid, 49.0 mol % of isophthalic acid and 2.5 mol % of 5-sodium sulfoisophthalic acid as the acid component, and 61.0 mol % of ethylene glycol and 39.0 mol % of neopentyl glycol as the glycol component.
In a four-mouthed 1 l-separable flask equipped with a thermometer, a condenser and a stirrer were put 34 parts by weight of the obtained copolymer polyester (A1) and 10 parts by weight of butyl cellusolve, and the mixture was dissolved at 110° C., whereafter 56 parts by weight of water at 80° C. was added to give the aqueous dispersion of the copolymer polyester (B1).
In a four-mouthed 1 l-separable flask equipped with a thermometer, condenser and a stirrer were put 834 parts by weight of the aqueous dispersion of the copolymer polyester (B1), 35 parts by weight of deionized water and 5.6 parts by weight of dimethylaminoethyl methacrylate, and the temperature was raised to 70° C. After 100 parts by weight of an aqueous solution containing 0.2 part by weight of ammonium persulfate was added dropwise over 40 minutes, the mixture was reacted at 70° C. for 60 minutes. Thereby, the particles of the copolymer having a particle diameter in submicron order existing in the aqueous dispersion of the copolymer polyester grew in size to yield the polyester particles (C1) having the average particle diameter D of 8.7 μm in which the occupation percentage (by number) of the particles having a particle diameter ranging from 0.5D to 2.0D was 92% and the occupation percentage of the particles having a sphereness of not less than 0.7 was 89% by number average.
By adding water to the obtained polyester particles (C1), 20% by weight of the aqueous dispersion of the polyester particles (D1) was obtained.
To 500 parts by weight of the obtained aqueous dispersion of the polyester particle (D1) was added a dispersion of 10 parts by weight of Sumikaron.yellow SE-5G (C.I. disperse yellow 5), a disperse dye manufactured by Sumitomo Chemical Co., Ltd., in 100 parts by weight of water, and the mixture was heated at 130° C. under stirring and kept standing still for 60 minutes. Thereafter, cooling, filtration and washing were conducted, followed by spray drying to afford the yellow toner (E1Y).
In the same manner, the magenta toner (E1M) and the cyan toner (E1C) were obtained from the dispersion of the polyester particles (D1) with the use of Sumikaron.red E-FBL (C.I. disperse.red 60) and Sumikaron.blue E-FBL (C. I. disperse.blue 56), a disperse dye manufactured by Sumitomo Chemical Co., Ltd.
The obtained color toners, respectively in the amount of 5 parts by weight, were mixed with 95 parts by weight of carrier (spherical reduced iron powders having the average particle diameter of 80 μm) to yield two-component developing agents for electrophotography.
The electrification of the toners after mixing with carriers were as follows:
(E1Y)-75 μC/g
(E1M)-68 μC/g
(E1C)-60 μC/g
Using said developing agents, consecutive copies on 5000 sheets of paper were made by an electrophotographic color copier with an amorphous silicon as the photosensitive material. The obtained copies were free from thin spots or fogs, showing clear and fine images.
Using the developing agents, copies on transparent films for overhead projectors were made in the same manner. The obtained copies were excellent in spectral transmittance, and the images projected on the screen by the overhead projection were free from turbidity and showed clear color tone.
There were not found any particular problems in humidity-dependency in electrification characteristics, flowability and insulation capability, fixing characteristics, sharpmelt characteristics, offset resistance and other characteristics.
EXAMPLE 13
In an autoclave equipped with a thermometer and a stirrer were placed 815 parts by weight of dimethyl-terephthalate, 320 parts by weight of dimethyl isophthalate, 491 parts by weight of ethylene glycol, 549 parts by weight of neopentyl glycol and 0.6 part by weight of zinc acetate, and ester interchange reaction was conducted by heating at 180°-230° C. for 120 minutes, followed by addition of 40 parts by weight of 5-sodium sulfoisophthalic acid. The mixture was reacted at 220°-230° C. for 60 minutes, and then the temperature was raised to 250° C. Thereafter, the reaction was continued with the pressure of the system reduced to 1-10 mmHg, to give the copolyester (A2).
The obtained copolyester (A2) had the molecular weight of 2500 and the amount of the sulfonic acid metal salt groups was 116 equivalent/1000000 g, which was calculated by measuring the concentration of sulfur of the copolymer polyester. From the results of NMR analysis, the copolyester (A2) contained
______________________________________terephthalic acid 70.0 mol %,isophthalic acid 27.5 mol % and5-sodiumsulfoisophthalic acid 2.5 mol % as the acidcomponent andethylene glycol 48.0 mol % andneopentyl glycol 52.0 mol % as thealcohol component.______________________________________
Roughly pulverized pieces of 100 parts by weight of the obtained copolyester (A2) and 5 parts by weight of azo yellow pigments were mixed and pulverized in a ball mill. Then, the mixture was fluxed in a roll mill to yield the colored copolyester (A2Y).
In a four-mouthed 1 -separable flask equipped with a thermometer, a condenser and a stirrer, 34 parts by weight of the obtained colored copolyester (A2Y) and 10 parts by weight of butyl cellusolve were fluxed at 110° C., whereafter 56 parts by weight of water at 80° C. was added to give the aqueous dispersion of the colored copolycster (B2Y).
In a four-mouthed 1l-separable flask equipped with a thermometer, a condenser and a stirrer were put 834 parts by weight of the aqueous dispersion of the colored copolyester (B2Y), 35 parts by weight of deionized water and 5.6 parts by weight of dimethylaminoethyl methacrylate, and the temperature was raised to 70° C. After 100 parts by weight of an aqueous solution containing 0.2 part by weight of ammonium persulfate was added dropwise thereto over 40 minutes, the reaction was conducted at 70° C. for further 60 minutes. Thereby, the particles of the copolymer of a particle diameter in submicron order existing in the aqueous dispersion of the colored copolymer polyester grew in size to yield the polyester particles (C2Y) having the average particle diameter D of 6.7 μm in which the occupation percentage by number average of the particles having a sphereness of not less than 0.7 was 85% and the occupation percentage (by number) of the particles having a particle diameter ranging 0.5 D to 2.0D was 92%.
Subsequent cooling, filtration, washing and spray drying afforded the yellow polyester particles (D2Y). In the same manner, with the use of a rhoddamine red pigment and a phthalocyanine blue pigment, the magenta polyester particles (D2M) and the cyan polyester particles (D2C) were obtained respectively.
By the Hosokawa's atomizer, 100 parts by weight of the obtained yellow polyester particles (D2Y) and 5 parts by weight of acryl micropowders MP-1000 (manufactured by Soken Kagaku, Ltd.) were admixed, and by coating silica micropowders on the surface of the polyester particles, the yellow toner (T2Y) was obtained. In the same manner, the magenta toner (T2M) and the cyan toner (T2C) were obtained.
The obtained colored toners respectively in the amount of 5 parts by weight were mixed with 95 parts by weight of carrier (spherical reduced iron powders having the average particle diameter of 80 μm), to yield the two-component developing agents for electrophotography. The electrification amount of the toners after mixing with the carrier were respectively as follows:
(T2Y)-99 μC/g
(T2Y)-87 μC/g
(T2Y)-93 μC/g:
Using the obtained developing agents, consecutive copies on 5000 sheets of paper were made by an electrophotographic copier with an amorphous silicon used as the photosensitive material. The obtained copies were free from thin spots or fogs, showing clear and excellent images.
There were not found any particular problems in respect of humidity-dependency of electrification characteristics, flowability and insulation characteristics; sharpmelt characteristics; offset resistance and other characteristics.
COMPARATIVE EXAMPLE 3
By mixing 90 parts by weight of the copolyester (A2) as obtained in Example 10 with 10 parts by weight of an azo yellow pigment, a rhodamine red pigment or a phthalocyanine blue pigment in a ball mill respectively in advance, fluxing the mixture in a roll mill, pulverising by an atomizer and classifying, the colored polyester particles (D5Y), (D5M), (D5C) having the average particle diameter of 11 μm were obtained respectively.
By mixing 100 parts by weight of the obtained colored polyester particles and 5 parts by weight of acryl micropowders MP-1000 (Soken Chemical, Ltd.) and coating silica micropowders on the surface of the polyester particles by a mechanofusion means by the Hosokawa's atomizer, the yellow toner (T5Y), the magenta toner (T5M) and the cyan toner (T5C) were obtained.
In the same manner as in Examples, the obtained color toners respectively in the amount of 5 parts by weight were mixed with 95 parts by weight of a carrier (spherical reduced iron powders having the average particle diameter of 80 μm) to give the two-component developing agents for electrophotography.
The electrification amounts of the toners after mixing with the carrier were respectively as follows:
(T5Y)-34 μC/g
(T5M)-37 μC/g
(T5C)-29 μC/g
Using these developing agents, consecutive copies on 5000 sheets of paper were made by an electrophotographic copier with an amorphous silicon used as the photosensitive material therein, in the same manner as in Example 10. The obtained copies included many thin spots in fine lines and failed to show clear images.
EXAMPLE 14
By mixing 100 parts by weight of the roughly pulverized pieces of the copolyester (A1) obtained in Example 9, 5 parts by weight of carbon black and 30 parts by weight of ferrite magnetic powders in a ball mill and pulverizing, followed by fluxing in a roll mill, the copolymer polyester (A4Y) was obtained.
In a four-mouthed 1 l-separable flask equipped with a thermometer, a condenser and a stirrer were put 34 parts by weight of the obtained copolyester (A4Y) and 10 parts by weight of butyl cellusolve, and the mixture was fluxed at 110° C., followed by addition of 56 parts by weight of water at 80° C. to yield the aqueous dispersion of the copolyester (B4Y).
In a four-mouthed 1 l-separable flask equipped with a thermometer, a condenser and a stirrer were put 834 parts by weight of the aqueous dispersion of the colored copolyester (B4Y), 35 parts by weight of deionized water and 5.6 parts by weight of dimethylaminoethyl methacrylate, and the temperature was raised to 70° C. Thereafter, 100 parts by weight of an aqueous solution containing 0.2 part by weight of ammonium persulfate was added dropwise over 40 minutes, and the reaction was continued at 70° C. for another 60 minutes. Thereby, the particles of the copolymer having a particle diameter in submicron order existing in the aqueous dispersion of the colored copolymer polyester grew in size to yield the polyester particles (C4Y) having the average particle diameter D of 6.7 μm in which the occupation percentage (by number) of the particles having a particle diameter ranging from 0.5D to 2.0D was 92% and the occupation percentage (by number average) of the particles having a sphereness of not less than 0.7 was 92%. Subsequent cooling, filtration, washing and drying in vacuum gave the yellow polyester developing agent (D4Y).
Using these developing agents, consecutive copies on 5000 sheets of paper were made by an electrophotographic laser printer with OPC used as the photosensitive material. The obtained copies were free from thin spots or fogs, showing clear and fine images.
There were not found any particular problems in flowability, fixing characteristics, sharpmelt characteristics, offset resistance and other characteristics. | Spherical resin particles in micron order with a narrow particle diameter distribution, methods for the production thereof and uses thereof are disclosed. Overcoming various problems comprised in the hitherto-known polymerization granulation methods, resin particles using a condensation polymer in micron order of the present invention having spherical form and narrow particle diameter distribution serve well for various applications. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Priority is claimed from U.S. Provisional Patent Application 61/191,692, filed 10 Sep. 2008, which is hereby incorporated by reference.
BACKGROUND
[0002] Since the inception of modern chromatography, silica based stationary phases have dominated the world of chemical separations. Unfortunately, silica has certain limitations. Under acidic conditions, silica tends to lose its functionality and under basic conditions it dissolves entirely after a matter of hours. Not until recently have alternatives to silica been available such as polymer based stationary phases. These tend to swell when exposed to organic solvents and are therefore not ideal for reversed-phase separations.
[0003] Chemists have worked around the limitations of available stationary phases, but these workarounds often result in less than ideal outcomes. For instance, certain separations may need to occur under basic or acidic conditions because the analyte of interest may only be stable under a certain pH range. It is would therefore be ideal to find a phase that could perform a separation under extreme pHs that current phases cannot successfully do separations at.
[0004] Diamond has usually been assumed to be inert and relatively little has been done to investigate the possibility of diamond as the basis for a stationary phase. Nosterenko et al. has performed separations of proteins using oxidized/cleaned diamond and Saini et al. has been successful in coating the diamond surface with poly(allylamine). This coated diamond was then used as a normal phase in Solid-phase Extraction (SPE). Saini's study also showed that his phase was extremely stable under extreme pH conditions (from pH 0-pH 14) for 24 h. The SPE column was able to be reused many times and showed no signs of degradation. It also performed in the same manner experiment after experiment and only required a flush with ethyl acetate in between uses.
[0005] These two groups have shown that separations can indeed be performed with diamond as the basis for a stationary phase. Nesterenko's study lacked good resolution in it HPLC spectra and Saini's capacity was quite low, but efforts are being made to remedy the capacity issue.
CITED REFERENCES
[1] US Patent 20050189279
[2] US Patent 20040118762
SUMMARY
[0006] A new phase is directly bonded to the diamond surface which has been largely hydroxyl terminated. In a specific example, diamond cleaned with piranha solution is treated with lithium aluminum hydride (LAH). This reaction greatly increases the amount of hydroxyl groups on the diamond surface. Since hydroxyl groups are reactive to various functional groups, this chemistry is exploited to attach ligands directly to the diamond surface. For example, isocyanates and acyl halides (primarily Br and Cl) are reactive to the hydroxyl functional group and form urethane and ester linkages respectively, that are directly bonded to the diamond surface. (See FIG. 1 )
[0007] Bases do have the ability to hydrolyze this linkage at the carbonyl site, so bulky groups (methyl, isopropyl, tert-butyl, phenyl etc.) can be attached to the α-carbon of the ligand to sterically hinder the binding site and prevent bases from accessing the partially negative carbon. This should give this type of linkage greater stability in the presence of acids and bases. The reusability and consistency of the column is also expected to be similar to that of Saini's column and this chemistry can be applied to HPLC and SPE stationary phases.
[0008] An aspect is a method for preparing modified diamond particles for use in chromatography where hydroxyl groups at the diamond surfaces are reacted with a reactive molecule to introduce a desired functional group at the diamond surface. An example is the reaction of Isocyanates and acyl halides with hydroxyl-terminated diamond to form HPLC/SPE stationary phases.
[0009] Another aspect is a method for preparing modified diamond particles for use in chromatography where i) diamond particles are reacted with an oxidizing agent that introduces carboxyl groups at the surface of the diamond, ii) the carboxyl groups are reduced to primary alcohols, and iii) the primary alcohols are reacted with a reactive molecule to introduce a desired functional group at the diamond surface.
[0010] The diamond particles of the present method can by used in any suitable type of chromatography type. These include, for example, high performance liquid chromatography (HPLC), ultra performance liquid chromatography (HPLC), solid phase extraction, electrochromatography, size-exclusion chromatography, ion chromatography, affinity chromatography.
[0011] The chromatography may be practiced at any suitable pressure, such as for example, between 1000 psi and 15000 psi.
[0012] The diamond surface may be prepared by reducing the surface with a suitable reducing agent prior to reaction with the reactive molecule. Any suitable reducing agent is contemplated, such as, for example, lithium aluminum hydride.
[0013] The reactive function group may be any suitable functional group with the desired reactivity, and may have attached to the reactive group an alkyl group or aryl group. The alkyl group may have the form —(CH 2 ) n CH 3 , where n=0-25. The alkyl group may be branched or unbranched. The alkyl group may be partially or fully fluorinated, The aryl group may have the form —C 6 H 6 . The aryl group may be partially or fully fluorinated.
[0014] Examples of the reactive functional groups include, one of or a mixture of an alkyl isocyanate, an aryl isocyanate, an acid chloride with an aromatic group, an acid chloride with an alkyl group, an acid bromide, an alkyl halide, an aryl halide, a benzyl halide, a benzyl triflate, a benzyl mesylate, an alkyl mesylate, an alkyl tosylate, and an alkyl triflate.
[0015] The reactive functional group may contain more than one other group near the reactive site of the molecule, which provides steric hindrance for the adsorbed species.
[0016] The reactive molecule may contain C—H bonds. The reactive molecule may contain an electrophilic site and a leaving group.
[0017] Another aspect is a diamond particle for use in chromatography containing groups tethered to the diamond surface through ether, ester, or urethane linkages.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 : Scheme outlining basic chemistry for the formation of the isocyanate and acyl halide reacted diamond particles
[0019] FIG. 2 : Spectra confirming the step by step synthesis of a carbamide linked C 18 chain to the diamond surface
[0020] FIG. 3 : Possible examples of the types of groups attached at the α-carbon site to increase sterics of the area in order to prevent nucleophilic attack of a base at the carbonyl resulting in hydrolysis of the ether or urethane linkage.
DETAILED DESCRIPTION
Example
Experimental
[0021] Micro-diamond or diamond powder is treated with piranha solution (3:7 30% H 2 O 2 :conc. H 2 O 2 :conc. H 2 SO 4 ) or any other suitable cleaning/etching solution. This cleans/etches the diamond surface and exposes the various functional groups that naturally occur on the diamond surface. The diamond must be dried thoroughly before the next step. This can be performed by pulling argon through the powder or placing the powder in a vacuum for many hours. The dryness can be verified by diffuse reflectance infrared Fourier transform (DRIFT).
[0022] The cleaned dry diamond is then treated with 1M LiAlH 4 (LAH) suspended in THF (or any other strongly reducing base) [1] for 24-68 h at room temperature (about 1 g diamond:5 mL LAH solution). Warning: LAH is extremely reactive to water. Use proper PPE. The reaction must be performed under inert atmosphere (argon) and all glassware must be dry. The reaction is quenched by 1M HCl. This should be added very slowly due to the reactivity of LAH with water and HCl. Once the reaction is quenched, the diamond is filtered over a fine fritted Buchner funnel and washed with copious amounts of water. If white particles are present, rinse with more 1 M HCl to dissolved the reacted LAH. Once thoroughly rinsed, the powder is dried completely. This gives hydroxyl terminated diamond.
[0023] The reduced surface has been disclosed US patent [1], the reaction of the hydroxylated surface with various functional groups is not disclosed. The present method is an improvement over the disclosed diamond-based chromatographic processes.
[0024] Another US patent [2] discloses powders “attached with hydrocarbon, amino, carboxylic acid, or sulfonic acid groups.” The present method is specifically targeting the reaction of the hydroxylated surface with a reactive molecule to introduce a desired functional group at the diamond surface, such as, for example, reactive isocyanates and acyl halides, and this chemistry and these functional groups are not disclosed.
[0025] In a specific example, for this final step the hydroxyl terminated diamond is then placed in a reaction vessel which is subsequently flushed with inert atmosphere. Then a reactive molecule is added to the powder. For example, a desired isocyanate or acyl halide is added to the powder (about 0.5 mL:1 g hydroxyl terminated diamond) then add enough dry tetrahydrofuran (THF) or ether to completely dissolve the isocyanate or acyl halide. The reaction should then react for at least 18 h at room temperature. Filter the diamond over a fine fritted Buchner funnel and wash with a large amount of THF or ether to rinse away the unreacted isocyanate or acyl halide. Dry the powder completely. The powder is then suspended in a solvent and pressed into an HPLC column.
[0026] Results and Discussion
[0027] Thus far, only octadecyl isocyanate has been reacted with the hydroxyl terminated diamond. The evidence of the successive reactions can be seen in FIG. 2 by the DRIFT, ToF-SIMS and XPS spectra. There is a decrease in the height of the alcohol peak (˜3500 cm −1 ) seen in the octadecyl isocyanate DRIFT spectrum as compared to the LAH spectrum. It is clear that not all of the alcohol functional groups are reacted and this is attributed to the steric hindrance of the diamond surface. The 2° amine peak at 3342.43 cm −1 , asymmetric and symmetric C—H stretches at 2920.95 cm −1 and 2848.21 cm −1 and the carbonyl stretches at 1612.33 cm −1 and 1572.64 cm −1 are indicative of successful bonding of octadecyl isocyanate to the hydroxyl terminated surface as evidenced by the urethane (carbamide) linkage.
[0028] The ToF-SIMS data shows an increase of hydrocarbon fragments in the positive ion spectra and a decrease of O (16 m/z) and OH (17 m/z) fragments in the negative ion spectra. This result is predicted because fewer O and OH groups would be exposed on the diamond surface once the isocyanate group has reacted with the OH functional group. The XPS spectrum shows the presence of nitrogen which is absent from the piranha and LAH treated diamond powders. The only source of nitrogen in this experiment is from the isocyanate group. This therefore further confirms the formation of the carbamide linkage on the diamond surface.
[0029] In another embodiment, an HPLC column is packed with 5 μm octadecyl isocyanate reacted diamond powder. If non-porous diamond is used, few plates are expected to be present on the column. This should be remedied by using porous diamond powder.
[0030] The chemistry of the present method is expected to work with various isocyanates and acyl halides, including compounds with the disubstituted α-carbons (see FIG. 3 for some examples). The acyl halide derivatives of these compounds would also be used including the tert-butyl group not shown in the figure. Other functional groups past the functionalized α-carbon could include but are not limited to phenyl, naphthyl, chiral, perfluorinated, C 8 , and C 10 .
CONCLUSION
[0031] The chemistry for creating urethane (carbamide) linkages to the diamond surface is straight forward and should prove useful in the creation of diamond-based HPLC and SPE stationary phases. The attachment of octadecyl isocyanate to the diamond surface has been verified and other isocyanates/acyl halides should also react in a similar manner to the hydroxyl terminated diamond surface.
[0032] Once a diamond-based HPLC column is successfully created and used, the added stability, reusability and consistency of these diamond columns will exceed that of its similarly functionalize silica-based counterparts. This strength comes from the urethane and/or ester linkages which bind the diamond and the functional group together. This will result in greater stability at more extreme pHs and the disubstituted α-carbon should help increase the stability further in basic conditions.
[0033] While invention has been described with reference to certain specific embodiments and examples, it will be recognized by those skilled in the art that many variations are possible without departing from its scope and spirit, and that any invention, as described by the claims, is intended to cover all changes and modifications that do not depart from the spirit of the invention. | A method for preparing modified diamond particles for use in chromatography where hydroxyl groups at the diamond surfaces are reacted with a reactive molecule to introduce a desired functional group at the diamond surface. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 12/533,025, filed Jul. 31, 2009 (Attorney Docket 01378 CON), now issued as U.S. Pat. No. ______, which is a continuation of U.S. application Ser. No. 10/017,630, filed Dec. 14, 2001 (Attorney Docket 01378), now issued as U.S. Pat. No. 7,587,323, with both applications incorporated herein by reference in their entirety.
[0002] This application relates to U.S. application Ser. No. 10/017,742, filed Dec. 14, 2001 (Attorney Docket 01341), and incorporated herein by reference in its entirety. This application also relates to U.S. application Ser. No. 09/496,825, filed Feb. 1, 2000 and now issued as U.S. Pat. No. 6,983,478 (Attorney Docket 95003 CON), and incorporated herein by reference in its entirety.
NOTICE OF COPYRIGHT PROTECTION
[0003] A portion of the disclosure of this patent document and its figures contain material subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, but otherwise reserves all copyrights whatsoever.
FIELD OF THE INVENTION
[0004] The present invention generally relates to the measurement of content-access patterns. The present invention more particularly relates creating content related to subscriber content-access patterns and associated behaviors.
BACKGROUND
[0005] Individuals receive information and entertainment content from a wide variety of media sources. These sources include radio, newspapers, the Internet, and television content providers.
[0006] To support the creation and distribution of content, providers must derive revenue from the content. For example, television content providers derive substantial revenues from advertising. During the broadcast of a television program, advertisements, in the form of commercials, are inserted at various time intervals. An advertiser pays the broadcaster to insert the advertisement. Other sources of revenue include pay-per-view, subscription, and licensing fees paid by subscribers for specific content or content-related packages. Internet content providers derive revenue in similar ways.
[0007] The amount of money that an advertiser pays is related to the number of subscribers watching or accessing a broadcast. Conventionally, for television advertising, advertising revenue equals a rate per thousand viewers multiplied by the number of viewers estimated to be viewing a program. Web site content providers charge advertisers a fixed amount per advertising impression. Also, Pay-per-view, subscriptions, and licensing fees all increase as the number of viewers of content increase. Therefore, the higher the number of viewers or subscribers accessing content, the greater the revenue.
[0008] In the case of television programming, if a program is popular, the provider charges a higher advertising rate. In contrast, if a television program cannot produce at least as much revenue as it costs to produce the program, the provider will generally cancel the program. Therefore, television-programming providers are very interested in determining the popularity of specific programs.
[0009] Additional factors beyond the popularity of a program may affect the number of viewers who watch it. For example, a program scheduled adjacent to a popular program or between two popular programs may attain higher ratings than it might achieve without such opportune scheduling. A similar effect occurs on web sites. A large number of web site users may read content posted on a popular web site. However the same piece appearing on a less popular site may attract little attention. Therefore, content providers are interested in determining the interrelationships between various combinations of content and content types.
[0010] Conventional television programs and programming packages are designed to appeal, to the extent possible, to a large group of individual subscribers. Appealing to a large number of subscribers requires compromises that may lessen the appeal of a particular program or programming package to any one individual subscriber. And the less the appeal of a particular programming package to a subscriber, the less the subscriber will pay for the package. These same compromises are required when an advertiser produces a marketing campaign for use in television or creates a marketing bundle, which combines a programming or advertising package with products and services.
[0011] Content providers conventionally utilize various methods to evaluate the popularity of content and to evaluate the interrelationships between content. For example, a television-programming provider may implement a program of voluntary logging of television viewing by a viewer, followed by transmission and human processing to analyze the information contained in the log. In addition, a provider may utilize telephone, mail, or other types of surveys to inquire from random or selected viewers about the viewers' viewing habits and request their recollections regarding their viewing patterns. A provider may also utilize automated monitoring systems that attempt to intercept television channel choices and changes, record these events, and provide the recording to a clearinghouse or other facility for further processing.
[0012] The provider may enlist a ratings company to perform the monitoring and processing. For example, Nielsen Media Research (Nielsen Media Research, Inc., New York, N.Y.), Arbitron (Arbitron Inc., New York, N.Y.), and MeasureCast (MeasureCast, Inc., Portland, Oreg.) provide third-party monitoring and processing capability for television, radio, and Internet content.
[0013] The Nielsen Media Research (Nielsen) Ratings are perhaps the best known of the various third-party ratings services. Nielsen utilizes a variety of conventional sampling methods to determine the number of viewers watching a particular show. For example, in five thousand homes, Nielsen installs a People Meter. The People Meter records viewing patterns from television sets, cable television set-top boxes, videocassette recorders, satellite television set-top boxes, and other sources of television programming. The People Meter records what content the particular device is providing on an ongoing basis and periodically transmits this information to servers within a Nielsen facility. Nielsen combines the data uploaded from the People Meter with media content data to determine what programming and advertising a device displayed. Nielsen uses the combined data to provide a rating for each program and advertisement. In conjunction with the People Meter, Nielsen also utilizes viewer diaries and surveys to gather information from a broader spectrum of television viewers and to confirm the results generated by the People Meter.
[0014] Arbitron Inc. (Arbitron) is well known for providing radio broadcast ratings. Arbitron compiles ratings by utilizing surveys. Arbitron also provides television ratings based on various sampling techniques. In cooperation with Nielsen, Arbitron has developed a Portable People Meter to measure television ratings. The Portable People Meter is a pager-sized device, worn by a participant in a survey. The Portable People Meter records viewing by recording sounds encoded into each broadcast, which identify the program or advertisement. The survey participant periodically plugs the Portable People Meter into a recharger, which also includes a communicator that uploads the data in the Portable People Meter into a remote Arbitron server. The Portable People Meter may be a more accurate method of television ratings than a set-top box, such as the set-top box used by Nielsen. The Portable People Meter offers the advantage of capturing viewing outside of the home and of recognizing when the viewer is not within audible range of a television, and therefore, less likely to be viewing a particular program or advertisement.
[0015] As the use of the Internet increases, the distribution of programming via Internet channels becomes more important. MeasureCast, Inc. (MeasureCast) provides a ratings system for Internet media streaming. MeasureCast records the number of streams requested from a streaming server and provides reports to programming providers and advertisers detailing the popularity of particular streams. As is the case in traditional broadcast media, the more popular the stream, the higher the advertising rate a broadcaster is able to charge.
[0016] Nielsen, Arbitron, and MeasureCast provide direct methods of measuring the popularity of a program. Various indirect methods are also used to determine the popularity of programming and the effectiveness of advertising. For example, advertising effectiveness is often measured in terms of viewer attitudes and subsequent viewer actions, such as purchases, inquiries, behavior changes, and other actions. Method of obtaining these indirect measures include: focus group tests, post-advertising surveys questioning whether an advertisement was viewed, remembered and possible impact, and measures of product purchases or other indirect results that may indicate whether or not an advertising campaign has been successful.
[0017] Conventional systems and methods for determining subscriber content-access patterns and preferences are inefficient and poorly suited for the immediate, timely creation of customized content. In addition, conventional systems, such as the Nielsen and Arbitron meters rely on extremely small samples, which may not be representative of the target market for a particular advertiser.
[0018] Also, surveys are expensive and highly dependent on identifying individuals that may have been viewing television at the time of the advertisement. And post-advertising results measurements suffer from questions of causality and external influences. Focus groups allow reasonably efficient low-volume viewer analysis, but statistical analysis requires an adequate number of participants and tightly controlled tests, a combination that may be difficult to achieve.
[0019] Conventional systems and methods lack simple, effective, and efficient means for determining content genre preferences. Conventional systems and methods also lack simple and efficient means for determining the duration of viewing patterns, especially as those patterns are affected by the genre or type of content, the time-of-day of a broadcast, and the content broadcast simultaneously with or adjacently to the content of interest.
SUMMARY
[0020] The present invention provides systems and methods for tailoring media content and related offerings to individual subscribers. An embodiment of the present invention includes a subscriber database, a data analyzer electronically connected to the subscriber database, and a distribution server. The data analyzer uses subscriber attributes in the subscriber database to create tailored content and content-related offerings. The tailored content is subsequently distributed by the distribution server.
[0021] The subscriber database includes attributes of a subscriber as well as a media-content-access history of the subscriber. Attributes of a subscriber include demographic measures of the subscriber. The media-content-access history of the subscriber may comprise a subscriber content-choice database.
[0022] In order to merge content and subscriber actions, an embodiment of the present invention includes a merge processor and national and local content databases. Also, in order to categorize programming and advertising, in an embodiment of the present invention, a category database is electronically linked to the media-content database. The category database may comprise a program category or genre database and/or an advertisement category database. The merge processor operates to assign a category to a media-content detail and create a content choice record by merging a subscriber action detail with the categorized media-content detail. An embodiment of the present invention may comprise a computer-readable medium comprising computer code to implement the process.
[0023] In another embodiment of the present invention, the merge processor receives a series of subscriber actions, merges the actions with media-content detail, and then attempts to correlate the actions with one another. The merge processor may also assign a category to the media-content detail and perform a probability analysis on the subscriber content choice information created as a result of the process in order to predict future subscriber actions.
[0024] In an embodiment of the present invention, a subscriber action database may contain additional information, including a subscriber identifier and a clickstream database. The media-content database includes programming and/or advertising content. In various embodiments of the present invention, programming and advertising information may be included in a single database or in multiple databases. Each of these databases includes a common key data element.
[0025] An embodiment of the present invention provides numerous advantages over conventional systems for using subscriber content-choice information to tailor content-related offerings for individual subscribers or to small groups of subscribers.
[0026] It is difficult and inefficient in conventional systems to tailor content-related offerings because the information necessary to tailor the offerings is often unavailable. In an embodiment of the present invention, the necessary subscriber-specific data is made available by merging subscriber content choices with various other subscriber attributes. Content providers are able to tailor content-related offerings and charge a premium for these offerings.
[0027] Further details and advantages of the present invention are set forth below.
BRIEF DESCRIPTION OF THE FIGURES
[0028] These and other features, aspects, and advantages of the present invention are better understood when the following Detailed Description is read with reference to the accompanying drawings, wherein:
[0029] FIG. 1 is a diagram of an exemplary embodiment and an exemplary environment for operation of an embodiment of the present invention.
[0030] FIG. 2 is a flowchart illustrating a process implemented by a merge processor in an embodiment of the present invention.
[0031] FIG. 3A is a table illustrating various sources of programming and advertising content available to a subscriber during a period of time in an embodiment of the present invention.
[0032] FIG. 3B illustrates content displayed on a subscriber's television during a period of time in an embodiment of the present invention.
[0033] FIG. 4 is a flowchart illustrating the process of merging the data shown in FIG. 3A to create the merged data shown in FIG. 3B in an embodiment of the present invention.
[0034] FIG. 5 is a table illustrating the programming viewed by the subscriber during the period shown in FIGS. 3A , 3 B, and 4 in an embodiment of the present invention.
[0035] FIG. 6 is a flowchart illustrating a method of analyzing the data collected and combined in the subscriber database to formulate a new programming offering in an embodiment of the present invention.
DETAILED DESCRIPTION
[0036] Embodiments of the present invention provide systems and methods for creating tailored television content-related offerings based on subscriber-specific data. In an embodiment of the present invention, a offering may be tailored based solely on subscriber content choices or based on subscriber content choices in combination with other attributes of the subscriber such as demographics, purchasing history, and/or other relevant attributes.
[0037] Various types of offerings may be made available in an embodiment of the present invention. For example, a cable television content provider may create a direct marketing campaign based on subscriber data. In addition, a television content provider may create a programming offering tailored to an individual subscriber's needs and measured preferences. In an embodiment of the present invention, a content provider also determines an individual subscriber's willingness to pay for a programming offering based on subscriber-related information.
[0038] In another embodiment of the present invention, a television content provider utilizes information in a subscriber database to develop incentives, which are made available to viewers evidencing “desirable viewer patterns.” Such special incentives would be of value to advertisers as well as to television program providers. In addition, a content provider may use the information available in an embodiment of the present invention to bundle programming offerings with other products and services.
[0039] In an embodiment of the present invention, a subscriber's television viewing patterns are combined with programming and advertising media-content detail to determine the subscriber's content choices. These content choices are categorized so that the data may be analyzed at various levels and from various perspectives. In another embodiment, a subscriber's content choice is correlated with preceding and succeeding content choices to determine how various combinations of advertising and programming content affect a subscriber's content choices.
[0040] FIG. 1 is a block diagram illustrating an exemplary environment for an embodiment of the present invention. In the embodiment shown, a cable operator's head-end facility 102 includes a merge processor 104 , which is in communication with a plurality of databases. These databases include a local-content database 106 , a subscriber-action database 112 , and a national-content database 114 . The merge processor 104 is programmed to receive and merge data from the two databases 112 , 114 .
[0041] The local-content database 106 includes information from the advertising 108 and programming 110 databases. The advertising database 108 includes information related to local advertising produced and/or provided by the cable operator or other local source. Likewise, the programming database 110 includes information related to locally produced and/or provided programming. The advertising database 108 includes attributes of advertisements, such as the advertiser, producer, brand, product type, length of the content, and other descriptive information. The programming database 110 includes similar information related to programming, including the producer, type of programming, length, rating, and other descriptive information. The local-content 106 , programming 108 , and advertising 110 databases include a date-time identifier, which indicates when a program or advertisement has been provided. The date-time indicator provides a key value for merging various databases with one another.
[0042] In the embodiment of the present invention shown in FIG. 1 , the cable operator head-end 102 also includes a national-content database 114 . The national-content database 114 includes information from an advertising database 116 and a programming database 118 . The information contained in each of these respective databases is similar to that contained in the local advertising 108 and programming 110 databases. However, the content is produced for a national audience and subsequently provided to the cable operator. The national-content 114 , programming 118 , and advertising 116 databases also include a date-time identifier.
[0043] The cable operator head-end 102 also includes a subscriber-action database 112 . The subscriber-action database 112 includes the actions taken by subscribers while viewing television sets. For example, in the embodiment shown in FIG. 1 , subscriber-action database 112 is in communication with cable network 120 . A processor (not shown) in cable network 120 receives any subscriber actions transmitted via cable network 120 and inserts the actions as records in subscriber-action database 112 . Also in communication with cable network 120 is a set-top box 124 , which is installed in a subscriber's home 122 . Also located in subscriber's home 122 is a television (TV) 126 . As a subscriber 123 makes viewing choices on TV 126 via set-top box 124 , these choices or actions are transmitted via a processor (not shown) in cable network 120 to the subscriber-action database 112 .
[0044] The subscriber-action database may include a clickstream database. A clickstream database is common in Internet monitoring applications. Each time a web-browser user clicks on a link in a web page, a record of that click is stored in a conventional clickstream database. A database that includes similar information for television viewers is disclosed in a patent application filed on May 25, 2000 by Edward R. Grauch, et. al., Ser. No. 09/496,92, entitled “Method and System for Tracking Network Use,” which is hereby incorporated by reference. In the database described, each action taken by a television subscriber 123 , such as “channel up” and “channel down” are stored in a database with a date-time stamp to allow tracking of the television subscriber's actions.
[0045] In the embodiment shown in FIG. 1 , a merge processor 104 receives information from the local-content 106 , national-content 114 , and subscriber-action 112 databases and merges the data based on date-time attributes of the data. For example, a detail record in the subscriber-action database 112 indicates that a subscriber's set-top box 124 was tuned to channel 12 , a National Broadcasting Company (NBC) affiliate. A record in the national-content database 114 indicates that at the same point in time, NBC was broadcasting a Professional Golf Association (PGA) tournament. A record in the local-content database 106 further indicates that the cable provider preempted the PGA tournament to broadcast an infomercial for a real estate investment strategy video. The merge processor 104 receives information from each of these sources and determines that at the point in time of interest, the subscriber 123 was watching the infomercial. The merge processor stores the resultant data in the subscriber content-choice database 128 . In one embodiment of the present invention, the merge processor collects information from the various databases rather than receiving it. For example, a program on the merge processor 104 includes instructions for connecting to the various databases and extracting data from each one.
[0046] In another embodiment of the present invention, subscriber content-choice database 128 includes merged information for a period of time and for a plurality of subscribers. For example, a program provider may wish to track the popularity of a program for several thousand subscribers for an entire month. Another provider may be interested in analyzing the seasonal differences in subscriber viewing behaviors.
[0047] The embodiment shown in FIG. 1 also includes a subscriber database 130 . Subscriber database 130 includes various attributes about a subscriber. In addition, subscriber database 130 includes information from subscriber content-choice database 128 .
[0048] An analyzer 131 accesses the information in the subscriber database 130 . The analyzer 131 provides tools to an analyst or other person associated with a content provider to discern patterns in the subscriber database 130 for which specific programming or advertising packages are developed. The analyzer 131 may include simple query tools or may include complex online analytical processing tools, such as a multidimensional database or data mining application.
[0049] An embodiment of the present invention also includes a content distribution server 132 . Once a content provider has created content tailored to individual subscribers, the content provider places the content on the content distribution server 132 . A content distribution server 132 may include, for example, a digital video storage and broadcast server. The content distribution server 132 distributes the tailored content to a subscriber's set-top box 124 via cable network 120 .
[0050] Although in the embodiment shown in FIG. 1 , the cable network is a two-way digital cable network, various other network types may also be utilized. For example, in one embodiment, subscriber's home 122 receives cable service via a digital one-way cable system. In such a system, set-top box 124 may communicate subscriber actions to subscriber-action database through a modem and telephone connection periodically. In another embodiment, subscriber 123 receives content through a digital subscriber line (DSL) from a DSL provider. In a DSL system, the set-top box 124 is able to perform two-way communications and can therefore transmit subscriber actions to subscriber-action database 112 directly.
[0051] Although in the embodiment shown, the various databases and merge processor 104 are located in the head-end facility 102 , in other embodiments, the databases and merge processor 104 exist as software within the set-top box 124 or as software residing within a television network's facility (not shown). The data may be captured and analyzed by programming and advertising producers or distributors or may be utilized within a subscriber's set-top box 124 to provide advanced services tailored to the subscriber 123 .
[0052] FIG. 2 is a flowchart illustrating the general process the merge processor ( 104 ) shown in FIG. 1 implements to categorize and merge data from the various databases in an embodiment of the present invention. FIGS. 3-5 illustrate the process in greater detail.
[0053] Referring to FIG. 2 , merge processor ( 104 ) receives subscriber action data from the subscriber-action database ( 112 ) 202 . Subscriber action data may include data indicating that the subscriber 123 viewed an alternate data source for a period of time. For example, the subscriber 123 may view video from a VCR or DVD or other video source for a period of time. This video source supersedes both national and local-content in the subscriber content-choice database 128 .
[0054] The merge processor ( 104 ) also receives data from the national-content database ( 114 ) 204 . National-content data includes data describing media, such as programming and media, supplied by national providers. The merge processor ( 104 ) next assigns a category or genre to the national-content data 206 . A genre is a specific type of category used in relation to artistic compositions, and genre and category are used interchangeably herein. The merge processor ( 104 ) assigns categories to content based on attributes of the content. For example, a program has a name and a creation date. The name of the program is “Wake Forest University vs. Duke University Basketball Game,” and a creation date equal to the current date. The merge processor ( 104 ) uses logic in a computer program to determine that the program should be categorized as a “Live Sporting Event.” The merge processor ( 104 ) may assign multiple categories to a single program, such as “Basketball,” “Sports,” “College-Related Programming,” or some other broad descriptive term.
[0055] The merge processor also receives data from the local-content database ( 106 ) 208 . The merge processor ( 104 ) then assigns a category to the local-content data 210 in a manner similar to the process of assigning a category to national-content data.
[0056] Once the merge processor has assigned a category to data in each of the content databases, the merge processor merges the categorized content data, national and local, with data from the subscriber-action database ( 112 ) 212 and creates records with the combined data in the subscriber content-choice database ( 128 ) 214 . Since the content data was categorized prior to the merge process, the data in the subscriber content-choice database 214 retains the assigned categories. Therefore, data in the subscriber content-choice database 214 can be sorted, filtered, reported, and used for various other processes, which utilize groupings of the data.
[0057] The subscriber content-choice database 128 may be implemented in various ways. For example, the database 128 may simply be a number of tables in a relational database. To simplify the process of querying the data, the database may include an online analytical processing tool, such as a multidimensional database.
[0058] FIG. 3A illustrates the sources of programming and advertising content available to the subscriber 123 while the set-top box 124 is tuned to a single channel. FIG. 3B illustrates the content displayed on the TV. FIG. 4 is a flowchart illustrating the process of merging the various content types shown in FIG. 3A to determine the content displayed on a particular channel.
[0059] FIG. 3A includes a Content Type column 302 . The various content types displayed in the Content Type column 302 are shown in relation to Time 304 . Time 304 in FIG. 3A is divided into hour 306 and quarter-hour 308 segments. FIG. 3A represents a simplistic scenario in which set-top box 124 is tuned to a single channel. Therefore, the Content Type 302 column includes five types of content: National Programming 310 , National Advertising 312 , Local Programming 314 , Local Advertising 316 , and Other Video Source 318 . In order to present a simplified view of the available content types during the period, several content types overlap, when in reality, they would actually occur in series. For example, National Programming 310 and National Advertising 312 do not occur at the same time, but it is likely that programming and advertising both would be broadcast for at least some period of time during the fifteen minute periods of overlap shown in FIG. 3A . For example, during a television program provided by a broadcast network, a two or three-minute break occurs approximately every fifteen minutes. Therefore, a fifteen-minute period in which a three-minute break occurs will include twelve minutes of programming and three minutes of advertising.
[0060] As shown in FIG. 3A , multiple types of content may be provided during any period of time. The fact that the content is provided does not indicate that it is available on the set-top box ( 124 ) or that the subscriber 123 is viewing the content. For example, in the embodiment shown, the cable provider provided National Programming 310 continuously throughout the period. The provider provided National Advertising 312 approximately every 15 minutes during the same period. Also, the cable provider provided Local Programming 314 from 1:00 until 2:30, and Local Advertising 316 approximately every 15 minutes during that period. The cable provider subsequently provided Local Advertising 316 during the period beginning at 5:15. Also during the period shown in FIG. 3A , the subscriber 123 viewed input from the Other Video Source 318 , e.g., VCR or DVD, from 2:30 until 4:15.
[0061] FIG. 4 illustrates the process for determining which programming is displayed on the subscriber's television during any specific period of time and inserting that data into the subscriber content-choice database 128 if the subscriber 123 is viewing that channel. Although various sources of content, such as a cable TV channel or a DVD movie, may be available to the subscriber ( 123 ) during any period of time, the subscriber ( 123 ) generally views only one source of programming or advertising at any one time. In addition, a content provider, such as a cable operator, makes determinations regarding which content will be available via a communications channel.
[0062] In an embodiment of the present invention, a computer program executing on merge processor ( 104 ) processes the potentially viewable data sources as a hierarchy. The program first determines, using information in the subscriber-action database ( 112 ) whether the subscriber ( 123 ) was viewing another video source, such as a VCR or DVD 402 . If so, the program inserts data describing the other video source 404 into the subscriber content-choice database ( 128 ), and the process ends 416 .
[0063] If the subscriber ( 123 ) was not viewing an alternate source of video and was tuned to a particular channel, then the subscriber ( 123 ) was viewing the content provided by the cable operator on that channel. To determine what content was provided by the cable provider, the program executing on the merge processor ( 104 ) determines whether the cable provider was providing local programming or advertising during the period of time 406 by accessing the local-content database ( 106 ). If so, the program inserts data describing the local programming or advertising 408 into the subscriber content-choice database ( 128 ), and the process ends. If the cable provider was not providing local programming or advertising, the program determines whether or not the provider was providing national programming or advertising 410 by accessing the national-content database ( 114 ). If so, the program inserts data describing the national programming or advertising 412 into the subscriber content-choice database ( 128 ), and the process ends 416 .
[0064] If the program determines that the subscriber 123 was not viewing another video source and the provider was providing no content, the program either inserts a record in the subscriber content-choice database 128 indicating that no content was available during the specific period of time or inserts no data at all 416 . For example, if TV 126 is left on after a broadcaster ends broadcasting for the rest of the day, no content is available after the broadcaster ceases broadcasting, so either a record indicating the lack of content is inserted, or no data is inserted.
[0065] It is important to note that in an embodiment of the present invention, the process illustrated in FIG. 4 is repeated for each period of time that is of interest for analyzing the data. The result of the process is a plurality of records describing a subscriber's viewing patterns during a period of time. In one embodiment of the present invention, the subscriber content-choice database ( 128 ) includes data from a plurality of subscribers as well. The databases and processor ( 104 ) in such an embodiment are configured appropriately to process the anticipated volume of data.
[0066] In the embodiment shown in FIGS. 3A and 3B , the process is repeated for each quarter hour. In other embodiments, the time period may be divided into smaller increments, such as tenth-of-a-second increments.
[0067] FIG. 3B illustrates the result of merging the data records shown in FIG. 3A using the process illustrated in FIG. 4 . As in FIG. 3A , FIG. 3B is a simplistic view of this data, including the Content Type 302 and the various slices of time 304 , 306 , 308 . In the table shown in FIG. 3B , the Content Type column 302 includes only a Programming 320 and an Advertising 322 row.
[0068] As shown in FIG. 3A , during the period from 1:00 until 2:30, the cable provider provides local programming and advertising 312 , 314 . The process of FIG. 4 determined that the subscriber 123 was viewing no other video source 318 , and therefore, the program inserts data into the subscriber content-choice database 128 related to local programming and advertising 320 , 322 . During the period beginning at 2:30 and ending at 4:15, the subscriber 123 viewed video from another source 318 . Therefore, the program inserts data related to the other source for this time period. During the period from 4:15 until 5:15, the provider provided national programming and advertising with the exception of the period from 5:15 until 5:30, during which local advertising was provided. The program inserts this data into the subscriber content-choice database.
[0069] FIG. 5 is a table illustrating the programming that the subscriber 123 viewed during the period shown in FIGS. 3A and 3B . As with FIGS. 3A and 3B , the table includes a Time section 502 and a Content section 504 . The Time section 502 is divided into hour and quarter-hour segments.
[0070] According to FIGS. 3A and 3B , between 1:00 and 2:30, the subscriber 123 viewed local programming and advertising. By accessing the local-content database ( 106 ), the merge processor ( 104 ) determines that the local programming consisted of a NCAA (National Collegiate Athletic Association) basketball game and local advertising 506 .
[0071] According to FIGS. 3A and 3B , during the period from 2:30 until 4:15, the subscriber ( 123 ) viewed a DVD 508 . The merge processor ( 104 ) determines that the DVD was a science fiction DVD by extracting data from the subscriber-action database ( 112 ).
[0072] And according to FIGS. 3A and 3B , between 4:15 and 5:15, the subscriber ( 123 ) viewed national content and advertising, with the exception of the period between 5:15 and 5:30 during which the cable operator inserted a local advertisement segment in the content stream in place of the national content 510 . By accessing the national-content database ( 114 ), the merge processor ( 104 ) determines that the national content viewed by the subscriber ( 123 ) was an NBA (National Basketball Association) basketball game.
[0073] In an embodiment of the present invention, an analyst evaluates the data shown in FIG. 5 to determine preferences and viewing habits of the subscriber ( 123 ). In one embodiment of the present invention, the analyst is a computer program executing on a processor (not shown). The analyst also attempts to extrapolate the data in order to project purchase habits of the subscriber 123 . In order to evaluate the data shown in FIG. 5 , the analyst begins by assigning a category or genre to the programming. For example, during the period between 1:00 and 2:30, the subscriber 123 viewed a NCAA basketball game 506 . An analyst would assign various types and levels of categories to the game, such as basketball, college athletics (type of program), college name, and conference. The analyst may also note that sometime between 2:15 and 2:30, a PGA golf tournament began, and the subscriber 123 started a DVD movie. This might indicate that the subscriber 123 did not enjoy watching golf on TV. During the same period, the subscriber 123 also watched several advertisements. The analyst categorizes these as well. The analyst repeats the process of categorization of programming and advertising for the remainder of the data 508 , 510 .
[0074] By categorizing content using multiple category types and multiple levels, the analyst is able to provide an abundance of information to programming and advertising producers, and providers, as well as to the product owners and manufacturers who pay to have the ads produced and distributed. Categorization in this manner also provides the analyst with multiple perspectives from which to analyze the data.
[0075] In addition, in an embodiment of the present invention, the analyst may look for patterns or correlations between multiple programs and advertisements or between categories of multiple programs and advertisements. In correlating data, the analyst is seeking causal, complementary, parallel, or reciprocal relations between various occurrences of data. For example, in the embodiment shown in FIG. 5 , the subscriber 123 viewed a basketball game, a science fiction movie, and another basketball game. An analyst may correlate this data and find that the subscriber 123 generally watches primarily sports-related broadcasts, and otherwise watches content from video sources in the home. The analyst may also perform a probability analysis to determine the likelihood that a subscriber 123 will watch a particular category or genre of show if presented with the opportunity.
[0076] Although only a brief period of time is shown in the Figures, the subscriber content-choice database includes data recorded continually over many days. By analyzing various days and time periods, an analyst can determine a subscribers time-of-day viewing patterns as well as the subscriber's patterns of viewing duration. For example, an analyst may determine whether the subscriber 123 tends to view the entirety of a program or of an advertisement.
[0077] Determining the duration of viewing of advertisements is important to advertisers. If a subscriber 123 initially views an entire advertisement but subsequently, views only a small portion of the advertisement, then the advertiser may need to reschedule the advertisement so that it runs less frequently, or replace the advertisement altogether. Also, if subscribers viewing a particular category of programming generally view ads in their entirety, but other viewers do not, the advertiser may want to focus resources on presenting the advertisement to these viewers.
[0078] Beyond analyzing ads in general, advertisers may also desire information related to specific ads or even of a competitor's ads. Using the information, the advertiser may be able to determine the relative strengths and weaknesses of the advertisers own strategy versus a competitor's strategy.
[0079] In an embodiment of the present invention, various indirect methods are also used to determine the popularity of programming and the effectiveness of advertising. For example, advertising effectiveness is often measured in terms of viewer attitudes and subsequent viewer actions, such as purchases, inquiries, behavior changes, and other actions. Method of obtaining these indirect measures include: focus group tests, post-advertising surveys questioning whether an advertisement was viewed, remembered and possible impact, and measures of product purchases or other indirect results that may indicate whether or not an advertising campaign has been successful. In an embodiment of the present invention, additional databases store the data derived through these indirect methods. The merge processor 104 combines this data with the data in the subscriber content-choice database 128 to provide additional information to analysts and content providers.
[0080] The embodiment shown in FIG. 1 includes an analyzer 131 . The analyzer 131 is a computer, which includes program code for analyzing data in the subscriber database 130 . In one embodiment, the analyzer 131 creates reports, including both summary and detailed information regarding subscribers' content choices. Content providers, such as a cable operator, use these reports for various purposes, including creating directly marketing campaigns, designing program offerings, pricing program offerings, creating incentive packages that will appeal to certain groups of subscribers, and creating offerings including content along with complementary products and/or services.
[0081] FIG. 6 is a flowchart illustrating a method of analyzing the data collected and combined in the subscriber database 130 shown in FIG. 1 to formulate a new programming offering in an embodiment of the present invention. The content provider first uses the analyzer 131 to analyze data in the subscriber database ( 130 ) 602 . For example, analyzer 131 generates a report, which details the viewing history of subscribers for Saturday afternoons from September until November. A cable provider reads the report and determines that a group of the cable operator's subscribers watch nothing but football between noon and midnight. In another embodiment, a data-mining application executing on the analyzer 131 reaches the same conclusion.
[0082] Referring again to FIG. 6 , based on the results of the analysis, the content provider attempts to identify any unfulfilled subscriber demand evident in the output from the analyzer 603 . For example, in the case of the football fans, the cable provider may limit the subscribers' channel hopping behavior by offering an all-football channel. If the subscribers limit their channel-hopping, they may also be more likely to view the advertisements that the cable operator includes with the programming. Since the cable operator can also create reports that include advertisement viewing, the cable operator has the ability to demonstrate the decrease in channel hopping and increase in advertisement viewing to the advertisers.
[0083] Once the content provider has identified what is needed, the content provider determines whether or not an existing offering would fulfill the unmet demand 604 . If the content provider has an offering meeting the unmet need, the subscriber determines how to direct the identified subscribers to the offering 605 . For example, the cable operator may already offer an all-football-all-the-time channel. However, few subscribers are aware of the channel. The cable operator may direct advertising to the football fans, informing them that the all-football-all-the-time channel exists.
[0084] If an offering meeting the unmet demand does not already exist, the content provider develops a new offering 606 . For example, if the cable operator does not have an all-football-all-the-time channel, the subscriber may create one by combining various national and local programming.
[0085] The content provider next sets the pricing for the existing or new offering 608 . If the content provider has created a new offering, the price will likely be set higher than it would be for an existing offering because the cost in time and resources to develop the offering must be recouped. Also, the smaller the group for which a offering is tailored, the higher the price is likely to be because the cost of producing the offering is spread out among a small group of subscribers. For example, if the cable operator has an existing all-football-all-the-time channel, the cost of direct advertising to the football fans may be minimal compared to the increases in ratings and therefore advertising revenue derived from the advertising. However, if the cable operator purchases additional broadcasting rights in order to create the all-football-all-the-time channel, the cost will likely be passed on to subscribers who opt to subscribe to the channel.
[0086] Once the pricing is set, the provider delivers the content offering 610 . The content provider may determine what an offering includes in various ways, including, for example, writing various options on paper or using a simple computer application, such as a spreadsheet. The offering may be created using a computer. For example, in one embodiment of the present invention, a computer program on analyzer 131 is able to analyze subscriber content-access histories to determine unfulfilled needs and creates content offerings specifically targeted to those needs.
[0087] At some point, the program must be made available to actual subscribers. For example, in the embodiment shown in FIG. 1 , a cable operator loads the all-football-all-the-time channel offering on the content-distribution server 132 for delivery via the cable network 120 .
[0088] In an embodiment of the present invention, a similar process may be implemented to bundle combinations of various content offerings or bundles that include content offerings and products and/or services. For example, a cable operator offering the all-football-all-the-time channel may partner with a travel agency to offer a bundle including travel to and accommodations in the city hosting the Super Bowl. The price for the bundle is set in a manner similar to the process used to price a simple content offering: a new bundle or a bundle directed to a small number of subscribers carries a higher price than an existing bundle or a bundle targeted at a large group of subscribers. For example, very few football fans are likely to attend the Super Bowl, to the price of the bundle is discounted only slightly from the normal cost of accessing the channel and traveling to the Super Bowl host city.
[0089] An embodiment of the present invention provides great value to content providers. As a result, content providers are willing to pay for the outputs derived from the various reports and analysis. The content providers may be billed a flat subscription-type rate for access to all information collected or they may pay for each report and/or analysis that they request.
[0090] An embodiment of the present invention includes a computer-readable medium, having computer-readable instructions for analyzing subscriber-specific data to develop subscriber-specific content offerings. A computer-readable medium includes an electronic, optical, magnetic, or other storage or transmission device capable of providing a processor, such as the processor in a web server, with computer-readable instructions. Examples of such media include, but are not limited to, a floppy disk, CD-ROM, magnetic disk, memory chip, or any other medium from which a computer processor can read. Also, various other forms of computer-readable media may transmit or carry instructions to a computer, including a router, private or public network, or other transmission device or channel.
[0091] The foregoing description of the preferred embodiments of the invention has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Numerous modifications and adaptations thereof will be apparent to those skilled in the art without departing from the spirit and scope of the present invention. | Methods, systems, and products tailor content to users. Clickstream data is merged with a user attribute and content information. A merged record is compared to advertising attributes of advertisements. When the merged record matches an advertising attribute, an advertisement associated with the advertising attribute is retrieved and sent to the user. | 6 |
FIELD OF THE INVENTION
[0001] The invention describes a lighting arrangement, a lighting element, a light redirecting element, and a number of lighting units.
BACKGROUND OF THE INVENTION
[0002] With developments in light-emitting diode (LED) technology, lighting solutions that comprise LEDs instead of conventional light bulbs are becoming more popular. An LED comprises a semiconductor diode chip that emits light from an emitter surface. The emitter surface area is very small, usually in a region of only a few square millimetres, sometimes even only a few hundredths of a square millimetre. Such an LED chip can be a top-emitting device, or can emit from the top as well as from the sides. To protect the diode chip, it is usually sealed inside a protective cover, which can also act to improve light extraction. For example, a low-power LED chip inside a transparent plastic or epoxy cover for use as an indicator light of a domestic appliance is generally referred to as “packaged LED”. High-power LED chips such as those used in lighting applications can be mounted directly onto a circuit board, or onto a carrier element that can be connected to a circuit board. The high-power LED chip can be encapsulated or provided with a protective cover that also serves as a filter or other optical element.
[0003] A disadvantage of an LED is that the light emitted from the small area of the LED chip is perceived as a small, bright point of light. To make the light source appear larger and less point-like, the light can be spread, for example by an encapsulating dome or a diffusing cover. However, some of the light can be lost in this way, and the overall brightness is diminished. Furthermore, to obtain a large light source for an application such as a brake light, for example, in a prior art arrangement several LED light sources must be arranged over an area corresponding to the area of the desired “light source” in order to provide the necessary luminous flux. However, when several LEDs are arranged thus, the overall impression is one of several distinct bright points of light separated by darker zones. To better achieve the impression of a single light source, such lighting arrangements require diffusers or dedicated lenses to collect, refract and re-combine the light in the desired distribution, whereby such optical elements are always associated with some degree of loss. Furthermore, failure of one of an array of light sources will result in a “hole” in the overall light arrangement.
[0004] Since an LED chip emits light according to the Lambert cosine law, the light emitted by the LED is spread essentially evenly in all directions. This is advantageous if a round or circular light source shape is desired. Here, the term “light source shape” refers to the shape of the light source as perceived by an observer, e.g. the shape of a cover of the lighting arrangement containing the LED light source. However, owing to the nature of the light emission from the LED chip, a light source shape that is not round will exhibit less bright regions towards any “corners” or extremities of the light source shape. Clearly, such an uneven light distribution over the light source shape is unfavourable and even unacceptable for certain lighting applications that require an overall even brightness. Therefore, to obtain a light source shape that is not “round”, the light emitted by an LED chip or packaged LED must be manipulated, for example by a system of collectors, reflectors or light guides in order to obtain the light distribution. However, these manipulations result in losses and in a reduction of the overall light output, so that such arrangements are unfavourably inefficient. Also, these arrangements are complicated, bulky and expensive.
[0005] Therefore, it is an object of the invention to provide an improved lighting arrangement that overcomes the problems mentioned above.
SUMMARY OF THE INVENTION
[0006] The object of the invention is achieved by the lighting arrangement of claim 1 ; the lighting element of claim 4 ; the light redirecting element of claim 9 ; and the lighting units of claims 13 to 15 .
[0007] According to the invention, a lighting arrangement comprises a light source for generating light; a spreading element realised to laterally spread at least a portion of the generated light in a spreading plane, which spreading plane is defined by an optical axis of the light source and a longitudinal axis of the spreading element, to give an essentially uniform quantity of light per unit area at a collecting plane orthogonal to the spreading plane and parallel to the longitudinal axis of the spreading element and a light redirecting element arranged in the collecting plane, which light redirecting element comprises a longitudinal planar emission face, and is realised to collect the laterally spread light and to emit the collected light essentially uniformly from the emission face, which is to be understood to mean that the manner in which the light is emitted from the emission face is essentially the same for any point on the emission face.
[0008] An advantage of the lighting arrangement according to the invention is that it provides a uniform longitudinal light source without any significant loss of light. The light emitted by the light source which can be a point-like light source is initially spread essentially only in the spreading plane, so that none of the light is “wasted” in regions that do not contribute to the overall light source appearance. Furthermore, the lighting arrangement is realised such that the light is spread to give an essentially uniform quantity of light per unit area at the collecting plane. This means that at any region of the collecting plane, whether at a central region or an outer region, the light per unit area is the same. The spread light is then “captured” in the collecting plane by the light redirecting element, which acts to direct the light outward towards an observer, giving the appearance of a longitudinal light source with a favourably even or uniform appearance, i.e. with a favourably uniform light distribution over the entire longitudinal planar emission face. The expression “spreading plane” is to be understood as the plane in which the emitted light is largely confined by the optical characteristics of the spreading element. Since the spreading element has a certain width, the spreading plane may be regarded as a spatial “slice” through which the spread light is caused to travel. Here, the optical axis of the light source is to be understood as the main direction of emission of light from the light source.
[0009] The lighting arrangement according to the invention delivers a uniform distribution of light over its emission surface, which may therefore be referred to as an “apparent light source” in the following, since an observer will only see a uniformly emitting surface. This is in contrast to prior art lighting arrangements in which the observer sees a brighter central region and darker outer regions.
[0010] According to the invention, a lighting element, in particular a lighting element for use in such a lighting arrangement, comprises a light source for generating light; and a spreading element, which spreading element is realised to laterally spread at least a portion of the generated light in a spreading plane, defined by an optical axis of the light source and a longitudinal axis of the spreading element, to give an essentially uniform quantity of light per unit area at a collecting plane orthogonal to the spreading plane and parallel to the longitudinal axis of the spreading element.
[0011] An advantage of the lighting element according to the invention is that it can be realised in a very compact manner, since the spreading element can be arranged very close to the light source. No additional reflecting or collecting elements are needed to direct the light into any outer regions of the collecting plane, since this effect can be achieved entirely by the lighting element itself. Furthermore, the light spread over the collecting plane exhibits a favourable uniform quantity of light per unit area, making such a lighting element particularly suited for use in applications that require a non-circular light source shape with even or uniform light distribution.
[0012] According to the invention, a light redirecting element, realised for use in such a lighting arrangement, comprises a longitudinal planar emission face and is realised to collect laterally spread light, which laterally spread light originates from a spreading element of the lighting arrangement, and to emit the collected light essentially uniformly over the longitudinal planar emission face.
[0013] An advantage of the light redirecting element according to the invention is that it can be placed in the collecting plane of a lighting arrangement of the type described above, to optimally collect the spread light and to direct it outward towards an observer, giving the appearance of a longitudinal light source with a favourably even or uniform appearance.
[0014] According to the invention, a lighting unit can comprise an automotive lighting unit, a display lighting unit, a retro-fit lighting unit, etc., whereby each type of lighting unit comprises one or more lighting arrangements according to the invention, realised and/or dimensioned according to any relevant requirements of the lighting unit. Examples of such lighting units will be given in the description below.
[0015] The dependent claims and the following description disclose particularly advantageous embodiments and features of the invention. Features of the embodiments may be combined as appropriate. Features described in the context of one claim category can apply equally to another claim category.
[0016] The lighting arrangement according to the invention can be used in conjunction with any suitable light source. A light source that is compact and emits essentially outward from an emitting surface can be favourably used in the lighting arrangement, since all the light emitted from such a light source is emitted above that emitting surface. In a particularly preferred embodiment of the invention, therefore, the light source comprises a light-emitting diode, preferably a single light-emitting diode chip. The choice of chip can depend on the desired luminance at the planar emission face of the lighting arrangement. For example, for an automotive stop light application with a relatively large light source shape, covering several square centimetres, an LED chip with 1 mm 2 and 3 watt may be preferable, whereas for a small indicator light of a domestic appliance, an LED chip with 0.04 mm 2 and 0.1 watt can be sufficient.
[0017] The dimensions of the longitudinal planar emission face are preferably chosen to complement the dimensions of the spreading element and its spreading plane. Therefore, in a particularly preferred embodiment of the invention, a length of the emission face exceeds a width of the emission face by a factor of at least 3, more preferably by a factor of at least 6; most preferably by a factor of at least 10, i.e. the aspect ratio of the emission face is at least 1:3, more preferably at least 1:6, most preferably at least 1:10. The planar emission face therefore provides a light source shape that is favourably long and narrow, making the lighting arrangement particularly suitable for lighting applications that require a long, narrow and uniform light source shape.
[0018] Preferably, the spreading element is formed in one piece using a transparent material such as an epoxy resin, plastic, glass, etc. Preferably, such a material has a high degree of visible transmittance. To obtain the desired distribution of light in the spreading plane, the shape of the spreading element can be chosen accordingly. In a particularly preferred embodiment of the invention, the spreading element comprises two distinct lobes arranged along a longitudinal axis of the spreading element and is arranged to accommodate the light source essentially symmetrically between the two lobes, i.e. the light source is preferably arranged symmetrically about a plane that bisects the spreading element. This arrangement can have the appearance of a two-lobed peanut. In a symmetrical design, each lobe can deflect the same amount of light outward in a longitudinal direction away from the light source. The thickness, length and height of the diametrically opposing lobes can be chosen according to a desired radiation angle pattern, i.e. according to “how far” the light should be deflected in the longitudinal direction away from the light source. Preferably, the “peanut” or spreading element is realised at the same time to encapsulate an LED chip as a packaged lighting element. To this end, the “peanut” can be manufactured in one piece to also fit tightly over a carrier element onto which the LED chip is mounted.
[0019] The spreading element itself can provide a favourable spreading effect for a light source such as a top-emitting LED chip. LED chips that also emit to the side are also available. Therefore, in a particularly preferred embodiment of the invention, the lighting element comprises a receptacle for containing the light source, which receptacle comprises a reflective outer surface, and wherein the receptacle and the spreading element are realised to obtain a light output distribution comprising a first lateral spread portion in a first half of the spreading plane to one side of the optical axis, and a second lateral spread portion in the other half of the spreading plane, wherein a lateral spread portion of the radiation angle pattern is bounded by a first angle subtended from the optical axis and a second angle subtended from the optical axis. The receptacle or “cup” is specifically shaped and finished to guide any light emitted from the sides of the LED chip outward to obtain the desired radiation angle pattern. Preferably, the receptacle or cup is shaped as a recess with one or more sloping faces, arranged according to the arrangement of lobes. For example, a receptacle with an essentially rectangular perimeter can comprise a sloping face on each side of a square or rectangular LED chip. Such a receptacle can comprise a long or “major” sloping face with a shallow inclination that extends some distance under a lobe of the spreading element. The receptacle can also comprise a “minor” sloping face on each of the two remaining sides of the LED chip, preferably with a steep inclination. Alternatively, a receptacle with an essentially rectangular perimeter can comprise two long “major” sloping faces as described above, while the remaining two sides are essentially vertical. Such a combination of long, shallowly inclined receptacle surfaces and short, steeply inclined side faces, together with the light-refracting function of the “peanut”, can achieve the desired wide and simultaneously narrow spreading plane or spreading “slice”. The angle of a major sloping face is preferably chosen according to the desired spreading effect. Evidently, a flatter angle will result in a more lateral spreading of the light in the spreading plane, and a correspondingly “longer” aspect ratio, whereas a steeper angle will result in a more compact spreading of the light in the spreading plane, and a correspondingly “shorter” aspect ratio.
[0020] Preferably, the spreading element, with or without a receptacle as described above, is realised to spread the greater portion of the light in a lateral spread portion between a first angle subtended from the optical axis and a second angle subtended from the optical axis. Preferably, the lateral spread portion is obtained by a suitable combination of a first angle comprising at least 35°, more preferably at least 45°, most preferably at least 55° subtended from the optical axis; and a second angle exceeding the first angle by at most 25°, preferably by at most 20°, most preferably by at most 15°, whereby the first and second angles are chosen such that a lateral spread portion with a desired span is obtained. In other words, the greater portion of the light is emitted into the spreading plane in an angular region given by a suitable combination of a first angle of 45°±10° and a second angle of 67.5°±12.5°, so that a favourably “lateral” or “wing-like” light distribution is achieved within the spreading plane.
[0021] For example, such an angular region can be bounded by a first angle of 35° and a second angle of 55°; by a first angle of 50° and a second angle of 75°; by a first angle of 55° and a second angle of 85°; etc. The choice of the first and second angles can depend on a desired aspect ratio of the longitudinal planar emission face of the light redirecting element. For example, an aspect ratio of about 1:3 can be obtained by an angular region defined by a first angle of 35° and a second angle of 55°, while an aspect ratio of about 1:12 could be obtained by an angular region defined by a first angle of 55° and a second angle of 85°.
[0022] The remainder of the light emitted by the light source is spread, in the spreading plane, beyond the lateral spread portions bounded by the first and second angles on each side of the “peanut”. For example, a relatively minor fraction of the light is spread in a central angular region defined by the first angle on either side of the optical axis between the lateral spread portions. Another minor portion of the light can be spread in the angular region “below” the lateral spread portion on each side of the “peanut”.
[0023] Since the light is spread on both sides of the “peanut”, this light distribution or radiation angle pattern has the appearance of a “batwing”, as will be shown in the description of the drawings. The “batwing” distribution between these angles in the spreading plane ensures an essentially uniform quantity of light per unit area at the collecting plane. In another preferred embodiment of the invention, the lighting element is realised to spread the light in the spreading plane such that losses in the light redirecting element may be compensated for. For example, light in the outer reaches of the spreading plane will need to be bent or manipulated by the light redirecting element, to a greater extent than, for example, light that is emitted closer to the optical axis, which undergoes less bending or manipulating as it passes through the light redirecting element. The secondary losses occurring during light transmission through the outer ends of the light redirecting element are preferably compensated for in advance by realising the lighting element to direct more light into the relevant outer reaches of the spreading plane. For example, for a lighting element intended to emit the greater portion of its light into angular regions between 65° and 75° on each side of its optical axis, the “peanut” and/or the reflective cup of the lighting element can be shaped to direct additional light into the region bounded by 73.5° and 75°. In this way, a favourably homogenous light distribution can be achieved all along the longitudinal planar emission face of the light redirecting element.
[0024] The light in the spreading plane is collected by a light redirecting element relatively close to the lighting element, so that the spread light is collected at a level in which the spread light can provide the appearance of a rectangular or longitudinal “light source” of the desired dimensions. To this end, the light redirecting element can be positioned directly above the spreading element, at a slight distance from the spreading element, or at a greater distance from the spreading element, depending on the desired effect.
[0025] The light redirecting element can be manufactured according to the desired optical effect of the light direction. In one exemplary preferred embodiment of the lighting arrangement according to the invention, the light redirecting element is realised to emit the collected light with uniform luminance. To this end, the light redirecting element is preferably dimensioned according to light distribution in the spreading plane and preferably comprises a diffusion layer such as a phosphor layer. For example, the light redirecting element can comprises a relatively long rectangular strip that comprises a phosphor layer. The phosphor layer can be a phosphor coating applied to the outer surface of the rectangular strip, or can be arranged in the rectangular strip in a sandwich manner, as appropriate. Such a light redirecting element can be useful for a lighting application in which the appearance of a rectangular light source is desired, from which the light is emitted isotropically, i.e. uniformly in all directions, for example according to the Lambert cosine law. An example of such a lighting application might be a display illumination arrangement comprising a display plate with a number of in-coupling faces arranged around a perimeter of the display plate; and a number of lighting arrangements according to the invention, with such phosphor-coated light redirecting element arranged such that the outer surface of the light redirecting element is directed at an in-coupling face of the display plate. Another application might be a retro-fit lighting unit comprising a housing realised to correspond to the dimensions of a conventional fluorescent lighting unit, and a number of lighting arrangements, each with such a phosphor-coated light redirecting element, arranged in a row within the housing. Viewed from outside the housing, the retro-fit lighting unit gives the appearance of a uniform light source similar to a conventional fluorescent tube, but is more economical since it consumes less power per lumen. Another advantage of such a lighting application is that an existing lighting fitting could be left in place and used again by simply replacing the conventional fluorescent tube by a glass tube containing the lighting arrangements according to the invention, and any driving arrangement required to convert a mains power supply to a level suitable for use with the LED chips of the lighting arrangements.
[0026] Other lighting applications may require that the light is directed in essentially only one direction from the emission face of the light redirecting element. Therefore, in a particularly preferred embodiment of the invention, the light redirecting element comprises a plurality of distinct lateral refracting zones for collecting and refracting the laterally spread light in an emission plane, wherein the emission plane comprises a continuation of the spreading plane. Each lateral refracting zone can be realised to collect and refract a portion of the laterally spread light. The light redirecting element can also be realised to direct some portion of the light into the emission plane via total internal reflection. Preferably, the light redirecting element is realised as a Fresnel lens, in which each distinct lateral refracting zone comprises a collecting face arranged to collect a light portion having a certain incidence angle range, and a refracting body for refracting the light portion through the emission face and essentially parallel to the optical axis. Preferably, the collecting face and/or the refracting body of a distinct lateral refracting zone are dimensioned according to the fraction of the laterally spread light directed at that distinct lateral refracting zone. Therefore, the light redirecting element can comprise an arrangement of smaller and larger distinct lateral refracting zones, whereby the size of a lateral refracting zone depends on its position in the light redirecting element. The number of distinct lateral refracting zones can be chosen according to the size of the spreading element and/or the size of the desired longitudinal apparent light source. Furthermore, the number of distinct lateral refracting zones can be determined on the basis of a desired degree or level of homogeneity of the output light.
[0027] Preferably, the light redirecting element comprises a central refracting zone arranged about the optical axis of the lighting arrangement, coinciding with the optical axis of the light source, which central refracting zone is arranged to collect and refract a central light bundle originating from a central region of the spreading element, i.e. from the region between the two lobes of the “peanut”.
[0028] Such a realisation of the light redirecting element can be suitable for lighting applications in which the light is usually only seen from directly in front of the light source, i.e. by an observer looking essentially directly at the emission face of the lighting arrangement. For example, the lighting arrangement according to the invention, with such a Fresnel realisation of the light redirecting element, can be put to good effect in an automotive lighting unit such as a combined stop/tail light or a Centre High Mount Stop Lamp (CHMSL). Such an automotive lighting unit according to the invention comprises a lighting arrangement in which the longitudinal planar emission face comprises a rectangular output surface of a Fresnel light redirecting element as described above. In this way, an effective and reliable lighting arrangement with a uniform apparent light source with the desired dimensions can be achieved with a single LED chip. Such an effect cannot be achieved by the prior art lighting arrangements that require several LEDs in a row in an attempt at achieving a “long” light source, since those individual or separate light sources can be clearly distinguished in such arrangements. Of course, the lighting arrangement according to the invention can be used for any application requiring a long, uniformly lit apparent light source, for example an interior panel indicator light in the cockpit of any type of vehicle, a domestic appliance, display panel lighting, etc.
[0029] Other objects and features of the present invention will become apparent from the following detailed descriptions considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for the purposes of illustration and not as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 shows a lighting element according to an embodiment of the invention;
[0031] FIG. 2 shows a polar grid with a radiation characteristic of the lighting element of FIG. 1 ;
[0032] FIG. 3 shows a rendering of the light output by an embodiment of the lighting element of FIG. 1 ;
[0033] FIG. 4 shows a schematic representation of a light distribution generated by the lighting element of FIG. 1 ;
[0034] FIG. 5 shows a perspective view of the lighting element of FIG. 1 ;
[0035] FIG. 6 shows a lighting arrangement according to a first embodiment of the invention;
[0036] FIG. 7 shows a schematic side view of the lighting arrangement 1 of FIG. 5
[0037] FIG. 8 shows a lighting arrangement according to a second embodiment of the invention;
[0038] FIG. 9 shows a prior art automotive lighting unit;
[0039] FIG. 10 shows an automotive lighting unit according to an embodiment of the invention;
[0040] FIG. 11 shows a display illumination arrangement according to an embodiment of the invention.
[0041] In the drawings, like numbers refer to like objects throughout. Objects in the diagrams are not necessarily drawn to scale.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0042] FIG. 1 shows a schematic cross section through a lighting element 10 according to an embodiment of the invention. This exemplary embodiment of the lighting element 10 comprises an LED chip 2 arranged between contacts 23 , 24 in a type of SnapLED construction. An encapsulating spreading element 3 comprises two distinct lobes 30 and a cover part 31 , and is arranged over a carrier or heat sink 20 to seal in the LED chip 2 . The LED chip 2 is placed centrally relative to the spreading element 3 , so that these both share a common optical axis A O . The interior ends of the contacts 23 , 24 are shaped to form a receptacle 21 or “cup” 21 in which the LED chip is positioned. The upper surfaces of the receptacle 21 are reflective, for example by means of polishing or by applying a reflective coating. The receptacle 21 and the lobes 30 of the spreading element 3 act to direct the generated light predominantly outward as shown by the exemplary bounding light rays R 1 and R 2 at the right of the diagram, defining the lateral spread portion on that side of the spreading element 3 . The upper light ray R 1 subtends a first angle α from the optical axis A O , while the second ray R 2 subtends a second angle β from the optical axis A O .
[0043] FIG. 2 shows a polar grid with a radiation characteristic 6 of the lighting element 10 of FIG. 1 . As the diagram clearly shows, the radiation characteristic 6 has two distinct side portions or “wings” directed away from the centre, i.e. away from the light source. Most of the light is directed outward into these side portions. The radiation characteristic 6 effectively has a “batwing” appearance, since the light is directed into the spreading plane such that essentially all the light is directed into these zones. A lateral zone is bounded by the first angle α and the second angle 13 subtended from the optical axis A O , whereby the first angle α comprises about 40° and the second angle 13 comprises about 55°.
[0044] FIG. 3 shows another rendering of the light output by an embodiment of the lighting element 10 of FIG. 1 , given in candelas [cd] against degrees [O] measured radially about the lighting element 10 , commencing at a point on the optical axis A O at 0° and terminating at a point at 90° from the optical axis A O . The diagram clearly indicates a peak P in light intensity on each side of the optical axis A O . For this light distribution, a spreading element and/or a receptacle has been realised to obtain a peak P on each side of the optical axis between first and second angles α, β of about 60° and 75° respectively. This light distribution is suitable for a light redirecting element with a rectangular outer face having an aspect ratio of about 1:6.
[0045] FIG. 4 shows a schematic representation of a light distribution 7 generated by the lighting element 10 of FIG. 1 . The spreading plane S is indicated by the “slice” S between the dotted lines. The plane of the diagram can be understood to correspond to a collecting plane of a light redirecting element such as a phosphor-coated strip, or the emission surface of a Fresnel lens as described above. The emission face 5 , 41 of a light redirecting element is indicated by the dotted line. As the diagram clearly shows, the light distribution comprises a brighter, essentially rectangular central portion 70 , and successive outer portions of decreasing brightness. The light redirecting element is positioned in the collecting plane to optimally collect the light in the spreading plane S and to emit it from the emission surface to give the desired rectangular apparent light source.
[0046] FIG. 5 shows a perspective view of the lighting element 10 of FIG. 1 . Here, the lobes 30 of the peanut-shaped spreading element 3 can clearly be seen. The lobes 30 are arranged symmetrically about the optical axis of the lighting element 10 , which coincides with the optical axis of the LED chip 2 enclosed within the spreading element 3 and indicated by the dotted lines. Also, the lobes 30 are arranged symmetrically about a longitudinal axis L of the lighting element 10 , which can coincide with a longitudinal axis of a light redirecting element arranged above the lighting element 10 .
[0047] FIG. 6 shows a lighting arrangement 1 according to a first embodiment of the invention. Here, the lighting element 10 is arranged below a Fresnel lens element 4 , comprising a body with a plurality of lateral refracting prism elements 40 , 40 ′, 40 ″, a central refracting portion, and an essentially rectangular emission face 41 . The Fresnel lens element 4 is preferably formed in one piece, for example by an extrusion or milling process. The light emitted by the lighting element 10 is spread outward by the double-lobed spreading element such that a “batwing” characteristic is predominantly obtained, indicated here by the broken lines. The lateral refracting prism elements 40 , 40 ′, 40 ″ are shaped to collect the light of various sectors of the “batwing” and refract the collected light essentially perpendicularly outward from the emission face 41 of the Fresnel lens 4 . To an observer looking at the emission face 41 , therefore, this appears as a uniform rectangular source of light with a length l e and width w e , i.e. with an aspect ratio of w e :l e . Such a lighting arrangement 1 can be used to good effect in, for example, an automotive lighting application such as a brake light. It could also be used in a display application, for example to provide a longitudinal and uniform light source for directing into the sides of a display screen.
[0048] FIG. 7 shows a schematic side view of the lighting arrangement 1 of FIG. 6 . The diagram illustrates the effect of the Fresnel refracting element 4 . The light in the spreading plane S (indicated by the dotted lines), originating from the spreading element 3 , is collected and refracted in such a way that it is emitted essentially perpendicularly, as indicated by the vertical arrows) from the emission face 41 in an emission plane E that is essentially a continuation of the spreading plane S. Of course, a minor portion of the collected and refracted light can be emitted as scattered or stray light, but the major portion of the light is emitted in the emission plane E.
[0049] FIG. 8 shows a lighting arrangement 1 ′ according to a second embodiment of the invention. Here, the lighting element 10 is arranged below a translucent strip 5 that is coated with or otherwise treated to comprise a phosphor layer, indicated by the stippled pattern. The phosphor layer is illuminated by the batwing distribution of the light spread by the lighting element 10 when the enclosed LED is driven by a voltage across its electrodes. Since the phosphor collects the incident light and re-emits or scatters the light essentially uniformly according to the Lambert cosine law, i.e. the phosphor layer acts as an isotropic radiator, the effect of this lighting arrangement 1 ′ is to provide an evenly “emitting” surface 5 that itself appears to act as a light source 5 . The light collected and emitted by the phosphor from a point on the translucent strip 5 is indicated here by groups of light rays emitted essentially uniformly in all directions. Such a lighting arrangement 1 ′ can be used to good effect to provide, for example, a retro-fit replacement for a fluorescent tube lamp. One or more such lighting arrangements 1 ′ could be placed in a long row, side by side, in a glass tube of such a lamp, so that, during operation, the lighting arrangements 1 ′ provide the appearance of an evenly illuminated “fluorescent tube”.
[0050] FIG. 9 shows a prior art automotive lighting unit comprising a number of light sources such as conventional packaged LEDs 8 arranged below a wave guide or light guide 80 . At an emission surface of the lighting unit, distinct bright areas 81 (indicated by stippling) are perceived, separated by less brightly illuminated zones (these remain white in the drawing but would in fact be darker than the bright areas 81 ), since the conventional lighting unit does not have any means of first spreading the light to suit the dimensions of the light guide before the light enters the light guide.
[0051] FIG. 10 shows an automotive lighting unit according to an embodiment of the invention. Here, the lighting unit comprises a number of lighting arrangements 1 according to the invention, each with a lighting element 10 and a light redirecting element 4 . The light redirecting elements 4 can be realized as a single entity with a single emission face 41 . The light passing through the emission face 41 is favourably uniform and already directed perpendicularly upward into a light guide 9 . An observer will see an image 90 of the apparent light source generated at the emission face 41 . This image 90 is uniform in appearance without any noticeably brighter zones or intermediate darker zones, in contrast to the arrangement shown in FIG. 9 above.
[0052] FIG. 11 shows a display illumination arrangement according to an embodiment of the invention, comprising a transparent display 100 and a number of lighting arrangements 1 arranged along one or more side faces 101 of the display 100 . The light directed into the display 100 serves to evenly illuminate the display surface.
[0053] 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.
[0054] 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. | Lighting arrangement ( 1, 1 ′) comprising a light source ( 2 ) for generating light; a spreading element ( 3 ) realised to laterally spread the generated light in a spreading plane (S), defined by an optical axis (A O ) of the light source ( 2 ) and a longitudinal axis (L) of the spreading element ( 3 ), to give an essentially uniform quantity of light per unit area at an emission face ( 41, 51 ) orthogonal to the spreading plane (S) and parallel to the longitudinal axis (L) of the spreading element ( 3 ) and a light redirecting element ( 4, 5 ) arranged to collect the spread light, which comprises a longitudinal planar emission face ( 41, 51 ), and is realised to collect the laterally spread light and to emit the collected light essentially uniformly from the emission face ( 41, 51 ). | 5 |
TECHNICAL FIELD
The invention relates generally to image sensor arrays and more particularly to methods of fabricating an image sensor array having closely spaced pixels.
BACKGROUND ART
Digital images sensors include an array of differentiated photosensitive elements. Depending upon the application, the sensor may have a one-dimensional array or a two-dimensional array of the photosensitive elements. For each element, an electrical charge is generated during each sampling time period, with the electrical charge being proportional to the intensity of light received at the element during the sampling time period.
One type of sensor array utilizes photo diodes to generate the signals that are responsive to received light. FIG. 1 illustrates a single photo diode 10 formed on a pixel interconnection structure 12 . The interconnection structure is typically formed on a substrate, such as a semiconductor substrate, using conventional CMOS (Complementary Metal Oxide Silicon) fabrication techniques. A conductive via 14 extends through the interconnection structure to conduct signals from the photo diode. The interconnection structure may be silicon oxide or silicon nitride having tungsten vias 14 .
Atop the interconnection structure 12 are three amorphous silicon layers 16 , 18 and 20 which form a PIN diode structure. The PIN diode structure is referred to as an “elevated” sensor element, since it is positioned above the surface of the supporting substrate. A lowermost amorphous silicon layer 16 contains an N-type dopant to form one electrode. Atop this bottom electrode is an intrinsic layer 18 . The third layer 20 is a P-doped amorphous silicon layer. While only one photo diode is shown in FIG. 1 , an array of closely spaced photo diodes is simultaneously fabricated. A substantially transparent top conductive layer 22 provides a common connection to all of the photo diodes. One available material for forming the top conductive layer is ITO (Indium Tin Oxide).
There are a number of issues which must be considered in the design and fabrication of sensor arrays. Defects or impurities along the interfaces of two of the amorphous silicon layers 16 , 18 and 20 will degrade performance. If an interface is damaged or is laced with impurities, intended blocking and contact properties will be adversely affected. Ideally, pristine interfaces between the imaging layers are preserved. However, the traditional fabrication techniques for differentiating the pixels within the image array require at least one of the amorphous silicon layers to be patterned in a manner which requires exposure of a layer surface to the ambience and to contamination processing.
Another concern is that defects in the amorphous silicon layers 16 , 18 and 20 may be formed by exposure to intense radiation during and after fabrication, such as by the SWE (Staebter-Wronski Effect). Defects and/or impurities lead to inter-pixel leakage during the operation of the image sensor array.
Yet another concern is that the layer patterning which typically occurs prior to deposition of the top conductive layer 22 must consider the step coverage of the material used to form the top conductive layer. Thus, if the upper amorphous silicon layer 20 is patterned in order to differentiate the adjacent pixels, the step coverage of the top conductive layer 22 must be sufficient to conformally cover the resulting topology, or there will be electrical discontinuity within the array. It is difficult to reliably and controllably pattern the upper amorphous layer without encroaching upon or damaging the intrinsic imaging layer 18 . Moreover, if only the upper amorphous silicon layer 20 is patterned, the lowermost amorphous silicon layer 16 will be common to all of the pixels, causing some pixel-to-pixel shorting.
FIGS. 2-5 illustrate process steps described in U.S. Pat. No. 5,936,261 to Ma et al., which is assigned to the assignee of the present invention. As shown in FIG. 2 , in addition to the three amorphous silicon layers 16 , 18 and 20 , there is an inner metal layer 24 . The inner metal layer is an optional layer that has a low resistivity, enhancing the connection between the conductive vias 14 and the photo diode structure defined by the three amorphous silicon layers. Below the interconnection structure 12 is a substrate 26 and an intermediate interconnection structure 28 . Often, the substrate includes CMOS sense circuitry and signal processing circuitry. The intermediate interconnection structure 28 includes pixel-specific conductive paths 30 aligned with the vias 14 and includes an additional conductive path 32 that is subsequently connected to the transparent top conductive layer, not shown. The intermediate interconnection structure 28 may be formed of a subtractive metal or may be formed of a single or dual damascene material.
In FIG. 3 , the inner metal layer 24 and the three amorphous silicon layers 16 , 18 and 20 have been wet or dry etched in order to form the desired pattern of photo diodes 34 and 36 . Then, in FIG. 4 , an insulating layer 38 is deposited. As one possibility, silicon dioxide or silicon nitride may be deposited using CVD (Chemical Vapor Deposition) processing. The insulating layer fills the gaps between the photo diodes.
In FIG. 5 , the upper surface is planarized by polishing or etching the insulating layer 38 . While not shown, the insulating layer may be patterned to expose the conductive via 40 aligned with the path 32 and the transparent top conductive layer may be formed to interconnect all of the photo diodes 34 and 36 to the via 40 . The resulting structure is shown in FIG. 6 .
A concern with the processing of FIGS. 2-5 is that it requires exacting tolerances with regard to the planarization from FIG. 4 to FIG. 5 , such that the upper amorphous silicon layer 20 is not thinned abnormally across the pixel array. Different post-polish or post-etch thicknesses of layer 20 will affect the spectral response across the pixel array. A relaxation of the required tolerances would increase the fabrication yields in forming image sensor arrays.
Another approach to defining the array of photo diodes is to merely pattern the lower electrode or the lower amorphous silicon layer of the different pixels. For example, in FIG. 2 , this would result in only the N-type layer 16 or the inner metal layer 24 being patterned, while the upper amorphous silicon layers 18 and 20 are blanket deposited. However, as previously noted, there is a susceptibility to introducing physical defects and/or impurities when the patterning techniques are applied while one of the interface surfaces of the amorphous silicon layers is exposed.
Another approach is to form trenches between adjacent photo diodes before the amorphous silicon layers are formed. Then, when the lower electrode layer is deposited, the layer will “pinch off”, at the inter-pixel trenches, thereby isolating the photo diodes. However, this pinch off approach does not isolate the intrinsic amorphous silicon layer, which is the imaging layer, so that extremely pure and stable intrinsic film is required. At different light-induced voltages, parasitic transistor devices can be undesirably formed between the photo diodes. These parasitic transistor devices promote inter-pixel leakage. An extension of the this approach is to pattern both the upper and lower electrodes (layers 16 and 20 in FIG. 1 ) to provide greater isolation. Again, inter-pixel leakage will occur within the unpatterned intrinsic semiconductor layer 18 , which is the imaging layer. Moreover, as previously noted, it is difficult to reliably and controllably pattern the upper electrode layer without encroaching upon or damaging the intrinsic imaging layer. The patterned upper electrode may also introduce successive topology that results in poor conformality of the transparent top conductive layer. Thus, while known approaches provide desired results when sufficient care is taken, each known approach carries risks.
SUMMARY OF THE INVENTION
A method of forming an image sensor array includes utilizing an operationally dependent transparent top conductive layer in the fabrication process to define an array of active pixel regions. By “operationally dependent,” what is meant herein is that the optical and/or electrical properties of the top conductive layer are significant during operations of converting light to corresponding electrical signals. Then, the patterning of the top conductive layer is used to determine patterning of the layer stack.
In one application of the invention, the transparent top conductive layer is used as a hard mask in removing selected portions of consecutive amorphous silicon layers that form a PIN structure of a P-type layer, an intrinsic layer, and an N-type layer. The top conductive layer is also used as an etch stop in planarizing the electrically insulating material that is formed within the etched gaps between active pixel regions. By example, if silicon oxide or silicon nitride are deposited after the use of the patterned top conductive layer as the hard mask, chlorine or fluorine chemistry may be used to etch the insulating layer without significantly affecting a top conductive layer of ITO.
The various layers of the layer stack and the top conductive layer may all be blanket deposited. Photolithography may then be used to pattern the top conductive layer. Masking material that is employed in photolithographically patterning the top conductive layer is removed by dry etching or wet stripping or in-situ prior to the deposition of the insulating layer.
Following the step of planarizing the deposited insulating layer using the top conductive layer as the etch stop, continuity of the top conducting layer is re-established. As one possibility, an additional blanket transparent conductive material is added. Alternatively, a dark metal or transparent conductive layer may be added in a pattern to establish electrical continuity along the top coat layer and to provide desired optical shading for interpixel optical isolation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a PIN photo diode which may be the focus of a fabrication process in accordance with the present invention.
FIGS. 2-5 illustrate a sequence of steps to form an image sensor array in accordance with a prior art approach.
FIG. 6 is a side sectional view of a fabricated image sensor array.
FIG. 7 is a sectional view of an imaging structure following the steps of forming PIN layers and a transparent top conductive layer in accordance with one embodiment of the present invention.
FIG. 8 is a sectional view of the imaging structure of FIG. 7 following patterning of the top conductive layer.
FIG. 9 is a sectional view of the imaging structure of FIG. 8 following the use of the patterned top conductive layer as a mask for etching the amorphous silicon layers.
FIG. 10 is a sectional view of the imaging structure of FIG. 9 following deposition of an insulating material.
FIG. 11 is a sectional view of the imaging structure of FIG. 10 following the planarization of the insulating layer and the deposition of a dark metal layer.
FIG. 12 is a sectional view of the structure of FIG. 11 , but with a blanket deposition of a transparent conductive material being used in place of the dark metal layer.
FIGS. 13-17 illustrate process steps in accordance with a second embodiment of the invention.
FIGS. 18-22 illustrate process steps for a third embodiment of the invention.
DETAILED DESCRIPTION
FIGS. 7-11 illustrate a sequence of fabrication steps in accordance with one embodiment of the invention. Other embodiments will be described when referring to subsequent figures. In each embodiment, the operationally dependent top conductive transparent layer is used to pattern an array of electrically and optically isolated photo elements. The results are repeatable, since the processing does not require adherence to exacting tolerances. Moreover, the processing is economical, since it eliminates at least one processing level relative to prior approaches of patterning the array. Specifically, the processing is simplified by decreasing the mask and etch levels as a consequence of patterning amorphous silicon layers by means of defining the layer geometries in the operationally dependent top conductive layer mask and in the pixel isolation etch.
With reference to FIG. 7 , a lower interconnection structure 42 is formed on a substrate. The interconnection structure 42 is known in the art. The structure may be formed of a subtractive metal or may be formed of a single or dual damascene material. The structure includes conductive paths 44 , 46 , 48 and 50 , which originate from metallic pads 52 , such as molybdenum or standard interconnect pads on the underlying substrate.
An upper interconnection structure 54 includes conductive vias 56 , 58 , 60 and 62 that are aligned with the paths 44 , 46 , 48 and 50 of the lower interconnection structure 42 . The upper interconnection structure provides reliability and structural advantages to the “elevated” PIN photo diodes that are to be fabricated. The bulk of the interconnect structure may be silicon dioxide or silicon nitride, while the vias may be formed of tungsten. The interconnection structure 54 enables formation of metal pads 64 , since the pads are formed over silicon oxide or silicon nitride rather than the material for forming the lower interconnection structure 42 . The metallic pads 64 may be titanium nitride or any other suitable conductive material that ensures a low resistance connection between the vias and the individual photo diodes to be fabricated. The benefit of the lower interconnection structure 42 is that the density of signal processing circuitry on the underlying substrate can be increased as compared to real estate availability if the photo diodes were to be fabricated directly atop the substrate.
Above the upper interconnection structure 54 are three amorphous silicon layers 66 , 68 and 70 . In one application of the invention, the three layers 66 , 68 and 70 combine to form a PIN photosensitive region, but NIP photosensitive regions are also a possibility. For the first deposited layer 66 , an N dopant is introduced into the amorphous silicon during the deposition process. A suitable dopant is phosphorous. The material should be sufficiently doped that the pixel electrode fully depletes when biased during operation. PECVD (Plasma Etched Chemical Vapor Deposition) techniques may be used. A silicon-containing gas (such as Si 2 H 6 or SiH 4 ) is often included when forming amorphous silicon pixel electrodes.
The center amorphous silicon layer 68 is an intrinsic layer. Such layers are generally formed from hydrogenated amorphous silicon and may be deposited using PECVD processing or reactive sputter processing. The deposition temperature should be sufficiently low that the hydrogen is retained within the deposited material. A suitable thickness is 1 micron.
The third amorphous silicon layer 70 is doped with a P-type material, such as boron. The thickness of the layer is selected to ensure that it does not absorb excessive short wavelength light (e.g., blue) during operation. As with the other two amorphous silicon layers 66 and 68 , PECVD processing may be used to form the layer. All three layers are blanket deposited. The layers are patterned to expose the conductive via 62 . The non vertical left edges of the layers (as viewed in FIG. 7 ) are a result of anisotropic etching of the layers. Other processing may be substituted.
A top conductive layer 72 is then formed. The top conductive layer may be ITO, but other suitable materials include thin layers of titanium nitride, silicide and certain types of transition metal nitrides and oxides. Important properties of the top conductive layer 72 are the ability to electrically connect photosensitive pixels and the ability to allow light to pass through the layer in order to impinge upon the photosensitive pixels.
In FIG. 8 , the transparent top conductive layer 72 of FIG. 7 has been altered using photolithographic techniques to yield a patterned top conductive layer 74 . A photomask 76 is shown as residing on the patterned top conductive layer. Conventional photolithographic processing may be employed, but other methods of providing a patterned top conductive layer may be substituted. For example, techniques are known for selectively depositing the ITO material, so that etching of the material is not required.
In FIG. 9 , the patterned top conductive layer 74 is used as a hard mask to pattern isolation trenches 78 , 80 , 82 and 84 that define the array of photosensitive pixels 86 , 88 and 90 . In the embodiment of FIG. 9 , each photosensitive pixel is a PIN photo diode. An etchant is selected on the basis of having a high selectivity in etching the amorphous silicon layers 66 , 68 and 70 relative to the material of the patterned top conductive layer 74 .
In FIG. 10 , an insulating layer 92 is shown as having been deposited on the surface of the patterned top conductive layer 74 and in the isolation trenches 78 , 80 , 82 and 84 . The insulating material should have sufficient step coverage to fill a substantial portion of each trench, although complete coverage of the volume of the trenches is not imperative. PETEOS deposition at 300 degrees Celsius may be used, where PETEOS refers to Plasma-Enhanced deposition of oxides from TEOS (tetra-ethyl-ortho-silicate). In comparing FIGS. 9 and 10 , it can be seen that the photomask 76 no longer resides on the surface of the patterned top conductive layer 74 . The photomask layer 76 was removed by wet etching or dry stripping or in-situ prior to PETEOS deposition. Even if a process were to be developed to provide PETEOS deposition at less than 100 degrees Celsius, with the photomask 76 remaining intact, the end product would be adversely affected, since the photomask over the transparent ITO will significantly alter the imaging properties of the photosensitive pixels 86 , 88 and 90 .
Referring now to FIG. 11 , the patterned top conductive layer 74 is used as an etch stop in providing PETEOS etch back. That is, the planarization of the insulating material employs the transparent conductive layer as an etch stop.
In addition to the planarization, FIG. 11 illustrates the deposition of a patterned connectivity layer 94 . The connectivity layer re-establishes the electrical conductivity along the top conductive layer 74 , so that the entire layer is connected to the via 62 and the conductive path 50 that provide the correct bias to each photosensitive pixel 86 , 88 and 90 . In the embodiment shown in FIG. 11 , the connectivity layer may be a dark metal layer that provides shading, as described in U.S. Pat. No. 6,326,601 to Hula et al. and U.S. Pat. No. 6,455,836 to Hula. The dark metal layer may be tungsten or titanium-tungsten that provides the connectivity function and that acts as a light-shielding layer over one or more of the photosensitive pixels in the array to form a dark reference device or dark pixel. As an alternative to using the dark metal layer 94 , FIG. 12 illustrates the use of a second transparent conductive layer 95 may be blanket deposited across the structure. The thin transparent layer 95 may be used to provide the connectivity for applications in which light shielding is not desired.
FIG. 11 also shows a substrate 96 and a single transistor 98 that is used to represent the image collection and signal processing circuitry fabricated on the substrate 96 . As previously noted, the substrate may be a semiconductor substrate, such as silicon.
FIGS. 13-17 illustrate a second embodiment of the invention. Many of the features and steps are identical to those described with reference to the first embodiment, allowing reference numerals to be duplicated in the drawings. In FIG. 13 , the only difference is that the sequence of depositing a layer stack includes the formation of a metal layer 100 that will be subsequently patterned to form pads similar to the pads 64 of FIG. 7 . As one possibility, the layer 100 may be titanium nitride. The metal layer 100 is the same as the layer that forms the pads, except that layer 100 is not patterned initially.
In FIG. 14 , photolithography yields the patterned top conductive layer 74 that is used as the hard mask and the etch stop for the isolation of photosensitive pixels. In FIG. 15 , the pixels 86 , 88 and 90 are formed by etching the trenches 78 , 80 , 82 and 84 . In this embodiment, the etching includes patterning the metal layer 100 , in addition to the three amorphous silicon layers 66 , 68 and 70 . The deposition of the insulating layer 92 in FIG. 16 extends to the surface of the upper interconnection structure 54 . The insulating material is then etched in order to planarize the top surface, with the patterned top conductive layer 74 being used as the etch stop. Finally, in FIG. 17 , a thin layer 102 is deposited to re-establish continuity along the surface of the patterned top conductive layer 74 . The layer 102 takes the place of the dark metal connectivity layer 94 of FIG. 11 . The layer 102 may be ITO or any other transparent conductive material. However, one can also employ a patterned dark metal connectivity 94 in this embodiment of the invention.
FIGS. 18-22 illustrate a third embodiment of the invention. Referring firstly to FIG. 18 , in this embodiment, the top conductive layer 72 is blanket deposited prior to the preliminary etching of the amorphous silicon layers 66 , 68 and 70 and the metal layer 100 . Thus, the various layers extend continuously across the surface of the upper interconnection structure 54 . As a consequence, the patterned top conductive layer 74 of FIG. 19 has a different configuration than in the first two illustrated embodiments. Specifically, the patterning includes a leftward portion (as viewed in FIG. 19 ) that exposes the region of the amorphous silicon layers and the metal layer 100 that are to be etched in order to reach the conductive via 62 . Optionally, the etching process may be implemented to allow the metal layer 100 to remain intact while the amorphous silicon is etched.
In FIGS. 20 and 21 , the patterned top conductive layer 74 is used as a hard mask in the etching of the layers to yield the trenches 78 , 80 , 82 and 84 that space apart the adjacent photosensitive pixels 86 , 88 and 90 . The insulating layer 92 is deposited within the trenches and on the exposed region of the upper interconnection structure 54 . In FIG. 22 , the assembly is planarized and the connectivity layer 94 is added. In this embodiment, the connectivity layer is a patterned dark metal layer, but a blanket deposition of a transparent conductive material, such as ITO, may be substituted.
While the layers that form the PIN photo diode have been described as being amorphous silicon layers, other materials may be used. As one example, the layers may be appropriately doped amorphous germanium layers. Moreover, the photosensitive pixels may be NIP photo diodes, as previously noted. Other modifications of the previously described embodiments are also possible without diverging from the invention. | A method of forming an image sensor array uses a transparent top conductive layer first as an etch mask in forming inter-pixel trenches and then as an etch stop in a planarization step, whereafter the top conductive layer is integral to operation of the completed image sensor array. During fabrication, a stack of layers is formed to collectively define a continuous photosensitive structure over an array area. The operationally dependent transparent top conductive layer is then used in the patterning of the photosensitive structure to form trenches between adjacent pixels. An insulating material is deposited within the trenches and the top conductive layer is then used as the etch stop in planarizing the insulating material. The method includes providing a connectivity layer that provides electrical continuity along the patterned top conductive layer. | 7 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention generally relates to integrated circuits, and more particularly, to a thermal sensor for an integrated circuit.
BACKGROUND OF THE INVENTION
[0002] Temperature gradients across the dies of today's high performance very large scale integration (VLSI) components, such as a microprocessor, can adversely affect component performance. For example, a temperature variation between two clock driver circuits within a microprocessor often results in a skew in the system clock of the microprocessor. Moreover, the die of the microprocessor may reach an unacceptable temperature that causes the microprocessor to malfunction or stop functioning.
[0003] To protect a microprocessor from thermal damage, a diode is typically placed in the die of the microprocessor to provide a die temperature indication. This diode is driven with a fixed amount of current, and the corresponding voltage drop across the diode provides an indication of the microprocessor temperature. Unfortunately, the diode provides a temperature reading that is accurate to about ±10° C., which is often not accurate enough to provide an early indication of a temperature abnormality. Moreover, a single diode is typically utilized to measure the die temperature of the entire microprocessor.
[0004] Given the size and complexity of current and future microprocessors, it is extremely difficult to determine a temperature gradient across the microprocessor using only a single diode positioned at a single location on the microprocessor die. As such, substantial variations in temperature across the die of the microprocessor can go undetected. Consequently, early indications that a thermal related problem exists in a portion of the microprocessor go undetected.
SUMMARY OF THE INVENTION
[0005] The present invention addresses the above-described limitations of sensing the temperature of an integrated circuit. The present invention provides a thermal sensor and a method to accurately sense the temperature of an integrated circuit.
[0006] In one embodiment of the present invention, a thermal sensor having an oscillator circuit and a counter circuit is provided to sense a temperature of an integrated circuit. The oscillator circuit generates a first oscillating reference signal that oscillates at a frequency substantially independent of the temperature of the integrated circuit. The oscillator circuit also generates a second oscillating signal at a frequency that varies depending on the temperature of the integrated circuit. The counter circuit is configured to include a first counter circuit to perform a count on the oscillating reference signal and a second counter circuit to perform a count on the temperature dependent oscillating signal. In operation, the oscillating reference signal oscillates at a higher frequency value than the frequency value of the temperature dependent oscillating circuit. In this manner, when the first counter of the counter circuit reaches a predetermined value, the first counter asserts an output signal that halts the second counter from performing the count on the temperature dependent oscillating signal. The count held by the second counter when the first counter asserts its output signal represents the sensed temperature of the integrated circuit. Once the second counter is halted, the count held by the second counter is shifted in a parallel manner to a shift register so that the temperature value can be serially shifted to a controller, such as a service microprocessor for further processing.
[0007] The counter circuit also includes a first synchronizer to synchronize the output signal of the first counter to the temperature dependent oscillating signal's frequency domain. This synchronized signal is utilized as a first control signal to halt the incrementing of the second counter. The counter circuit also provides a second synchronizer to synchronize the output signal of the first counter to the main system clock's frequency domain. This synchronized signal is utilized as a second control signal to trigger the loading of the serial shift register with the count held by the second counter. The first control signal asserted by the first synchronizer is also utilized to reset a counter register of the counter circuit utilized to hold the count on the temperature dependent oscillating signal.
[0008] The above-described approach provides an integrated circuit with an integrated thermal sensor capable of providing a temperature response with an accuracy of ±1.5° C. As a result, a temperature spike in a particular area of the integrated circuit can be more easily detected before a malfunction can occur due to an elevated temperature of the integrated circuit. In this manner, multiple thermal sensors can be placed at multiple locations throughout the die of the integrated circuit to accurately track and monitor the thermal profile of the entire integrated circuit.
[0009] In accordance with another aspect of the present invention, a method is performed in an integrated circuit having a thermal sensor to sense a die temperature of the integrated circuit. The sensor generates two oscillating signals. The first oscillating signal has a frequency value that is substantially independent of the die temperature of the integrated circuit while the second oscillating signal has a frequency value that is dependent upon the die temperature of the integrated circuit. A counter performs a first count on the first oscillating signal and a second count on the second oscillating signal until the first count of the first oscillating signal reaches a desired value. Upon reaching the desired value of the first count, the counter halts the second count of the second oscillating signal. The second count of the second oscillating signal is then sampled to indicate the die temperature of the integrated circuit as sensed by the thermal sensor. To ensure the accuracy of the second count of the second oscillating signal, the control signal utilized to halt the second count of the second oscillating signal is synchronized to the second oscillating signal's frequency domain. The control signal is further synchronized with an edge of a system clock signal to ensure that a shift register that asserts the second count of the second oscillating signal is holding stable data before it serially shifts data in unison with the system clock signal.
[0010] The above-described approach benefits a microprocessor architecture that utilizes an active sensor to report a die temperature of the microprocessor. As a consequence, the microprocessor is able to monitor and react to an unacceptable die temperature measurement by the thermal sensor without the processor malfunctioning or halting altogether. Moreover, the thermal sensor merely utilizes the system clock to synchronize the operation of a shift register that asserts the sensed die temperature of the integrated circuit. In this manner, the thermal sensor is still able to accurately sense a die temperature of an integrated circuit even if the system clock is slowed or throttled due to over temperature concerns of the integrated circuit or due to any other effect that would reduce the operating frequency of the system clock.
[0011] In yet another aspect of the present invention, a thermal sensor embedded in an integrated circuit that asserts a die temperature value is provided. The thermal sensor includes a sensor circuit that generates an oscillating reference signal and a temperature dependent oscillating signal. The oscillating reference signal generated by the sensor circuit is substantially temperature independent. The thermal sensor also includes an output circuit that converts the oscillating reference signal and the temperature dependent oscillating signal into the die temperature value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] An illustrative embodiment of the present invention will be described below relative to the following drawings.
[0013] [0013]FIG. 1 depicts a block diagram of an integrated circuit suitable for practicing the illustrative embodiment of the present invention.
[0014] [0014]FIG. 2 illustrates a block diagram of the exemplary thermal sensor suitable for practicing the illustrative embodiment of the present invention.
[0015] [0015]FIG. 3 depicts a block diagram of the oscillator circuit of the exemplary thermal sensor suitable for practicing the illustrative embodiment of the present invention.
[0016] [0016]FIG. 4 depicts a block diagram of an exemplary counter circuit of the exemplary thermal sensor suitable for practicing the illustrative embodiment of the present invention.
[0017] [0017]FIG. 5 is a flow diagram illustrating steps taken for practicing an illustrative embodiment of the present invention.
DETAILED DESCRIPTION
[0018] The illustrative embodiment of the present invention provides a thermal sensor that indicates a die temperature of an integrated circuit with an accuracy of ±1.5° C. In the illustrative embodiment, a thermal sensor of an integrated circuit is adapted to have an oscillator circuit to produce two oscillating signals and a counter circuit to convert the two oscillating signals into a value that represents the sensed die temperature of the integrated circuit.
[0019] In the illustrative embodiment, the thermal sensor is attractive for use in integrated circuits that desire a highly accurate die temperature measurement. The internal sensor operates in an independent manner, that is, without the need for an independent voltage or current source. Moreover, the thermal sensing properties of the thermal sensor are unaffected by frequency variation of the system clock. The illustrative embodiment allows for an active thermal sensor to be placed in multiple locations across an integrated circuit, such as a microprocessor to permit thermal profiling of the integrated circuit as its executes various functions, for example various code streams.
[0020] [0020]FIG. 1 is a block diagram of an exemplary integrated circuit 12 that is suitable for practicing the illustrative embodiment of the present invention. The thermal sensor 14 is an active device within the exemplary integrated circuit 12 . The thermal sensor 14 is an independent sensor in that it operates without an independent current source or an independent voltage source. The thermal sensor 14 is embedded in the die of the exemplary integrated circuit 12 to provide an accurate die temperature measurement of the exemplary integrated circuit 12 . The measurement accuracy of the thermal sensor 14 is about ±1.5° C. Those of ordinary skill in the art will recognize that the thermal sensor 14 can also be adapted to operate with an independent voltage source and an independent current source. In this manner, the thermal sensor 14 can be utilized as a calibration sensor to provide a baseline measurement of the exemplary integrated circuit 12 while the exemplary integrated circuit 12 is in a power down state. Moreover, those of ordinary skill in the art will recognize that the exemplary integrated circuit 12 can include more than one thermal sensor 14 , for example two sensors, three sensors, four sensors or more depending on the die size of the integrated circuit or the number of areas that are to be monitored or both.
[0021] [0021]FIG. 2 illustrates the thermal sensor 14 in more detail. The thermal sensor 14 is adapted to include an oscillator circuit 20 and a counter circuit 22 . The oscillator circuit 20 generates an oscillating reference signal and a temperature dependent oscillating signal that drives the counter circuit 22 . The counter circuit 22 performs a count on the oscillating reference signal and a count on the temperature dependent oscillating signal to determine a die temperature value of the exemplary integrated circuit 12 . Those of ordinary skill in the art will recognize that the counter circuit 22 can perform the count of each signal asserted by the oscillator circuit 20 based on either a rising edge transition of each oscillating signal, a falling edge transition of each oscillating signal or based on any other suitable manner, for example, the number of zero-point crossings, or the like. When the count for the oscillating reference signal reaches a desired or predetermined value, a control signal within the counter circuit 22 is asserted to halt the count of the temperature dependent oscillating signal. To generate the control signal utilized to halt the count of the temperature dependent oscillating signal, an output signal 47 of the first counter circuit 40 , which are illustrated in FIG. 4, is synchronized to an edge of the temperature dependent oscillating signal to ensure an accurate count. The control signal is then synchronized with a system clock signal of the exemplary integrated circuit 12 to control when the count of the temperature dependent oscillating signal is loaded in parallel into a shift register. The count loaded into the shift register represents the newest temperature measurement of the thermal sensor 14 and is shifted out of the thermal sensor 14 in serial fashion in conjunction with the system clock signal.
[0022] [0022]FIG. 3 illustrates the oscillator circuit 20 in more detail. The oscillator circuit 20 is adapted to include a temperature dependent oscillator circuit 24 and a reference oscillator circuit 26 . The temperature dependent oscillator circuit 24 generates the temperature dependent oscillating signal and the reference oscillator circuit 26 generates the oscillating reference signal. Typically, the oscillating reference signal oscillates at a higher frequency value than the temperature dependent oscillating signal.
[0023] The temperature dependent oscillator circuit 24 includes a temperature dependent voltage source 28 coupled to a voltage regulator 30 that drives the voltage controlled oscillator (VCO) 32 with a temperature dependent voltage signal to generate the temperature dependent oscillating signal. The temperature dependent voltage source 28 generates a voltage signal having a voltage value that is dependent upon the temperature of the substrate on which the die of the exemplary integrated circuit 12 is built. As the temperature of the substrate increases the voltage value of the voltage signal asserted by the temperature dependent voltage source 28 decreases. In contrast, as the temperature of the substrate on which the die of the exemplary integrated circuit 12 is built decreases, the voltage value of the voltage signal asserted by the temperature dependent voltage source 28 increases. The temperature dependent voltage source 28 is configured as a Delta Voltage base-emitter (V BE ) circuit. The temperature dependent voltage source 28 utilizes an output node of the Delta V BE circuit to generate the temperature dependent voltage signal. The output node utilized by the temperature dependent voltage source 28 is not affected by the current mirroring that occurs within the Delta V BE circuit to cancel a negative temperature coefficient and a positive temperature coefficient to generate the reference voltage signal that is discussed below in conjunction with the reference oscillator circuit 26 . Those of ordinary skill in the art will recognize that the Delta V BE discussed above is also know in the art as a bandgap reference circuit.
[0024] The voltage regulator 30 operates to control the current drive to the VCO 32 which, in turn, significantly improves the power supply rejection ratio (PSRR) of the temperature dependent oscillator circuit 24 . In this fashion, power supply noise associated with the power grid or bus that drives the oscillator circuit 20 can be dramatically reduced to ensure that the temperature dependent oscillator circuit 24 is desensitized to power supply noise. This allows the temperature dependent oscillator circuit 24 to generate a stable temperature dependent oscillating signal. Nevertheless, those of ordinary skill in the art will recognize that the temperature dependent oscillator circuit 24 can be configured to operate without the voltage regulator 30 .
[0025] The VCO 32 generates a temperature dependent oscillating signal having a frequency value directly proportional to the voltage value of the temperature dependent voltage signal generated by the temperature dependent voltage source 28 . In this manner, as the temperature of the substrate on which the die of the exemplary integrated circuit 12 increases, the voltage value of the temperature dependent voltage signal asserted by the temperature dependent voltage source 28 falls in value, which, in turn, results in the VCO 32 generating a temperature dependent oscillating signal with a lower frequency value. In contrast, if the temperature of the substrate on which the die of the exemplary integrated circuit 12 is built decreases, the temperature dependent voltage source 28 generates a temperature dependent voltage signal having a higher voltage value, which, in turn, results in the VCO 32 generating a temperature dependent oscillating signal having a higher frequency value.
[0026] The reference oscillator circuit 26 is adapted to include a temperature independent voltage source 34 coupled to a voltage regulator 36 to drive a VCO 38 with a substantially temperature independent voltage signal to generate the oscillating reference signal. The temperature independent voltage source 34 provides a voltage signal having a voltage value that is substantially independent of the substrate temperature on which the die of the exemplary integrated circuit 12 is built. Those of ordinary skill in the art will recognize that the temperature independent voltage source 34 can be configured as a V BE reference circuit or bandgap reference circuit. In operation, the bandgap reference circuit generates a differential voltage between two bipolar base emitter voltages (V BE ). Essentially, the bandgap reference circuit generates a voltage with a positive temperature coefficient having the same magnitude as the V BE 's negative temperature coefficient, which are added together through a current mirroring technique to result in a voltage signal with a zero value temperature coefficient. Consequently, the voltage signal generated by the bandgap reference circuit is substantially independent of the die temperature of the exemplary integrated circuit 12 .
[0027] The voltage regulator 36 current limits the voltage signal generated by the temperature independent voltage source 34 to significantly improve the PSRR of the reference oscillator circuit 26 . In this manner, the voltage regulator 36 filters a significant amount of power supply noise associated with the power bus (V DD ) that provides power to the reference oscillator 26 . Consequently, the oscillating reference signal generated by the VCO 38 is a more robust and stable signal.
[0028] The VCO 38 generates an oscillating reference signal having a frequency value directly proportional to the voltage value of the voltage signal generated by the temperature independent voltage source 34 . The voltage value of the voltage signal generated by the temperature independent voltage source 34 remains substantially at the same voltage level regardless of an increase or decrease in the temperature of the substrate on which the die of the exemplary integrated circuit 12 is built. As such, the frequency value of the oscillating signal generated by the VCO 38 is substantially unchanged as the die temperature of the exemplary integrated circuit 12 increases or decreases.
[0029] From the discussion above, those of ordinary skill in the art will recognize that the temperature independent voltage source 34 and the temperature dependent voltage source 28 can be configured as a single voltage reference source, such as a bandgap reference circuit or as two distinct voltage reference sources, such as two bandgap reference circuits. Moreover, those of ordinary skill in the art will appreciate that the configuration of the oscillator circuit 20 offers a significant benefit in terms of noise immunity because Vss and substrate noise are common to both the temperature independent voltage source 34 and the temperature dependent voltage source 28 .
[0030] [0030]FIG. 4 illustrates the counter circuit 22 in more detail. The counter circuit 22 is adapted to include a first counter circuit 40 , a second counter circuit 42 and an 25 output circuit 43 . The first counter circuit 40 performs a first count on the oscillating reference signal generated by the reference oscillator circuit 26 . The second counter circuit 42 performs a second count on the temperature dependent oscillating signal generated by the temperature dependent oscillator circuit 24 . The output circuit 43 operates to assert the sensed die temperature as sensed by the thermal sensor 14 . Those of ordinary skill in the art will recognize that the first counter circuit 40 and the second counter circuit 42 can be configured to perform their respective count in a number of ways. For example, the counters can perform a count based on a rising edge, a falling edge or both, a count based on the number of threshold crossings or any analog to digital conversion technique that is suitable to the needs of the application.
[0031] The first counter circuit 40 includes a counter register 46 coupled to an incrementer 44 . The counter register 46 is clocked by the oscillating reference signal generated by the reference oscillator circuit 26 . The first counter circuit 40 is an edge sensitive circuit that increments the value held by the counter register 46 by one for each received cycle of the oscillating reference signal. Those of ordinary skill in the art will recognize that the first counter circuit 40 can be configured to increase the count held by the counter register on either a rising edge or a falling edge of the oscillating reference signal. Moreover, those of ordinary skill in the art will recognize that the first counter circuit 40 can be configured to be either an up counter or a down counter to perform the count on the oscillating reference signal.
[0032] In operation, the counter register 46 is typically configured to be a twelve-bit register. The counter register 46 stores the current count of the oscillating reference signal as determined by the incrementer 44 until the counter register 46 reaches a maximum count value. When the counter register 46 reaches its maximum count value, it asserts an output signal 47 to the first synchronizer circuit 51 . The incrementer 44 increments the count held by the counter register 46 by one in accordance with a detected edge of the oscillating reference signal. The incrementer 44 typically increments the count held by the counter register 46 by one upon the detection of a positive edge transition of the oscillating reference signal. Those of ordinary skill in the art will recognize that the first counter circuit 40 operates in a clock domain that is independent of the system clock domain for the exemplary integrated circuit 12 . In this manner, the first counter circuit 40 can perform an accurate count on the oscillating reference signal over a wide range of system clock frequencies. This capability is significant should the system clock frequency be reduced or throttled to reduce power dissipation of the exemplary integrated circuit 12 .
[0033] The second counter circuit 42 is adapted to include an incrementer 48 coupled to a counter register 50 to perform a count on the temperature dependent oscillating signal generated by the temperature dependent oscillator circuit 24 . The counter register 50 holds the current count of the temperature dependent oscillating signal as determined by the incrementer 48 . The incrementer 48 increments the count held by the counter register 50 by one upon detection of an edge of the temperature dependent oscillating signal. Typically, the incrementer 48 increments the count held by the counter register 50 by one for each detected rising edge of the temperature dependent oscillating signal. Nevertheless, those of ordinary skill in the art will recognize that the incrementer 48 can also be configured to increment the count held by the counter register 50 by one upon the detection of a falling edge of the temperature dependent oscillating signal. Those of ordinary skill in the art will recognize that the second counter circuit 42 operates in a clock domain that is independent of the system clock domain for the exemplary integrated circuit 12 and the clock domain of the first counter circuit 40 . In this manner, the second counter circuit 42 can perform an accurate count on the temperature dependent oscillating signal over a wide range of system clock frequencies. This capability is significant should the system clock frequency be reduced or throttled to reduce power dissipation of the exemplary integrated circuit 12 .
[0034] In operation, the counter register 50 is typically configured to be an eleven-bit register to hold the count determined by the incrementer 48 . Those of ordinary skill in the art will recognize that counter register 46 is configured to hold at least one more bit than the counter register 50 because the oscillating reference signal typically has a higher frequency value than the temperature dependent oscillating signal. In this manner, the most significant bit of the counter register 46 can be used to generate the output signal 47 , which, in turn, initiates assertion of the first control signal 53 to halt the count in the second counter circuit 42 . Moreover, those of ordinary skill in the art will recognize that the number of bits that the counter registers 46 and 50 hold can vary depending on the application, the accuracy of the temperature measurement required and the like.
[0035] As indicated above, the incrementer 48 and the counter register 50 operate in a second time domain that is independent of the system time domain provided by the system clock driver 64 and the time domain of the first counter circuit 40 . In this manner, the incrementer 48 and the counter register 50 are able to accurately measure the current die temperature of the exemplary integrated circuit 12 even if the system clock domain frequency is reduced to compensate for an over temperature condition in the exemplary integrated circuit 12 . As such, those of ordinary skill in the art will recognize that the thermal sensor 14 operates with three distinct clock domains.
[0036] The output circuit 43 is adapted to include a first synchronizer circuit 51 , a second synchronizer circuit 55 and a shift register 62 . The first synchronizer circuit 51 synchronizes an edge of the output signal 47 from the counter register 46 and an edge of the temperature dependent oscillating signal to assert a first control signal 53 . The second synchronizer circuit 55 synchronizes an edge of the first control signal 53 asserted by the first synchronizer circuit 51 with an edge of a system clock signal of the exemplary integrated circuit 12 to enable the loading of the shift register 62 . The shift register 62 serially shifts out the count from the second counter circuit 42 to indicate the temperature value sensed by the thermal sensor 14 .
[0037] The first synchronizer circuit 51 includes a synchronizer 52 to assert the first control signal 53 and an edge detector 54 . The first control signal 53 asserted by the synchronizer 52 is coupled to the edge detector 54 to detect an edge transition of the first control signal 53 asserted by the synchronizer 52 . The edge detector 54 is utilized to assert a reset signal to the counter register 50 upon the detection of a falling edge of the first control signal 53 to reset the counter register 50 to zero. The first control signal 53 asserted by the synchronizer 52 also provides the counter register 50 with an enable indication to begin a new count of the temperature dependent oscillating signal. Typically, the counter register 50 is adapted with an inverse logic enable. In operation, the first control signal 53 halts the count by the second counter circuit 42 . The count held by the counter register 50 when the second counter circuit 42 is halted by the first control signal 53 represents a current temperature of the die of the exemplary integrated circuit 12 as sensed by the thermal sensor 14 . The first control signal 53 asserted by the synchronizer 52 also drives a second synchronizer circuit 55 .
[0038] The second synchronizer circuit 55 includes a system clock driver 64 that asserts the system clock signal. Also included in the second synchronizer circuit 55 is a synchronizer 56 and a clock divider 60 . The clock divider 60 reduces the frequency value of the system clock signal asserted by the system clock driver 64 to ensure that the synchronizer 56 asserts a valid second control signal 57 . Those of ordinary skill in the art will recognize that the clock divider 60 is an optional element that allows the illustrative embodiment to operate over a range of system clock signal frequencies. The second valid control signal allows a shift register 62 to be loaded with the current count held by the counter register 50 . The second synchronizer circuit 55 also includes an edge detector 58 that is coupled to the output of the synchronizer 56 to detect an edge transition of the second control signal 57 asserted by the synchronizer 56 . Upon detection of a positive edge transition of the second control signal 57 by the edge detector 58 , the edge detector 58 asserts an enable signal to the shift register 62 to enable a parallel load of the current count held by the counter register 50 . The system clock driver 64 also clocks the shift register 62 to serially shift out the count held by the shift register 62 for evaluation.
[0039] [0039]FIG. 5 illustrates the steps taken by the thermal sensor 14 to determine a die temperature of the exemplary integrated circuit 12 . To sense a die temperature of the exemplary integrated circuit 12 , an oscillating reference signal is generated (Step 70 ) and a temperature dependent oscillating signal is generated (Step 72 ). The oscillating reference signal typically oscillates at a higher frequency value than the temperature dependent oscillating signal. The oscillating reference signal and the temperature dependent oscillating signal are each provided to a counter which performs a count on the number of cycles in the oscillating reference signal (Step 74 ) and a count on the number of cycles in temperature dependent oscillating signal (Step 76 ). When the counter for the oscillating reference signal reaches a pre-determined value an output signal is asserted and synchronized to the temperature dependent oscillating signal to assert a first control signal (Step 78 ). The assertion of the first control signal causes the count for the temperature dependent oscillating signal to halt.
[0040] The first control signal is further synchronized with the frequency of a system clock signal to produce a second control signal 57 . The second control signal 57 is monitored for a particular edge transition. When the particular edge transition is detected, the value stored by the counter performing the count of the temperature dependent oscillating signal is moved in parallel to a shift register to become the newest die temperature measurement of the thermal sensor 14 . The shift register then asserts its newly loaded value in serial fashion to indicate a die temperature of the exemplary integrated circuit 12 (Step 80 ). At this point, the counter performing the count of the temperature dependent oscillating signal is reset to zero and the measurement process begins again once the output signal of the counter performing the count on the oscillating reference signal returns to a logic “0” level (Step 82 ).
[0041] While the present invention has been described with reference to a preferred embodiment thereof, one of ordinary skill in the art will appreciate that various changes in form and detail may be made without departing from the intended scope of the present invention as defined in the pending claims. For example, the shift register that is responsible for serially shifting the sensed die temperature value can be configured with additional control features such as a shift enable or with a scan data port to add additional functionality and ensure proper operation. Moreover, the shift register that shifts out the sensed die temperature value can be adapted to shift out the sensed temperature value in parallel fashion. The thermal sensor can be configured to assert a signal to indicate to a microprocessor that a current die temperature value is available. In addition, multiple thermal sensors can be coupled together in a single serial shift chain. Furthermore, the sensed die temperature value can be further processed, for example the die temperature measurement can be subtracted from 2048 and the three most significant bits could be dropped to provide an 8-bit value that has the measurement accuracy as the 11-bit value and so on. | An apparatus and method are provided for sensing a physical stimulus of an integrated circuit. The apparatus and method allow for accurate die temperature measurements of the integrated circuit and are able to provide a highly accurate die temperature measurement without the need for an independent voltage source or current source. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 11/626,756, filed Jan. 24, 2007, which is a continuation-in-part of International Patent Application No. PCT/CA2006/001040, with an international filing date of Jun. 27, 2006, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 60/693,502, filed Jun. 24, 2005, the entire contents of each of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
In one of its aspects, the present invention relates to a lamp device. In another of its aspects, the present invention relates to a radiation lamp. In yet another of its aspects, the present invention relates to a radiation source assembly. In yet another of its aspects, the present invention relates to a radiation source module. In yet another of its aspects, the present invention relates to a fluid treatment system. In yet another of its aspects, the present invention relates to a water disinfection system.
2. Background Information
Fluid treatment systems such as water disinfection systems are generally known in the art.
See, for example, one or more of the following U.S. Pat. Nos.:
Re36,896,
3,418,370,
4,482,809,
4,872,980,
5,006,244,
5,471,063,
5,504,355,
5,538,210,
6,342,188,
6,500,346,
6,507,028,
6,646,269,
6,674,084,
6,803,586, and
6,863,078.
Many of the above-identified United States patents teach fluid treatment systems that employ ultraviolet (UV) radiation to kill, sterilize and/or prevent replication of microorganisms (bacteria, viruses, pathogens and the like) that may be present in the fluid.
Generally, such conventional fluid treatment systems employ an ultraviolet radiation lamp to emit radiation of a particular wavelength or range of wavelengths (usually between 185 and 400 nm) to kill, sterilize and/or prevent replication of microorganisms (bacteria, viruses, pathogens and the like) that may be present in the fluid.
Conventional ultraviolet radiation lamps include low pressure lamps, medium pressure lamps, low pressure high output lamps and the like.
In more recent years, it has become conventional to use such ultraviolet lamps configured to have all of the electrical connections disposed at one end of the lamp. See, for example, FIGS. 2-8 of U.S. Pat. No. 4,700,101 [Ellner, et al. (Ellner)] and FIGS. 1, 2 and 4 of U.S. Pat. No. 5,166,527 [Solymar].
As can be seen from the conventional radiation lamps taught by Ellner and Solymar, the electrical connection pins are elongate and are disposed such that the axes of the pins are parallel with the longitudinal axes of radiation lamp. In other words, the electrical connection is made by pushing an end cap or other connection base on to the pins in a direction parallel to the longitudinal axis of the radiation lamp.
The problem with this approach is that in many applications, the radiation lamp is immersed in a flow of water and turbulence created within that water treatment system invariably imparts a vibratory motion to the lamps which frequently results in lamps being vibrated or shaken loose of its electrical connection base or socket thereby causing the lamps to be rendered completely or intermittently inoperative. When such an event occurs, the water being treated may not be fully disinfected.
More recently, other attempts to address this problem have used a relatively complicated mechanical connection (e.g., a so-called “push-and-twist” connection) to secure the lamp to the connection base. See, for example, U.S. Pat. No. 5,422,487 [Sauska, et al. (Sauska)] and U.S. Pat. No. 6,884,103 [Kovacs]. The problem with these approaches is the complexity of the mechanical connection between the lamp and the base unit requiring the use of springs, specialized connection lugs and the like. Further, a connection system which is predicated on a dual motion system such that pushing and twisting gives rise to a higher incidents of lamp breakage and other damage to the module by field personal.
Accordingly, there remains the need in the art for a lamp device, particularly a radiation lamp, which will provide a reliable electric connection on the one hand, yet be relatively inexpensive, uncomplicated and simple to implement on the other hand.
SUMMARY OF THE INVENTION
It is an object of the present invention to obviate or mitigate at least one of the above-mentioned disadvantages of conventional fluid treatment systems.
Accordingly, in one of its aspects, the present invention provides a lamp device comprising a longitudinal axis, a first elongate electrical connector and a second elongate electrical connector, each of the first elongate electrical connector and the second elongate connector being non-parallel with respect to the longitudinal axis.
In another of its aspects, the present invention relates to a radiation source assembly comprising such a lamp device, together with a radiation transparent protective sleeve.
In another of its aspects, the present invention provides a radiation lamp comprising: an elongate radiation-emitting cavity having a longitudinal axis; a first electrical connection base disposed at a first end of the elongate radiation-emitting cavity; a pair of first elongate electrical connectors and a pair of second elongate electrical connectors disposed in the first electrical connection base; each of the first elongate electrical connector and the second elongate connector being non-parallel with respect to the longitudinal axis.
In yet another of its aspects, the present invention provides a radiation source module comprising such a radiation lamp and a first support member for supporting the radiation lamp, the first support member comprising a second electrical connection base for engagement with the first electrical connection base and connection to a power supply.
Other aspects of the present invention relate to fluid treatment systems and water disinfection systems incorporating the above lamp device, radiation source assembly, radiation lamp and radiation source module, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will be described with reference to the accompanying drawings, wherein like reference numerals denote like parts, and in which:
FIGS. 1-4 illustrate components of a first preferred embodiment of the present lamp device.
FIGS. 5-8 illustrate portions of a second preferred embodiment of the present lamp device.
FIGS. 9-14 illustrate portions of a third preferred embodiment of the present lamp device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described below with reference to FIGS. 1-14 . In FIGS. 1-14 , there is shown in detail the electrical connection portion of a radiation lamp and/or the connection thereof to a complementary base unit. The remaining detail of the lamp is not shown for easier understanding. However, those of skill in the art will readily recognize how the specific connection shown in the Figures can be implemented in a lamp design by reference to the various prior art patents referred to above.
With reference to FIGS. 1-4 , there is illustrated a first electrical base unit 100 and a second electrical base unit 150 .
First electrical connection base unit 100 comprises a housing 102 . An end portion 104 of unit 100 comprises a first pair of electrical connectors 106 and a second pair of electrical connectors 108 .
End portion 104 comprises an undulating shape having a series of peaks 110 and valleys 112 . Electrical connectors 106 , 108 are connected to wire or other suitable electrical conveyance (not shown) disposed within housing 102 which is then connected to the radiation-emitting cavity of the lamp in a conventional manner.
With particular reference to FIG. 2 , there is illustrated an enlarged view of base unit 150 . As shown, base unit 150 comprises a first pair of electrical receptacles 152 and a second pair of electrical receptacles 154 . These receptacles are disposed at a first end portion 156 of base unit 150 . Disposed at another end portion 158 of base unit 150 is a sealing system which functions in a manner similar to that described in U.S. Pat. Nos. 4,872,980 and 5,006,244 referred to above. Specifically, end portion 158 comprises a pair of annular seals 160 that serve to seal the interior of a radiation transparent protective sleeve ( FIG. 4 ) placed over the radiation lamp.
Also disposed on end portion 158 is a stop portion 162 that serves as stop for the open end of protective sleeves surrounding the lamp.
Portion 158 further comprises a pair of annular seals 164 that serve to seal against water ingress into the frame of a module in which the lamp is placed (again, reference can be made to U.S. Pat. Nos. 4,872,980 and 5,006,244 for further details on the function of the seals).
Electrical receptacles 152 , 154 are wired in a conventional manner with the electrical wires or other electrical conveyance emerging from an aperture 166 in end portion 158 connection unit 150 .
With particular reference to FIG. 3 , it will be seen that when base unit 100 is connected to the remaining components of the radiation lamp, there will be a longitudinal axes shown at line A through base unit 100 and the remainder of the lamp. Further, it will be seen that electrical connectors 106 , 108 are elongate and have a longitudinal axis through line B. An important feature of this preferred embodiment is that line B is non-parallel with respect to line A. In other words, the longitudinal axis through each of electrical connectors 106 , 108 is in a non-parallel relationship with the longitudinal axis through base unit 100 and the remainder of the radiation lamp. In the specific embodiment shown, electrical connectors 106 , 108 are disposed at an acute angle α toward the radiation-emitting cavity (not shown) of the lamp.
When it is desired to engage base unit 100 with base unit 150 , the base units are aligned as shown in FIG. 3 and moved with respect to one another in the direction of arrow C. The engaged components are shown in FIG. 4 and a radiation transparent protective sleeve 170 encases the connected units 100 and 150 . As will be appreciated by those of skill in the art, once the connection is shown as made in FIG. 4 , the connection will withstand vibration forces conveyed to the radiation lamp. Specifically, base unit 100 will not separate from base unit 150 in a direction of arrow D, particularly when radiation transparent protective sleeve 170 is disposed over the connection.
With reference to FIGS. 5-8 , there is illustrated a second embodiment of the preferred invention. In the description of FIGS. 5-8 , reference numerals will be used wherein the last two digits correspond to the same element appearing in FIGS. 1-4 and the first numeral will be “2” in FIGS. 5-8 instead of “1” in FIGS. 1-4 . Thus, it will be seen that a first major difference between the two embodiments is that the embodiment illustrated in FIGS. 5-8 comprises electrical connectors 206 , 208 that are angled away (β) from the radiation-emitting cavity. Another difference is that the cross-sectional shape base unit 200 in FIGS. 5-8 comprises a single valley 212 instead of the pair of valleys 112 in the embodiment illustrated in FIGS. 1-4 . Yet another difference is that the cross-sectional shape base unit 200 in FIGS. 5-8 comprises a single peak 210 instead of the pair of valleys 110 in the embodiment illustrated in FIGS. 1-4 . Otherwise, the embodiment shown in FIGS. 5-8 may be used in a manner similar to that described above with respect to FIGS. 1-4 .
With reference to FIGS. 9-14 , there is illustrated a third preferred embodiment of the present lamp device. More particularly, there is illustrated a first electrical base unit 300 and a second electrical base unit 350 .
First electrical base unit 300 comprises a housing 302 . An end portion 304 of first electrical base unit 300 comprises a first pair of electrical connectors 306 and a second pair of electrical connectors 308 .
Electrical connectors 306 , 308 are connected to wire or other suitable electrical conveyance (not shown) disposed within housing 302 which is then connected to the radiation-emitting cavity of the lamp in conventional manner.
End portion 304 of housing 302 further comprises a fin portion 320 which is disposed in a manner that separates electrical connectors 306 from electrical connectors 308 . Fin portion 320 comprises a series of rib portions 325 which serve to support fin portion 320 .
Fin portion 320 acts as a dielectric barrier so as to obviate or mitigate arcing between electrical connectors 306 and electrical connectors 308 . The use of fin member 320 and rib portions 325 is optional.
With particular reference to FIG. 12 , there is illustrated a view of base unit 350 . Base unit 350 is very similar in its design and function to base unit 150 described above with reference to FIGS. 1-4 . In the description of FIGS. 9-14 , reference numerals are used wherein the last two digits correspond to the same element appearing in FIGS. 1-4 , and the first numeral will be “3” in FIGS. 9-14 instead of “1” in FIGS. 1-4 .
The main difference between electrical base unit 350 in FIGS. 9-14 and electrical base unit 150 in FIGS. 1-4 is the provision in base portion 350 of a receptacle portion 351 that has a substantially complementary shape to the combination of fin portion 320 and rib portions 325 disposed in end portion 304 of electrical base unit 350 .
With particular reference to FIGS. 11 and 14 , it can been seen that a difference between the embodiments of the present invention described above with reference to FIGS. 1-8 and the embodiment illustrated in FIGS. 9-14 is the relative orientation of the electrical connectors. Specifically, in the embodiment illustrated in FIG. 1 , electrical connectors 106 and 108 are disposed in an offset manner with respect to line A (FIG. 3 )—i.e., the longitudinal axis. A similar arrangement exists in the embodiment illustrated in FIGS. 5-8 wherein electrical connectors 206 are offset longitudinally with respect to electrical connectors 208 .
In contrast, it can be seen that electrical connectors 306 are not offset with respect to electrical connectors 308 along line A ( FIG. 11 ) in the embodiment illustrated in FIGS. 9-14 . Thus, the distal ends of electrical connectors 306 and electrical connectors 308 are in substantial alignment along line E in FIG. 11 .
With reference to FIG. 14 , it can be seen that first electrical base unit 300 cannot be disengaged from second electrical base unit 350 along line A. Thus, when lamp device incorporating first electrical base unit 300 and second electrical base unit 350 is disposed in a protective (e.g., quartz) sleeve having a diameter very similar to that of stop portion 362 , first electrical base unit 300 can not be disengaged from second electrical base unit 350 in a direction along line A. Rather, the two base units may be disengaged by relative movement thereof in the direction of line C (i.e., after removal of the protective sleeve).
While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. For example, it is possible to reverse the arrangement of electrical connectors and electrical receptacles in the illustrated embodiments—i.e., the electrical connectors would be disposed in electrical connection base unit 150 , 250 , 350 and the electrical receptacles would be disposed in electrical connection base unit 100 , 200 , 300 . Also, it is possible to have a mixture of electrical connectors and electrical receptacles on electrical connection base unit 100 , 200 , 300 and a complementary mixture of electrical connectors and electrical receptacles on electrical connection base unit 150 , 250 , 350 . Yet another possible modification of the illustrated embodiments relates to disposing the electrical connectors such that the longitudinal axis of the electrical connectors is substantially orthogonal to the longitudinal axis of the radiation lamp (i.e., α≈90° and β≈90°). Yet another modification of the illustrated embodiments relates to the use of electrical connection bases that, in cross-section, contain no peaks or valleys. It is therefore contemplated that the appended claims will cover any such modifications or embodiments.
All publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety. | There is disclosed a lamp device including a longitudinal axis, a first elongate electrical connector and a second elongate electrical connector, each of the first elongate electrical connector and the second elongate connector being non-parallel with respect to the longitudinal axis. The present lamp device provides a reliable electric connection on the one hand, yet is relatively inexpensive, uncomplicated and simple to implement on the other hand. | 7 |
BACKGROUND
[0001] The present disclosure relates generally to the field of cryptography, and more particularly to generating challenge response sets utilizing semantic web technology.
[0002] Security challenge and response authentication is commonly employed to verify user identity. In most cases, if a user forgets their username and/or password, a set of challenge questions is posed to the user (e.g. What is the model of your first car?) and the user is expected to provide the correct answer based on his personal history. The answer to these security challenges are usually provided when a user signs up for a service.
[0003] Typically, sensitive and specific personal questions are posed for the challenge-response set due to the unlikelihood that unauthorized individual would provide the same response for a particular challenge. However, the same challenge questions are employed and users usually insert the same answers as the response, which may be a security concern, as a compromise of the answer at a single instance could potentially lead to subsequent issues at other instances.
SUMMARY
[0004] Embodiments of the present invention relate to generating challenge response sets utilizing semantic web technology. In response to detecting an authentication session for a user, a computing device generates a first challenge question that is semantically related to a second challenge question previously responded to by the user, wherein the authentication session seeks to validate an identification of the user. The computing device determines whether a response to the challenge question by the user is valid. In response to determining that the response to the challenge question by the user was valid, the computing device generates a third challenge question or a notification that the response to the challenge question validates the identification of the user.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0005] FIG. 1 is a block diagram illustrating an environment, in accordance with an embodiment of the present invention.
[0006] FIG. 2 depicts a graph representation of an example OWL-RDF data model, in accordance with an embodiment of the present invention.
[0007] FIG. 3 depicts an ontology graph, in accordance with an embodiment of the present invention.
[0008] FIG. 4 depicts the operational steps of a program function, in accordance with an embodiment of the present invention.
[0009] FIG. 5 depicts a block diagram of components of the computing device executing the program function, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0010] As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer-readable medium(s) having computer-readable program code/instructions embodied thereon.
[0011] Any combination of computer-readable media may be utilized. Computer-readable media may be a computer-readable signal medium or a computer-readable storage medium. A computer-readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of a computer-readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (hereinafter “EPROM” or “Flash memory”), an optical fiber, a portable compact disc read-only memory (hereinafter “CD-ROM”), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer-readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
[0012] A computer-readable signal medium may include a propagated data signal with computer-readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer-readable signal medium may be any computer-readable medium that is not a computer-readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
[0013] Program code embodied on a computer-readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
[0014] Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java® or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on a user's computer, partly on the user's computer, as a stand-alone software package and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (hereinafter “LAN”) or a wide area network (hereinafter “WAN”), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0015] Aspects of the present invention are described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0016] These computer program instructions may also be stored in a computer-readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer- readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0017] The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer-implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0018] Security challenge and response authentication is commonly employed to verify user identity. In most cases, if a user forgets their username and/or password, a set of challenge questions is posed to the user (e.g. What is the model of your first car?) and the user is expected to provide the correct answer based on his personal history. The answer to these security challenges are usually provided when a user signs up for a service. Embodiments of the present invention seek to generate an alternative challenge and response set through the use of semantic web technology. The generated set is related semantically to the original user response and does not directly translate back to the original user response.
[0019] Assuming that the user's response is a valid ontology object, an ontology database can be queried for the object, which has associated properties and classes. Based on the properties and classes of a particular object, a data generalization strategy can be used to generate a new-challenge response set. As a user reiterates through this process n-times, a confidence level may be reached that that it is highly unlikely to be based on chance.
[0020] Embodiments of the present invention will now be described in detail with reference to the Figures. FIG. 1 is a block diagram illustrating an environment, generally designated 100 , in accordance with one embodiment of the present invention. Environment 100 enables authorized users to access protects information subsequent to successfully answering challenge questions, wherein the challenge question is associated with a user's response to security challenge questions that were provided by the user upon signing up for a related service. Environment 100 includes computing devices 110 and 130 , all interconnected over network 120 . Network 120 can be, for example, a local area network (hereinafter “LAN”), a wide area network (hereinafter “WAN”) such as the Internet, or a combination of the two, and can include wired, wireless, or fiber optic connections. In general, network 120 can be any combination of connections and protocols that will support communications between computing devices 110 and 130 .
[0021] In various embodiments of the present invention, computing devices 110 and 130 may be laptop computer, tablet computer, netbook computer, personal computers (hereinafter “PCs”), desktop computers, personal digital assistants (hereinafter “PDAs”), or smart phones. In other embodiments, computing device 110 and 130 are included in a distributed computing system. Computing device 110 is a computing device that is used to respond to challenge questions to gain access to protected information stored on another computing device, in accordance with an embodiment of the present invention. Computing device 110 includes user interface 112 , which is used to access and/or manipulate information stored on computing device 130 .
[0022] Computing device 130 is a computing device that includes protected information that can only be accessed by authorized individuals, in accordance with an embodiment of the present invention. Computing device 130 includes exemplary information store 134 , authenticator 136 , exemplary information store 140 and program function 138 . Exemplary information store 134 is an information repository that is in communication with authenticator 136 and includes exemplary files 132 as well as user response files 133 . Exemplary files 132 include protected information that can only be accessed by authorized individuals after verifying their identification in response to successfully responding to one or more program function challenge questions, such as those challenge questions generated by program function 138 . User response files 133 include information that reflects user responses to the initial challenge questions there present to the user during the account setup stage.
[0023] Authenticator 136 is included in computing device 130 and is in communication with exemplary information store 134 and program function 138 . Authenticator 136 is software that authenticates a user's identity for access to protected information, such as exemplary files 132 , by presenting challenge questions to the user. However, unlike program function 138 , authenticator 136 does not present challenge questions that are generated utilizing Semantic Web technology (discussed below). Authenticator 136 can access information included in exemplary information store 134 . Authenticator 136 can receive instructions from program function 138 . Authenticator 136 can allow authorized users to access information stored in exemplary information store 134 .
[0024] Exemplary information store 140 is included in computing device 130 and is in communication with program function 138 . Exemplary information store 140 is an information repository that includes confidence level files 144 and ontology files 142 , in accordance with an embodiment of the present invention. Confidence level files 144 include predetermined information reflective of a particular user's required confidence level, such as a user of computing device 110 . Confidence levels reflect the number of challenge questions, which are generated by program function 138 , that a user must correctly answer to access protected information that is included in exemplary files 132 . Ontology files 142 include ontology-based database files. In an embodiment, ontology files 142 are OWL-RDF formatted user responses. In certain embodiments, ontology files 142 are generated using the information included in user response files 133 and a Web Ontology Language (hereinafter “OWL”), such as OWL-RDF.
[0025] OWL is a family of knowledge representation languages for authoring ontologies. The languages are characterized by formal semantics and RDF/XML-based serializations for the Semantic Web. Resource Description Framework (hereinafter “RDF”) is a framework for representing information on the Web and is designed to represent information in a minimally constraining, flexible way by organizing information in a simple data model that is easy for applications to process and manipulate. FIG. 2 depicts a graph representation of an example OWL-RDF data model, in accordance with an embodiment of the present invention. Specifically, FIG. 2 illustrates three (3) nodes, parent, child, and object B, wherein the child node is not only a subclass of the parent node, but also shares a particular relationship and/or property (hereinafter “predicate”) with Object B. A further discussion of OWL-RDF data models is included in below.
[0026] Program function 138 is included in computing device 130 and is in communication with authenticator 136 and exemplary information store 140 , in accordance with an embodiment of the present invention. Program function 138 is software that generates zero-knowledge proof-based challenge-response sets using Semantic Web technology. A zero-knowledge proof is a method by which one party can prove to another party that a given statement is true, without conveying any additional information apart from the fact that the statement is indeed true. Program function 138 can transmit instructions to authenticator 136 . Program function 138 can access information included in exemplary information store 140 , such as ontology files 142 and confidence level files 144 . In an embodiment, program function 138 generates challenge-response sets using data generalization. Program function 138 can generalize attributes, such as numeric, string, sets, and sequenced-based attributes.
[0027] Numeric values can be generalized to a range, for example, 2012 may be generalized to a range of 2010 - 2019 . Strings may be generalized using the characters contained therein and replacing them with ranges of characters, for example, “twelve” can be generalized to “*wel**”, wherein “*” denotes any single character. Set-valued attributes, such as (7, 11, “abc”), may be generalized to (7, 10-19, “a**”). Sequence-valued attributes may be generalized in the same in the same fashion as set-valued attributes. However, unlike set-valued attributes whose orders do not matter, the order of sequence-valued attributes have to be kept consistent with the raw data.
[0028] In other embodiments, generalizations can be created using aggregations, such as average, count and maximum, which produce summary values for a set of values. Aggregations are useful for generalizing set-valued or sequence-valued attributes or set of attributes. In this way, a correct response from the user increases confidence that they are the authorized user, without revealing the real value of the attribute to potential eavesdroppers while protecting the privacy of the user at the same time. Given the generalization of an attribute, a challenge question can confirm the user's knowledge of the generalization instead of the raw data, such as the information that is included in user response files 133 . Attributes should not be under-generalized, wherein the generalization of the attribute is similar to the actual value, which may not satisfy the user's privacy requirement and/or may result in divulging useful information to an eavesdropper.
[0029] In an embodiment, program function 138 can use generalization measures, such as instance size, full generalization, sensitivity and error rate, to generate challenge-response sets. Given an attribute A and its generalization A′, the instance size of A′ (hereinafter “[A′]) is the number of valid attributes that match it. For example, given an integer-valued attribute, its generalization 10-19 has instance size 10 since 10 integers: 10, 11, 12 . . . 19 match the range. Given an attribute A, a full generalization of A (hereinafter “A FG ”) is the generalization that covers all possible values of that attribute. For example, assuming a valid “age attribute” ranges from 1 to 120, age FG is 1-120 and [A FG ]=120. In other embodiments, sensitivity and error rate assume that attributes are independent of each other and attribute values are distributed uniformly.
[0030] Given an attribute A and its generalization A′, we define Sensitivity of A′ (denoted as S(A′)) to be 1/[A′]. Sensitivity measures how sensitive the generalization A′ is relative to its raw data. The larger the sensitivity of A′, the more sensitive A′ is, or equivalently, the less generalized A′ is. Sensitivity is measured in the range of 0 to 1. Likewise, given an attribute A and its generalization A′, we define Sensitivity of A′ (denoted as S(A′)) to be 1/[A′].
[0031] For example, suppose A′=10-19 is a generalization of the age attribute, and the value of age ranges from 1 to 120, we have S(A′)=1/[A′]=1/10 and E(A′)=[A′]/[A FG ]=10/120=1/12. Continuing, S(A′)*E(A′)=1/[A′]*[A′]/[A FG ]=1/[A FG ], which is a constant for a given attribute A. Therefore, the larger the sensitivity of A′, the smaller the error rate is, and vice versa. Intuitively, the closer A′ is to its raw value, the less likely that it can be chosen at random. Similarly, we can define Error rate for a set of generalizations. Given a set of attributes: A 1 , A 2 . . . A k and their generalizations: A 1 ′, A 2 ′ . . . A k ′, the error rate of A 1 ′, A 2 ′ . . . A k ′ (denoted as E(A1′∩A2′∩ . . . ∩Ak′)) is defined as [A 1 ′]*[A 2 ′]* . . . *[A k ′]/[A 1 FG ]*[A 2 FG ]* . . . *[A k FG ].
[0032] The error rate of a set of generalizations is the probability that the generalizations are selected at one time at random. Since attributes are independent, error rate is the product of the error rates of all of them. Because E(A i ′)≦1 for i in[1, k], E(A 1 ′∩A 2 ′∩ . . . ∩A k ′) usually decreases as the number of attributes, k, increases. In other words, with the increase in the number of generalizations that the user chooses correctly, the chance that they are chosen based on pure luck decreases and the likelihood that they are the authorized user increases. In other embodiments, the generalization algorithm can be any selection algorithm that takes into consideration the values of Sensitivity and Error Rate. In still other embodiments, logical operators, such as AND, OR, and NOT, may be incorporated into challenge questions to allow for additional diversity.
[0033] FIG. 3 depicts an ontology graph of information supplied by a user, in accordance with an embodiment of the present invention. Specifically, FIG. 3 depicts a ten node OWL-RDF graph model of a user's challenge response that is included in user response files 133 . The graph includes a parent node, Vehicles, and three (3) child nodes, Motorcycles, Cars, and Trucks. A Motorcycle Type A node is a child node of the Motorcycles node and is associated with the Cycle Corporation A (hereinafter “CCA”) node by a Make relationship. The CCA node also has a country of origin relationship with the USA node.
[0034] The Hatchback Type B node is an instance of the Cars node and is related to the Auto Corporation B (hereinafter “ACB”) node by Make. The ACB node is also related to the Japan node by a country of origin relationship. When a user of computing device 110 attempts to access exemplary files 132 , program function 138 accesses user related information that is included in ontology files 142 . In an embodiment, during account registration, the user selects a password recovery secret object, wherein computing device 130 prompts the user with the following, “Select from the following category: your previous vehicle, favorite cartoon character, favorite animal or famous person.” The user selects “previous vehicle” and provides the Year, Make and Model of the vehicle, 2008, ACB, Hatchback Type B, respectively. The OWL-RDF graph of the user's selection is reflected in FIG. 3 .
[0035] Program function 138 the retrieves the secret object from ontology files 142 and determines associated OWL-RDF triples. Program function 138 selects a predicate (discussed above), such as manufacturer, fuel economy, and vehicle's country of origin and generates the challenge-response sets included in Table 1.
[0000]
TABLE 1
Challenge
Response
Error Rate
1
What is the country of origin for the
Japan
1/30 countries
manufacturer of your secret object?
2
Name the manufacturer of your secret
ACB
1/n
object
manufacturers
in Japan
3
What is the highway fuel economy
35-37 mpg
1/n range
(mpg) of your secret object?
[0036] In an embodiment, program function 138 presents challenge question 1, 2, or 3 to the user, who has the ability to pick another challenge to respond to. For example, the user may be provided with the choice of skipping a particular challenge question, if they are not sure of the correct response. Subsequent to correctly responding to the challenge question, program function 138 retrieves the appropriate confidence level files that are associated with the user and determines whether the required confidence level has been achieved. In an embodiment, the correct response to a challenge question results in a particular amount of confidence level points. Program function 138 presents challenge questions to the user n-times until the required confidence level has been achieved. In an embodiment, program function 138 presents challenge questions to the user until a confidence level is achieved that is very unlikely to be random guesses and at the same time, not reveal the original secret. The error rate reflected in Table 1 defines the rate at which a non-authorized user is able to provide a correct response. For example, as per challenge 1, a non-authorized user has a one in thirty (1:30) chance of providing a correct response based on chance.
[0037] FIG. 4 depicts the operational steps of program function 138 , in accordance with an embodiment of the present invention. Program function 138 retrieves the secret object from the ontology database (step 400 ). Program function 138 determines OWL-RDF triples that are associated with the retrieved secret object (step 405 ). Program function 138 selects a predicate (step 410 ). If predicates for the object are exhausted (“yes” branch decisional 415 ), program function 138 generates a notification of the event (step 435 ). If the program function 138 determines that the associated predicates are not exhausted (“no” branch decisional 415 ), program function 138 generates a challenge-response set (step 420 ).
[0038] If program function 138 determines that the user did not answer the challenge question correctly (“no” branch decisional 425 ), program function 138 generates a notification of the event (step 435 ). If program function 138 determines that the user did answer the challenge question correctly (“yes” branch decisional 425 ), program function 138 increments the confidence level (step 430 ). If program function 138 determines that the confidence level is not high enough (“no” branch decisional 440 ), program function 138 returns to step 410 . If program function 138 determines that the confidence level is high enough (“yes” branch decisional 440 ), program function 138 generates a notification that user is the authorized user (step 445 ).
[0039] FIG. 5 depicts a block diagram of components of computing device 130 in accordance with an illustrative embodiment of the present invention. It should be appreciated that FIG. 5 provides only an illustration of one implementation and does not imply any limitations with regard to the environments in which different embodiments may be implemented. Many modifications to the depicted environment may be made.
[0040] Computing device 130 includes communications fabric 402 , which provides communications between computer processor(s) 404 , memory 406 , persistent storage 408 , communications unit 410 , and input/output (hereinafter “I/O”) interface(s) 412 . Communications fabric 402 can be implemented with any architecture designed for passing data and/or control information between processors (such as microprocessors, communications and network processors, etc.), system memory, peripheral devices, and any other hardware components within a system. For example, communications fabric 402 can be implemented with one or more buses.
[0041] Memory 406 and persistent storage 408 are computer-readable storage media. In this embodiment, memory 406 includes random access memory (hereinafter “RAM”) 414 and cache memory 416 . In general, memory 406 can include any suitable volatile or non-volatile computer-readable storage media.
[0042] Program function 138 , authenticator 136 , and exemplary information stores 134 and 140 are stored in persistent storage 408 for execution and/or access by one or more of the respective computer processors 404 via one or more memories of memory 406 . In this embodiment, persistent storage 408 includes a magnetic hard disk drive. Alternatively, or in addition to a magnetic hard disk drive, persistent storage 408 can include a solid state hard drive, a semiconductor storage device, read-only memory (hereinafter “ROM”), erasable programmable read-only memory (hereinafter “EPROM”), flash memory, or any other computer-readable storage media that is capable of storing program instructions or digital information.
[0043] The media used by persistent storage 408 may also be removable. For example, a removable hard drive may be used for persistent storage 408 . Other examples include optical and magnetic disks, thumb drives, and smart cards that are inserted into a drive for transfer onto another computer-readable storage medium that is also part of persistent storage 508 .
[0044] Communications unit 410 , in these examples, provides for communications with other data processing systems or devices, including computing device 110 . In these examples, communications unit 410 includes one or more network interface cards. Communications unit 410 may provide communications through the use of either or both physical and wireless communications links. Program function 138 and authenticator 136 may be downloaded to persistent storage 408 through communications unit 410 .
[0045] I/O interface(s) 412 allows for input and output of data with other devices that may be connected to computing device 130 . For example, I/O interface 412 may provide a connection to external devices 418 such as a keyboard, keypad, a touch screen, and/or some other suitable input device. External devices 418 can also include portable computer-readable storage media such as, for example, thumb drives, portable optical or magnetic disks, and memory cards. Software and data used to practice embodiments of the present invention, e.g., program function 138 and authenticator 136 , can be stored on such portable computer-readable storage media and can be loaded onto persistent storage 408 via I/O interface(s) 412 . I/O interface(s) 412 also connects to a display 420 . Display 420 provides a mechanism to display data to a user and may be, for example, a computer monitor.
[0046] The programs described herein are identified based upon the application for which they are implemented in a specific embodiment of the invention. However, it should be appreciated that any particular program nomenclature herein is used merely for convenience, and thus the invention should not be limited to use solely in any specific application identified and/or implied by such nomenclature.
[0047] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions. | Embodiments of the present invention relate to generating challenge response sets utilizing semantic web technology. In response to detecting an authentication session for a user, a computing device generates a first challenge question that is semantically related to a second challenge question previously responded to by the user, wherein the authentication session seeks to validate an identification of the user. The computing device determines whether a response to the challenge question by the user is valid. In response to determining that the response to the challenge question by the user was valid, the computing device generates a third challenge question or a notification that the response to the challenge question validates the identification of the user. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to closure actuated lamp switches and, more particularly, to a lamp switch and connector means assembly contained within an integral housing preferably suitable for installation in automobile glove boxes.
In automobiles, closure actuated switches are typically installed to control lamps or bulbs which illuminate the interiors of glove boxes or other compartments only when the compartments are open. Generally, closure actuated switches operate by means of a plunger to close and open a circuit. The plunger causes electrical contacts of opposite polarity in the electrical circuit either to engage each other directly or to be bridged in some fashion by a connecting means. Friction between opposing poles of an open circuit occurs generally in such switches when the opposing poles are moved into direct contact with each other or with a bridging means to complete the circuit. When opposing poles are biased, friction between them or a bridging means will be greater. The friction tends to cause wear and tear on the opposing poles which, in turn, often decreases the usable life of the switch. Repeated usage may strain the biased poles beyond their resiliency, thereby impairing the ability of the opposing poles to provide a stable electrical connection.
Known closure actuated switches have utilized plunger-type means to complete an electric circuit to light a lamp or bulb. For example, U.S. Pat. No. 2,646,477 discusses a closure actuated switch wherein a single terminal or tab of metal near the lamp portion of the assembly is connected to the ungrounded portion of an automobile battery. The grounding terminal is located at the plunger portion of the assembly and grounds the circuit through a metal frame located within the glove box. Accordingly, the terminals are located at opposite ends of the assembly. The switch completes an electrical circuit through movement of a plunger which brings two electrical contacts of opposite polarity into direct contact. A spring biasing means which forces the plunger to an extended position, thereby connecting the two electrical contacts, is part of the electrical circuit as it electrically connects the bulb with one of the electrical contacts.
An electrical switch is discussed in U.S. Pat. No. 4,384,181 wherein a conductive sleeve is positioned on a rod section of a plunger. The conductive sleeve contacts two terminals which are biased toward the conductive sleeve. The conductive sleeve travels a length of the biased terminals when engaging and disengaging them.
A combined illumination and minimum temperature control for refrigerators is discussed in U.S. Pat. No. 2,658,968. The control assembly is composed of a contact ring positioned on a plunger so as to make contact with terminals. The terminals are movable in response to temperature conditions within the refrigerator. A lamp is mounted on the back wall of the refrigerator remote from the control assembly. Also connected to the control assembly is a temperature-sensing unit. The control assembly lights the remote lamp even when the refrigerator door is not open to increase the temperature within the refrigerator.
A drawback of known closure actuated switches is their reliance upon sliding contact between nonstationary opposing poles either directly or through a bridging means to complete a circuit. The poles to be connected are often biased, requiring them to be strained upon making electrical contact. The resulting friction may produce wear and tear upon the poles themselves. Additionally, a problem arises when biased poles are strained by use beyond their resiliency. The poles may not retain enough resiliency to maintain stable electrical contact leading to premature failure of the circuit.
Therefore a need exists to provide a lamp switch and connector assembly which is integral in design, and preferably suitable for installation in automobile glove boxes. It is a particular object of an embodiment of the present invention to provide a closure actuated lamp switch and connector means assembly comprising an integral housing and a plunger-type actuating means. Other objects, features and advantages of the present invention will become apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF SUMMARY OF THE INVENTION
As stated previously, closure actuated switches are typically installed to control lamps or bulbs which illuminate the interiors of glove boxes or other compartments only when the compartments are open. A lamp switch and connector means assembly which is integral in design offers particularly desirable characteristics.
An embodiment of a lamp switch and connector means assembly of the present invention may comprise an integral housing. The embodiment may further comprise an electrical contact means within a lamp socket cavity within the integral housing, connector means for engaging an electrical power source, plunger means movably disposed within a plunger chamber within the integral housing, and electrical bridging means affixed to the plunger means for engaging and electrically connecting spaced electrical contacts within the plunger chamber when the plunger is biased toward an extended position by a biasing means. The plunger means may have a rod section extending axially out of the plunger chamber through a plunger passage and a head section integral with the rod section and extending radially within the plunger chamber.
The embodiment offers advantages in that the lamp switch and connector means assembly is comprised of an integral housing allowing for ease of installation within a glove box or other compartment. The embodiment may also be manufactured easily and economically, while offering a limited number of moving parts thereby reducing the likelihood of mechanical and electrical failure.
BRIEF DESCRIPTION OF THE DRAWINGS
The lamp switch and connector means assembly of the present invention may be more easily understood by referring to FIG. 1 which is an electrical circuit diagram of a preferred embodiment of the lamp switch and connector means assembly of the present invention.
FIG. 2 is a side elevation, partially in cross section, of the lamp switch and connector means assembly of FIG. 1 with a plunger being in an extended position.
FIG. 3 is a side elevation, partially in cross section, of the lamp switch and connector means assembly of FIG. 1 engaging a bayonetted-type lamp with a plunger being in a retracted position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The principles of the present invention may be applied with particular advantage to provide a lamp switch and connector means assembly comprising an integral housing. The lamp switch and connector means assembly is electrically interconnected as further described below.
FIG. 1 depicts a circuit diagram electrically connecting in series circuit, power source 100, for example an automobile battery, first terminal 110, first lamp contact 121, lamp 120, second lamp contact 122, spaced electrical contacts 130 and 131 of opposite polarity, moveable plunger 140 carrying electrical bridging means 150, and second terminal 160. A connector means for electrically connecting the circuit to the power source comprises first and second terminals 110 and 160. Plunger 140 and electrical bridging means 150 operate as a switch to open and close the circuit. Biasing means 18 as shown in FIGS. 2 and 3 forces plunger 140 and electrical bridging means 150 to an extended position, thereby simultaneously engaging and electrically interconnecting spaced electrical contacts 130 and 131. When plunger 140 is depressed to a retracted position, for example, by pressure of a glove box cover against extended end 145 of plunger 140, electrical bridging means 150 simultaneously disengages and electrically disconnects spaced electrical contacts 130 and 131. Spaced electrical contacts 130 and 131 are preferably nonbiased and stationary to reduce friction and loss of resiliency tending to decrease the life of the switch. More detailed features of a preferred embodiment are described below.
Referring to FIGS. 2 and 3, a lamp switch and connector assembly 200 in accordance with a preferred embodiment of the present invention comprises integral housing member generally indicated at 10 fashioned from electrically insulating material and having socket cavity 11, connector cavity 12 and plunger chamber 13. Integral housing 10 is generally "T" shaped with upper body portion 14 comprising socket cavity 11 and plunger chamber 13, and with lower body portion 15 comprising connector cavity 12. As shown in FIGS. 2 and 3, socket cavity 11 and connector cavity 12 are oriented to receive lamp 16 (shown in FIG. 3), and a power connector (not shown) to opposite poles of a power source, respectively, in a perpendicular fashion. Plunger chamber 13 is oriented such that movement of plunger 17 via biasing means 18 within plunger chamber 13 is perpendicular to the direction of insertion of lamp 16 into socket cavity 11. It is to be understood that the orientation as depicted in FIGS. 2 and 3 of socket cavity 11, connector cavity 12 and plunger chamber 13 within integral housing 10 is a preferred orientation and that depending upon the environment in which the lamp switch and connector means assembly is placed, different orientations can be employed.
As depicted in FIGS. 2 and 3, a preferred embodiment of connector means for accepting a power source in mating fashion includes first terminal 19 and second terminal 20 (corresponding to first terminal 110 and second terminal 160, respectively, of FIG. 1) extending in a parallel fashion within connector cavity 12 with connector cavity 12 extending beyond first and second terminals 19 and 20. In other embodiments, connector means comprising first and second terminals 19 and 20 may extend beyond connector cavity 12 or connector means may extend directly out of integral housing 10 absent connector cavity 12. It is to be understood that each terminal may be either positive or negative depending upon the flow of electricity. Preferably, first and second terminals 19 and 20 are elongated metal tabs which mate with corresponding female electrical connections. Connector cavity 12 has opening 21 and interior side wall 22 which may be contoured to register with an exterior surface of a power source connector to provide a secure mating connection between the connector means and the power source connector. Typical power source connectors include, for example, a standard Yazaki CO2 MW connector. When a connector means, preferably connector cavity 12 and first and second terminals 19 and 20, is engaged by an anchored power source connector, the lamp switch and connector means assembly 200 is securely mountable, for example, within an automobile glove box.
Socket cavity 11 has opening 23 capable of receiving lamp 16. Socket cavity 11 houses electrical contact means for electrically connecting lamp 16. As shown in FIGS. 2 and 3, first lamp contact 24 and second lamp contact 25 (corresponding to first and second lamp contacts 121 and 122, respectively, of FIG. 1) are adapted to engage and secure a bayonetted-type lamp. First and second lamp contacts 24 and 25 and the bayonetted-type lamp can be standard units well known to those skilled in the art. Each lamp contact can be comprised of 2 angled sections which are biased toward one another. Lamp 16 is inserted between the angled sections of each lamp contact thereby engaging lamp 16 in an electrically conductive manner. The biased nature of the angled sections serves to secure lamp 16 within socket cavity 11.
Disposed within plunger chamber 13, is plunger 17 which is axially moveable between an extended position and a retracted position within plunger chamber 13. Plunger 17 comprises rod section 26 extending axially out of plunger chamber 17 through plunger passage 27 and head section 28 integral with rod section 26 and extending radially therefrom within plunger chamber 13. The diameter of head section 28 is greater than the diameter of plunger passage 27, thereby preventing head section 28 from moving through plunger passage 27.
Biasing means 18 is disposed within plunger chamber 13, preferably between head section 28 of plunger 17 and end wall 29 of plunger chamber 13 for biasing plunger 17 toward an extended position as shown in FIG. 2. Preferably, biasing means 18 is a metal coil spring seated against end wall 29.
Also positioned within plunger chamber 13, on opposite sides of plunger passage 27, are spaced electrical contacts 30 and 31 of opposite polarity (corresponding to spaced electrical contacts 130 and 131, respectively, of FIG. 1). Preferably, spaced electrical contacts 30 and 31 are nonbiased stationary flat metal tabs.
Electrical bridging means 32 is affixed to plunger 17, preferably being seated against head section 28 at the base of rod section 26. Electrical bridging means 32 simultaneously engages and electrically interconnects spaced electrical contacts 30 and 31 when plunger 17 is in its extended position and not when plunger 17 is in its retracted position. Preferably, electrical bridging means 32 is an annular metal ring or the like which surrounds rod section 26 of plunger 17 and seats against head section 28 of plunger 17..
FIG. 3 depicts the lamp switch and connector means assembly of FIG. 1, engaging a bayonetted-type lamp 16 with plunger 17 in a retracted position. When plunger 17 is forced against biasing means 18, for example by a glove box cover forcing against end 33 of rod section 26, to a retracted position as depicted in FIG. 3, electrical bridging means 32 simultaneously and immediately separates from spaced electrical contacts 30 and 31.
It is to be understood that the embodiments of the present invention which have been described are merely illustrative of applications of the principles of the present invention. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention. | A lamp switch and connector means assembly comprising an integral housing which is mountable to the interior of a compartment for illuminating the compartment. The switch is operable by means of a biased plunger, for example, in response to the opening and closing of a compartment lid. Fixed to the plunger is an electrical bridging means which simultaneously and immediately engages stationary, nonbiased electrical contacts when the plunger is biased toward an extended position. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. application Ser. No. 14/173,876, filed Feb. 6, 2014, which claims benefit of priority under 35 U.S.C. §119(e) from Canadian Patent Application No. 2,818,322, filed May 24, 2013. The contents the aforementioned applications are hereby expressly incorporated by reference in its entirety and for all purposes.
FIELD OF THE INVENTION
The present invention relates to modifications of bitumen and heavy oil upgrading processes to synthesize synthetic crude oil and other valuable hydrocarbon byproducts operations in an efficient manner and produce high quality refined fuel products such as naphtha, gasoline, diesel and jet fuel for commercial application.
BACKGROUND OF THE INVENTION
It is well established that certain forms of hydrocarbons require upgrading in order to either transport them or enhance value for sale. Further, conventional refineries are not suited to processing heavy oil, bitumen etc. and thus the viscosity, density and impurity content, such as heavy metals, sulfur and nitrogen, present in such heavy materials must be altered to permit refining. Upgrading is primarily focused upon reducing viscosity, sulfur, metals, and asphaltene content in the bitumen.
One of the problems with heavy oil and bitumen upgrading is that the asphaltenes and the heavy fraction must be removed or modified to create value and product yield. Typical upgraders exacerbate the problem by the formation of petcoke or residuum which results in undesirable waste material. This material, since it cannot be easily converted by conventional methods, is commonly removed from the process, reducing the overall yield of valuable hydrocarbon material from the upgrading process.
The Fischer-Tropsch process has found significant utility in hydrocarbon synthesis procedures and fuel synthesis. The process has been used for decades to assist in the formulation of hydrocarbons from several materials such as coal, residuum, petcoke, and biomass. In the last several years, the conversion of alternate energy resources has become of great interest, given the escalating environmental concerns regarding pollution, the decline of world conventional hydrocarbon resources, and the increasing concern over tailings pond management, together with the increasing costs to extract, upgrade and refine the heavy hydrocarbon resources. The major producers in the area of synthetic fuels have expanded the art significantly in this technological area with a number of patented advances and pending applications in the form of publications. Applicant's co-pending U.S. application Ser. No. 13/024,925, teaches a fuel synthesis protocol.
Examples of recent advances that have been made in this area of technology includes the features taught in U.S. Pat. No. 6,958,363, issued to Espinoza, et al., Oct. 25, 2005, Bayle et al., in U.S. Pat. No. 7,214,720, issued May 8, 2007, U.S. Pat. No. 6,696,501, issued Feb. 24, 2004, to Schanke et al.
In respect of other progress that has been made in this field of technology, the art is replete with significant advances in, not only gasification of solid carbon feeds, but also methodology for the preparation of syngas, management of hydrogen and carbon monoxide in a XTL plant, the Fischer-Tropsch reactors management of hydrogen, and the conversion of carbon based feedstock into hydrocarbon liquid transportation fuels, inter alia. The following is a representative list of other such references. This includes: U.S. Pat. Nos. 7,776,114; 6,765,025; 6,512,018; 6,147,126; 6,133,328; 7,855,235; 7,846,979; 6,147,126; 7,004,985; 6,048,449; 7,208,530; 6,730,285; 6,872,753, as well as United States Patent Application Publication Nos. US2010/0113624; US2004/0181313; US2010/0036181; US2010/0216898; US2008/0021122; US 2008/0115415; and US 2010/0000153.
The Fischer-Tropsch (FT) process has several significant benefits when applied to a bitumen upgrader process, one benefit being that it is able to convert previously generated petcoke and residuum to valuable, high quality synthetic crude oil (SCO) and high quality refined products with notably increased paraffinic content. A further significant benefit is that the raw bitumen yield to refined products is near or greater than 100%, more specifically greater than 130% yield, a 35% to 65% product yield increase relative to certain current upgrader processes. Another benefit is that there is no petcoke and residuum waste product to impact the environment thus improving overall bitumen resource utilization.
A further benefit of the application of the FT process to a bitumen upgrader is that the FT byproducts can be partially and fully blended with the distilled, separated or treated fractions of the bitumen or heavy oil feed stream to formulate and enhance the quality of refinery products such as diesel and jet fuel. The significant overall benefit is the carbon conversion efficiency is greater than 90%, providing significant reduction in facility GHG emissions and 100% conversion of the bitumen or heavy oil resource without the formation of wasteful byproducts.
A further benefit of the application of the FT process to a bitumen upgrader is that a sweet, highly paraffinic and high cetane content synthetic diesel (syndiesel) is produced. More specifically, beneficial byproducts of the FT process such as paraffinic naphtha and FT vapours (such as methane and liquid petroleum gases (LPG)), have particular value within the bitumen upgrader process and upstream unit operations. FT vapours, virtually free from sulfur compounds can be used as upgrader fuel or as feedstock for hydrogen generation to offset the requirement for natural gas. FT naphtha, primarily paraffinic in nature, can also be used in the generation of hydrogen, but further, due to its unique paraffinic nature, it can also be used as an efficient deasphalting solvent not readily available from current upgrader operations.
It has also been well documented that the use of FT paraffinic naphtha as a solvent for an oil sands froth unit improves the operation and efficacy of fine tailings and water removal at a reduced diluent to bitumen (D/B) ratio and relatively low vapour pressure. This has significant advantages in terms of lowering the size and cost of expensive separators and settlers and increasing their separation performance and capacity rating. This results in virtually dry bitumen froth feed (<0.5 basic sediment and water) to the upgrader, while improving impact on the tailings pond.
Having thus generally discussed the appropriateness of the Fischer-Tropsch technique in synthesizing syngas to FT liquids, a discussion of the prior art and particularly the art related to the upgrading and gasifying of heavy hydrocarbon feeds would be useful.
One of the examples in this area of the prior art is the teachings of U.S. Pat. No. 7,407,571 issued Aug. 5, 2008, to Rettger et. al. This reference names Ormat Industries Ltd. as the Assignee and teaches a process for producing sweet synthetic crude oil from a heavy hydrocarbon feed. In the method, the patentees indicate that heavy hydrocarbon is upgraded to produce a distillate feed which includes sour products and high carbon byproducts. The high carbon content byproducts are gasified in a gasifier to produce a syngas and sour byproducts. The process further hydroprocesses the sour products along with hydrogen gas to produce gas and a sweet crude. Hydrogen is recovered in a recovery unit from the synthetic fuel gas. The process also indicates that further hydrogen gas is processed and hydrogen depleted synthetic fuel gas is also produced. Further hydrogen gas is supplied to the hydroprocessing unit and a gasifying step is conducted in the presence of air or oxygen. The gas mixture is scrubbed to produce a sour water and a clean sour gas mixture. The sour gas mixture is subsequently processed to produce a sweet synthetic fuel gas and a hydrogen enriched gas mixture from the synthetic fuel gas using a membrane. The overall process is quite effective, however, it does not take advantage of the conversion of synthesized streams which are useful for introduction into the hydroprocessing unit for production of synthetic crude, the recycling of unique streams for use in the upgrader, nor is there any teaching specifically of the integration of the Fischer-Tropsch process or the recognition of the benefit to the process of using a SMR and/or ATR in the process circuit to maximize SCO yields and reducing dependence on natural gas.
Iqbal et. al. in U.S. Pat. No. 7,381,320 issued Jun. 3, 2008, teaches a process for heavy oil and bitumen upgrading. In overview, the process is capable of upgrading crude oil from a subterranean reservoir. The process involves converting asphaltenes to steam power, fuel gas, or a combination of these for use in producing heavy oil or bitumen from a reservoir. A portion of the heavy oil or bitumen are solvent deasphalted to form an asphaltene fraction and a deasphalted oil, referred to in the art as DAO as a fraction free of asphaltenes and with reduced metals content. The asphaltene fraction from the solvent deasphalting is supplied to the asphaltenes conversion unit and a feed comprising the DAO fraction supplied to a reaction zone of a fluid catalytic cracking (FCC) unit with an FCC catalyst to capture a portion of the metals from the DAO fraction. A hydrocarbon effluent is recovered from this having a reduced metal content. Similar to the process taught in U.S. Pat. No. 7,407,571, this process has utility, however, it limits the conversion of the otherwise wasteful asphaltene to production of solid fuel or pellets or conversion to syngas for fuel, hydrogen or electric power production. There is no teaching specifically integrating the Fischer-Tropsch process.
In U.S. Pat. No. 7,708,877 issued May 4, 2010 to Farshid et. al. there is taught an integrated heavy oil upgrader process and in line hydro finishing process. In the process, a hydroconversion slurry reactor system is taught that permits a catalyst, unconverted oil and converted oil to circulate in a continuous mixture throughout a reactor with no confinement of the mixture. The mixture is partially separated between the reactors to remove only the converted oil while allowing unconverted oil in the slurry catalyst to continue on to the next sequential reactor where a portion of the unconverted oil is converted to a lower boiling point. Additional hydro processing occurs in additional reactors for full conversion of the oil. The so called fully converted oil is subsequently hydrofinished for nearly complete removal of heteroatoms such as sulfur and nitrogen.
This document is primarily concerned with hydroconversion of heavy hydrocarbon, while not being suitable for bitumen upgrading. It also fails to provide any teaching regarding the use of Fischer-Tropsch process, usefulness of recycle streams, hydrogen generation or other valuable and efficient unit operations critical to successful upgrading of raw bitumen.
Calderon et. al. in U.S. Pat. No. 7,413,647 issued Aug. 19, 2008, teach a method and apparatus for upgrading bituminous material. The method involves a series of four distinct components, namely a fractionator, a heavy gas oil catalytic treater, a catalyst regenerator/gasifier and a gas clean up assembly. The patent indicates that in practicing the method, the bitumen in liquid form is fed to the fractionator for primary separation of fractions with the bulk of the bitumen leaving the bottom of the fractionator in the form of a heavy gas oil which is subsequently pumped to the catalytic treater and sprayed on a hot catalyst to crack the heavy gas oil, thus releasing hydrocarbons in the form of hydrogen rich volatile matter while depositing carbon on the catalyst. The volatile matter from the treater is passed to the fractionator where condensable fractions are separated from noncondensable hydrogen rich gas. The carbon containing catalyst from the treater is recycled to the regenerator/gasifier and the catalyst, after being regenerated is fed hot to the treater.
The method does not incorporate the particularly valuable Fischer-Tropsch process or provide a unit for effecting the Fischer-Tropsch reaction and further, the method is limited by the use of the catalyst which would appear to be quite susceptible to sulfur damage and from this sense there is no real provision for handling the sulfur in the bitumen.
In United States Patent Application, Publication No. US 2009/0200209, published Aug. 13, 2009, Sury et. al. teach upgrading bitumen in a paraffinic froth treatment process. The method involves adding a solvent to a bitumen froth emulsion to induce a settling rate of at least a portion of the asphaltenes and mineral solids present in the emulsion and results in the generation of the solvent bitumen-froth mixture. Water droplets are added to the solvent bitumen-froth mixture to increase the rate of settling of the asphaltenes and mineral solids. The focus of the publication is primarily to deal with the froth. There is no significant advance in the upgrading of the bitumen.
A wealth of advantages are derivable from the technology that has been developed and which is described herein. These are realized in a number of ways including:
a) near 100% or greater yield of total refinery products slate from heavy oil or bitumen without the wasteful production of petcoke or residuum; b) high quality synthetic hydrocarbon byproducts such as synthetic naphtha, syndiesel, synjet, synthetic lubes and synthetic wax is produced to highest quality commercial standards; c) maximum utilization of carbon in heavy oil and bitumen to form high quality synthetic hydrocarbon byproducts, with the significant reduction (greater than 50%) in GHG from the facility; d) the distilled and treated streams are substantially void of undesirable chemical and physical properties such as heavy metals, sulfur, Conradson Carbon (CCR) and naphthenic acid (TAN number); e) less natural gas is required to generate hydrogen for upgrading as the FT naphtha, refinery fuel gas, LPG, FT vapours and hydroprocessing vapours can be recycled to generate a hydrogen rich syngas; f) pure hydrogen can be generated from the hydrogen rich syngas using membranes, absorption or pressure swing adsorption units, for use in the hydroprocessing (hydrocracking, isomerisation, hydrotreating) units; g) Fischer-Tropsch (FT) liquids are primarily paraffinic in nature improving the quality and value of refinery product slate; h) FT naphtha is rarely available in any quantity in current upgraders and would be very preferentially used for deasphalting distilled bottoms in a Solvent Deasphalting Unit (SDA) and in a oil sands Froth Treatment Unit; and i) concentrated CO 2 is available from the gasifier (XTL) syngas treatment unit, allowing the upgrader to be a low cost carbon capture ready CO 2 source for carbon capture and sequestration (CCS) projects.
As part of the further advancements that are within the ambit of the technology set forth herein, the refinery aspect is addressed.
In this embodiment of the invention, a process is elucidated to fully upgrade light crude oil typically having an API density of between 22 and 40 and heavy oil with an API density of between 12 to 22 or extra heavy oil or bitumen with a density of less than API 12 API without the production of undesirable hydrocarbon byproduct, such as petcoke, heavy fuel oil or asphalt. The process combines the Fischer Tropsch hydrocarbon synthesis unit with conventional refinery processing steps to produce full commercial specification refined products, such as, but not limited to, naphtha for petrochemicals feedstock, naphtha for gasoline blending, gasoline, diesel, jet fuel, lubricants, wax, inter alia.
Generally, conventional or simple topping, hydroskimming and light conversion refineries are designed to receive sweet or sour light crude oils>22 API, more specifically 30 to 40 API density for the production of refined fuels. Light refineries are primarily focused on production of gasoline, jet and diesel fuel and if required, the refinery will manage refinery bottoms as asphalt or fuel oil sales. Usually the volume of bottoms is minimal for crude densities greater than 30 API.
In recent years the supply and availability of light crude oil has fallen appreciably and become very costly relative to discounted heavier crude costs. Many conventional refineries have been recently reconfigured to medium conversion refineries to accept further lower cost heavy crude oils (20 to 30 API) resulting in higher fractions of the crude oil converting to residue and being converted to asphalt, sour heavy fuel oil or petcoke. In addition, many refineries have been forced to further upgrade the hydrotreating facilities to produce ultra-low sulfur gasoline (ULSG) and ultra-low sulfur diesel (ULSD) to meet tighter regulatory commercial market specifications. Economics of these modified refineries have become very challenging due to significant capital and processing costs without additional product yield or significant revenue gain.
To further complicate issues, the large volumes of low value world crude oil supplies now take the form of extra heavy crude (12 to 22 API) or bitumen (6 to 11 API) sources from in situ or mining oilsands operations. Complex refinery conversions are now required, involving the addition of deep conversion refinery units such as deep hydrocracking and coking, to accommodate the extra heavy oil and bitumen feeds. These deep conversion refineries, are capital intense and produce significantly lower value byproducts such as petcoke with significant increased emissions of GHG (Green House Gases). Refinery product yields based on extra heavy and bitumen crude oil are about 80 to 90 volume %.
Petcoke has undesirable properties, such as difficult and costly handling, storage and transportation requirements, major environmental impact and contains high levels of sulfur (6+ wt %) as well as toxic heavy metals such as nickel and vanadium (1000 ppm+). Therefore petcoke has limited markets and is often a commercial and environmental liability as it is stored or marketed at very low or negative returns.
As the world oil supply transitions more towards the supply of extra heavy oil (12 to 20 API) and bitumen (6 to 12 API), the vacuum bottoms approaches 60 vol % of the whole crude assay. Accordingly, there is a need for an improved process to convert all the heavy oil and bitumen feed to commercial high value product without the production of byproducts such as petcoke and CO2 (GHG), with reduced impact on the environment.
The refinery process to be discussed addresses the needs in this area. Advantages attributable to the process include:
a) Transformation of refinery bottoms, typically >950+ F material to synthetic fuels such as FT naphtha, synthetic diesel, synthetic jet fuel, synthetic lube oils, waxes, etc.; b) Elimination of the production of low value hydrocarbon byproducts such as heavy fuel oil, road asphalt and petcoke, resulting in full (100 wt %) utilization of the crude feed regardless of density or blended densities of crude slate; c) Retention and conversion of greater than 90% of all carbon in the feed streams (i.e. crude oil, natural gas, etc) resulting in greater than 50% reduction in CO2 or GHG emissions; and d) Substantial reduction of the Conradson Carbon (CCR), Naphthenic Acid (TAN) and heavy metals and significant amount of sulfur from the main conventional refinery processes. This is advantageous since it permits the use of lower cost, conventional hydroprocessing units (hydrocrackers) with single or multiple fixed bed catalyst systems to upgrade the heavy fractions to high value refinery fuels.
SUMMARY OF THE INVENTION
One object of the present invention is to provide an improved heavy oil and bitumen upgrading methodology for producing refined products and synthesizing hydrocarbons with a substantially increased yield without the production of waste byproducts such as petcoke or residuum.
A further object of one embodiment of the present invention is to provide a process for upgrading heavy oil or bitumen to formulate refined hydrocarbon byproducts, comprising:
(a) providing a feedstock source of heavy oil or bitumen; (b) treating said feedstock to form a distilled fraction and non-distilled bottoms fraction; (c) feeding said bottoms fraction to a syngas generating circuit for formulating a hydrogen lean syngas stream via a partial oxidation reaction and reacting said syngas in a Fischer-Tropsch reactor to synthesize hydrocarbon byproducts; (d) removing at least a portion of fully refined hydrocarbon byproduct for commercial application; and (e) adding an external source of hydrogen to said hydrogen lean syngas to optimize the synthesis of hydrocarbons at least one of which is synthetic hydrocarbon byproduct.
A further object of one embodiment of the present invention is to provide a process for upgrading heavy oil or bitumen to formulate refined hydrocarbon byproducts, comprising:
(a) providing a source of bitumen or heavy oil feedstock and treating said feedstock with distillation to form a distilled and non-distilled bottoms fraction; (b) feeding the non-distilled bottoms fraction to a syngas generating circuit for formulating a hydrogen lean syngas stream via a partial oxidation reaction; (c) treating at least a portion of the said hydrogen lean syngas stream to a water gas shift (WGS) reaction to generate an optimum Fischer-Tropsch syngas; (d) treating said optimum Fischer-Tropsch syngas stream in a Fischer-Tropsch unit to synthesize hydrocarbon byproducts and; (e) removing at least one of upgraded portion of fully refined synthetic hydrocarbon byproducts for commercial application.
The present technology mitigates the oversights exemplified in the prior art references. Despite the fact that the prior art, in the form of patent publications, issued patents, and other academic publications, all recognize the usefulness of a Fischer-Tropsch process, steam methane reforming, autothermal reforming, hydrocarbon upgrading, synthetic oil formulation, stream recycle, and other processes, the prior art when taken individually or when mosaiced is deficient a process that provides the efficient upgrading of bitumen and heavy oil in the absence of residuum and/or petcoke generation.
Synthetic crude oil (SCO) and refined hydrocarbon byproducts, such as naphtha, gasoline, diesel and jet fuel is the output from a bitumen/heavy oil upgrader facility used in connection with bitumen and heavy oil from mineable oilsands and in situ production. It may also refer to shale oil, an output from an oil shale pyrolysis. The properties of the synthetic crude or refined hydrocarbon byproducts depend on the processes used in the upgrading configuration. Typical full upgraded SCO is devoid of sulfur and has an API gravity of around 30 to 40, suitable for conventional refinery feedstock. It is also known as “upgraded crude”. The processes delineated herein are particularly effective for partial upgrading, full upgrading or full refining to gasoline, jet fuel and diesel fuel. Conveniently, the flexibility of the processes allows for fuel synthesis and synthetic crude oil partial upgrading within the same protocol or the partial upgrading as the entire process.
The present invention amalgamates, in a previously unrecognized combination, a series of known unit operations into a much improved synthesis route for a high yield, high quality production of synthetic hydrocarbons. Integration of a Fischer-Tropsch process, and more specifically the integration of a Fischer-Tropsch process with a hydrogen rich syngas generator which uses FT naphtha and/or FT upgrader vapours as primary fuel in combination with natural gas, in a steam methane reformer (SMR) and/or an autothermal reformer (ATR) results in a superior sweet synthetic hydrocarbon byproduct which is synthesizable in the absence of petcoke and residuum.
It was discovered that, by employing a steam methane reformer (SMR) as a hydrogen rich syngas generator using Refinery Fuel, Refinery LPG, FT LPG, FT naphtha and FT/upgrader vapours, in combination with natural gas, significant results can be achieved when blended with the hydrogen lean syngas created by the gasification of non-distilled or treated bitumen or heavy oil bottoms. A significant production increase in middle distillate synthetic hydrocarbons range is realized. The general reaction is as follows;
Natural Gas+FT Naphtha( v )+FT Upgrader Vapours+Steam+Heat→CO+ n H 2 +CO 2 .
As is well known to those skilled in the art, steam methane reforming may be operated at any suitable conditions to promote the conversion of the feedstreams, an example as shown in above equation, to hydrogen H 2 and carbon monoxide CO, or what is referred to as syngas or specifically as hydrogen rich syngas. Significant benefits resulted in greater than 100% increase in middle distillate synthesized hydrocarbon. Steam and natural gas is added to optimize the desired ratio of hydrogen to carbon monoxide to approximate range of 3:1 to 6:1. External CO2 can optionally be added to minimize the formation of undesirable CO2 and maximize the formation of CO in the hydrogen rich syngas. A water gas shift reaction (WGS), pressure swing adsorption (PSA) or membrane unit can also be added to any portion of the SMR syngas circuit to further enrich the hydrogen rich stream and generate a near pure hydrogen stream for hydroprocessing use. Generally natural gas, FT Vapours, Refinery Gas or any other suitable fuel is used to provide the heat energy for the SMR furnace.
The steam reformer may contain any suitable catalyst, an example of one or more catalytically active components such as palladium, platinum, rhodium, iridium, osmium, ruthenium, nickel, chromium, cobalt, cerium, lanthanum, or mixtures thereof. The catalytically active component may be supported on a ceramic pellet or a refractory metal oxide. Other forms will be readily apparent to those skilled.
It was further discovered that employing an autothermal reformer (ATR) as a sole hydrogen rich syngas generator or in combination with the SMR or as a hybrid combination of an ATR/SMR referred to as a XTR, significant benefits resulted in a greater than 200% increase in the FT middle distillate synthetic hydrocarbons. Feedstreams for the ATR or XTR consist of FT naphtha, FT vapours, H 2 rich upgrader vapours, CO 2 , O 2 and natural gas.
Similarly, as is well known to those skilled in the art, autothermal reforming employs carbon dioxide and oxygen, or steam, in a reaction with light hydrocarbon gases like natural gas, FT vapours and upgrader vapours to form syngas. This is an exothermic reaction in view of the oxidation procedure. When the autothermal reformer employs carbon dioxide, the hydrogen to carbon monoxide ratio produced is 1:1 and when the autothermal reformer uses steam, the ratio produced is approximately 2.5:1, or unusually as high as 3.5:1.
The reactions that are incorporated in the autothermal reformer are as follows:
2CH 4 +O 2 +CO 2 →3H 2 +3CO+H 2 O+HEAT.
When steam is employed, the reaction equation is as follows:
4CH 4 +O 2 +2H 2 O+HEAT→10H 2 +4CO.
One of the more significant benefits of using the ATR is realized in the variability of the hydrogen to carbon monoxide ratio. An additional significant benefit of using the ATR is that external CO 2 can be added to reaction to effect a reverse shift reaction to create additional carbon monoxide for enhancement of the FT synthesis unit and reduction of overall facility GHG emissions. In the instant technology, an ATR may also be considered as a hydrogen rich syngas generator, as described previously. It has been found that the addition of the ATR operation to the circuit separately or in combination with the hydrogen rich syngas generation circuit, shown in the example above as a steam methane reformer (SMR), has a significant effect on the hydrocarbon productivity from the overall process. Similarly, a water gas shift reaction (WGS), pressure swing adsorption (PSA) or membrane unit can also be added to any portion of the ATR and combined ATR/SMR or XTR syngas circuit to further enrich the hydrogen rich stream and generate a near pure hydrogen stream for hydroprocessing use.
The present invention further amalgamates, in a previously unrecognized combination, a series of known unit operations to integrate the Fischer-Tropsch process, using a water gas shift reaction for syngas enrichment resulting in a valuable sweet synthetic hydrocarbon byproduct which is synthesizable in the absence of petcoke and residuum.
Accordingly, it is another object of one embodiment of the present invention to provide the process, wherein the water gas shift reactor (WGS) is introduced to at least a portion of the hydrogen lean syngas stream to optimize the hydrogen content for the Fischer-Tropsch process.
Referring now to the drawings as they generally describe the invention, reference will now be made to the accompanying drawings illustrating preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a process flow diagram of methodology known in the prior art for processing of mineable and in situ heavy oil and bitumen;
FIG. 2 is a process flow diagram similar to FIG. 1 , illustrating a further technique known in the art;
FIG. 3 is a process flow diagram illustrating a further variation of the prior art technology;
FIG. 4 is a process flow diagram illustrating a further variation of the prior art technology;
FIG. 5 is a process flow diagram illustrating an embodiment of the present invention;
FIG. 6 is a process flow diagram illustrating a further embodiment of the present invention;
FIG. 7 is a process flow diagram illustrating yet another embodiment of the present invention;
FIG. 8 is a process flow diagram illustrating one embodiment for a low conversion refinery;
FIG. 9 is a process flow diagram illustrating a medium conversion refinery; and
FIG. 10 is a process flow diagram illustrating a deep conversion refinery
Similar numerals employed in the figures denote similar elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 , shown is a first embodiment of a bitumen production flow diagram based on the prior art. The overall process is denoted by 10 . In the process, the heavy oil or bitumen source 12 may comprise a bitumen reservoir which may be minable or in situ. Generally speaking, the bitumen then may be transported to a heavy oil or bitumen production unit 14 into which diluent or solvent may be introduced via line 16 from a heavy oil or bitumen upgrader 18 . The diluent or solvent can comprise any suitable material well known to those skilled in the art such as suitable liquid alkanes as an example. Once the diluent is introduced via line 16 into the production unit 14 , the result is a mobilizable bitumen blend (dilbit). Once the dilbit or diluted bitumen blend is processed in the upgrader 18 , the so formed synthetic crude, globally denoted by 20 is then treated in a petroleum refinery 22 where subsequently refined products are formulated and with the refined products being globally denoted by 24 .
The production unit 14 primarily removes water and solids from the stream. The diluent or solvent 16 is added to the raw bitumen to provide for the necessary mobilization and separation parameters, primarily providing a reduction in viscosity. In a situation where the bitumen is an oil sand derived bitumen, water is added to the raw material to provide a slurry for transport to the extraction and froth treatment plant and upgrader 18 , as further described in FIG. 2 . Dewatered bitumen is then transported by pipeline (not shown) as a diluent blend or dilbit to the upgrader 18 . The dry raw bitumen is treated to primary and secondary treatment to create a sweet or sour crude oil (SCO). The SCO is transported to the petroleum refinery 22 to be further processed into refined product 24 as indicated above, examples of which include transport fuel such as gasoline, diesel and aviation fuels, lube oils and other feedstocks for petrochemical conversion.
With respect to FIG. 2 , shown is a schematic process flow diagram of oil sands operation for bitumen upgrading. The overall process in this flow diagram is indicated by 30 . Other than the embodiment shown, the system relates to a minable oil sands bitumen production process where raw mined oil sands ore, generally denoted by 32 , from the mine are mixed with water 34 in an ore preparation unit 36 and subsequently hydrotransported to a primary extraction plant, denoted by 38 . In the extraction plant 38 , the greater portion of water 34 and course tailings 40 are separated and returned to a tailings pond 42 .
Partially dewatered bitumen, generally denoted by 44 is transferred to a froth treatment unit 46 . This is where a solvent, typically highly aromatic naphtha (derived from bitumen) or paraffinic solvent (derived from natural gas liquids) is added at 48 to separate the remaining water and refined clays as well as fine tailings. The froth is then treated in a solvent recovery unit 52 where the majority of the solvent is recovered for recycle to the froth treatment unit. The separated fine tailings passes through a tailings solvent recovery unit 50 for final recovery of solvent. The fine tailings are transferred into the tailings pond 42 . The clean dry froth is then introduced into the bitumen upgrader, generally denoted by 54 and illustrated in FIG. 2 in dashed line. Generally speaking the bitumen upgrader 54 incorporates two general processes, a primary and secondary upgrading. The primary upgrader typically consists of two processing methodologies. The first, namely, carbon rejection or coking where the heavy fraction of the bitumen is removed as petcoke. Generally, the synthetic crude oil yield is between about 80 to about 85% by volume and the remaining portion converted primarily by petcoke is returned for storage to the mine. Further the coking process is a severe processing method and leads to higher aromatic content in the synthetic crude oil. The second process, namely hydrogen addition, uses a slurry based catalytic hydroprocessing system with the addition of hydrogen to treat the bitumen blend and produce an unconverted asphaltene reject stream and a synthetic crude oil product. The volume yield of the synthetic crude oil typically is 95% to 103% due to product swelling.
The hydrocarbon product streams from primary upgrading are further treated in secondary upgrader, consisting of hydrotreating units using hydrogen to stabilize synthetic crude products generally indicated as 56 and reduce sulfur and nitrogen impurities. Natural gas is used in a hydrogen unit to generate hydrogen requirements for the upgrader and co-generate electric power for upgrader use. The overall operations in the bitumen upgrader are indicated within the dash lines and these operations are well known to those skilled in the art.
Turning to FIG. 3 , shown is a further partial upgrading process known in the prior art, in this arrangement, the process flow diagram delineates an in situ bitumen production unit. The overall process is denoted by 60 . In such an arrangement, the in situ heavy oil or bitumen is exposed to steam to extract the oil. The raw bitumen 62 is treated in a conventional SAGD or CSS plant 64 to remove water 66 . Diluent 68 is typically added to raw bitumen 62 in plant 64 to create water oil separation and to further provide a diluted blend for pipeline transportation, more commonly referred to in the art as “dilbit” denoted by 70 . The dilbit can be transported over long distances in a pipeline (not shown) to remote refineries where it is blended with conventional crude as a feedstock. More integrated configurations may use distillation, deasphalting or visbreaking, a processing to create a near bottomless sour heavy crude for feed to refineries. This operation creates an asphaltene or vacuum residue stream requiring disposal. This partially upgraded bitumen is suitable for pipeline transportation for heavy oil feed streams greater than 15 API. For heavy oil and bitumen feed streams less than 15 API, some quantity of diluent is still required to meet crude pipeline specifications. The dilbit is processed in a bitumen partial upgrader denoted by 72 with the operations being shown within the dashed line box. The transportable bitumen is denoted by 74 in FIG. 3 . The diluent is often separated at the refinery and returned to the in-situ operation resulting in significant overall inefficiencies. The option to this is external makeup diluent is provided locally at a significant expense.
As will be appreciated by those skilled, the process variations shown in FIGS. 1 through 3 of existing bitumen and heavy oil production facilities either create a waste product such as petcoke or residuum which leads to significant losses or further requires significant quantities of hydrogen or diluent to upgrade the product in order to be suitable as a refinery feedstock. Essentially, the existing processes do not provide a technology capable of capturing the full intrinsic value of the bitumen or heavy oil and has resulted in environmental impact related to disposal and management of undesirable waste products.
Turning to FIG. 4 , shown is a further variation in the prior art of an enhanced bitumen upgrading process. It is the subject matter of Canadian Patent No. 2,439,038 and its United States homolog, U.S. Pat. No. 7,407,571 issued to Rettger, et. al. (Ormat Industries Ltd.).
The overall process is denoted by 80 .
Dilbit or froth 70 is introduced into an atmospheric distillation unit 82 with the non-distilled heavy bottoms being transported and introduced into a solvent deasphalting unit (SDA) 84 and the asphaltene bottoms are then subsequently fed into a gasifier 86 , which gasifier is within the Ormat gasification unit, globally denoted by 88 . The deasphalted material, commonly denoted as DAO is transferred to the hydroprocessing unit 108 for upgrading to synthetic crude oil. As an option, there may be a vacuum distillation unit 110 in the circuit which may introduce captured vacuum gasoils for introduction into hydroprocessing unit 108 . Similarly, the vacuum bottoms are introduced into the SDA 84 to optimize process configuration.
The sour syngas generated by the gasification unit is then passed into a syngas treater 90 for acid gas removal. The acid gas is removed at 92 and treated in sulfur plant 94 producing at least products such as liquid sulfur 96 and CO 2 98 . The treated or “sweet” syngas is then processed in a water gas shift reaction (WGS) process as denoted in the FIG. 4 and referred to as a CO shift reactor 100 . Steam 102 is augmented in the reactor 100 . The water gas shift reaction is merely a shift from the CO to CO 2 to create a hydrogen rich syngas. The hydrogen rich syngas may be then further treated in a typical pressure swing unit (PSA) or a membrane unit where the hydrogen is concentrated to greater than 99 percent. It occurs in unit 104 . The hydrogen generated by 104 , denoted by 106 is then the feedstock for the hydroprocessing unit 108 . Once the hydroprocessing occurs, the result is synthetic crude oil (SCO) denoted by 116 representing about 95 vol % yield and fuel gas denoted by 114 .
Returning briefly to the hydrogen recovery unit 104 , the byproduct of the unit 104 is a tailgas or a low BTU syngas which is used in the SAGD thermal steam generators as fuel to offset the need for natural gas as the primary fuel. The process has merit in that if natural gas is in short supply or there can be significant historic price fluctuation, the enhanced upgrader process is less dependent on the natural gas and can rely on the synthesized fuel for the overall process benefits.
Turning to FIG. 5 , shown as a first embodiment of an enhanced bitumen upgrading circuit process incorporating Fischer-Tropsch technology and hydrogen synthesis. The embodiment of the overall process is denoted by 120 . The overall process is particularly beneficial relative to the processes that were previously proposed in the prior art in that sweet carbon rich syngas is not passed through a water gas shift reaction, as denoted as 100 in FIG. 4 , but rather is supplemented with external hydrogen 138 to create the optimum syngas composition, typically a ratio of hydrogen to carbon monoxide of greater than 1.8:1 to 2.2:1, and preferred as 2:1 as feed to Fischer-Tropsch reactor for producing high quality paraffinic Fischer-Tropsch liquids.
It is by the recognition of the usefulness of the Fischer-Tropsch reactor together with the avoidance of waste petcoke/residuum generation and the subsequent hydrogen source addition to maximize conversion of gasified carbon, that draws the proposed interim technology into the realm of being economical, convenient and highly efficient given the yields that are generated for the synthetic crude oil (SCO), greater than 115 vol %, and more specifically greater than 135 vol %.
As is evident, there are a number of unit operations which are common with those in the prior art, namely the atmospheric distillation, vacuum distillation, solvent deasphalting, hydroprocessing, gasification, and syngas treatment.
In the embodiment shown, the Ormat gasification, commonly denoted as unit 88 and discussed with respect to FIG. 4 is replaced with a further sequence of operations (the XTL operations) shown in dashed lines and indicated by 122 . In this embodiment, the gasifier 86 converts the non-distilled bottoms residue with typically oxygen (O 2 ) 124 to generate a hydrogen lean or carbon rich syngas 88 having a hydrogen to carbon dioxide ratio in range of 0.5:1 to 1.5:1, more specifically about 1:1, an example of which is shown in Table 1.
TABLE 1
Typical XTL Gasifier Hydrogen Lean Syngas Compositions
Vacuum
Feedstock Type
Heavy Fuel Oil
Residue
Asphaltene
Syngas Composition (mole %)
CarbonDioxide (CO 2 )
2.75%
2.30%
5.0%
Carbon Monoxide (CO)
49.52%
52.27%
50.4%
Hydrogen (H 2 )
46.40%
43.80%
42.9%
Methane (CH4)
0.30%
0.30%
0.3%
Nitrogen (+Argon)(N 2 )
0.23%
0.25%
0.4%
Hydrogen Sulfide (H 2 S)
0.78%
1.08%
1.0%
A common byproduct, containing heavy metals and ash, from the gasification is discharged as slag denoted as 126 . The hydrogen lean syngas 88 is then passed into the syngas treatment unit 90 for removal of acid gases 92 to create a sweet hydrogen lean syngas 91 . Additional scrubbing, adsorption and washing technologies (not shown), well known to those skilled in the art, are typically employed to ensure that the sweet syngas is devoid of contaminants such as sulfur compounds which will have significant detrimental impact on the Fischer-Tropsch catalyst. The acid gas is further treated in the sulfur plant 94 to generate elemental sulfur 96 and carbon dioxide (CO 2 ) as was the case with respect to the process of FIG. 4 . The sweet hydrogen lean syngas 91 is then passed into a Fischer-Tropsch unit reactor denoted by 128 . As a possibility, the hydrocarbon by products that are formed subsequently to reaction within the Fischer-Tropsch reactor 128 includes Fischer-Tropsch vapours 184 (CO+H 2 +C1+C2+C3+C4), naphtha 130 , light Fischer-Tropsch liquids 132 (LFTL) and heavy Fischer-Tropsch liquids (HFTL) 134 or commonly know as FT wax.
In order to trim or improve the efficiency of the overall process, the XTL unit 122 and specifically in advance of the syngas treatment unit 90 and/or the Fischer-Tropsch reactor 128 may be augmented with an external supply of hydrogen, indicated by 136 and 138 , respectively. Further, at least some of the vapour from the Fischer-Tropsch reactor may be reintroduced in advance of the syngas treatment unit 90 as indicated by 140 , and/or be used a fuel 114 in the upgrader. The liquids 130 , 132 and 134 are introduced into hydroprocessing unit 108 . This may also be augmented by straight run distillate naphtha 144 may be introduced from atmospheric distillation operation 82 , vacuum gas oil (VGO) 142 from the vacuum distillation operation 110 and optionally, deasphalted oil 112 (DAO) from the SDA unit 84 . A range of hydroprocessing treatments 108 , as an example, hydrocracking, thermal cracking, isomerization, hydrotreating and fractionation, may be applied to the combined streams, individually or in desired combinations, well known to those skilled in the art, to create at least the synthetic crude oil product 116 . As further options, any portion of the Fischer-Tropsch naphtha 130 particularly the paraffinic naphtha indicated by 150 may be reintroduced into the deasphalting unit 84 at 152 or further distributed as the solvent make up 156 for introduction into the oil sands froth treatment unit (not shown but generally noted by 158 ).
Further, additional hydrogen may be introduced into the hydroprocessing unit 108 and hydrotreating unit 160 at 166 and 164 . The hydrogen supply may be taken from the hydrogen supply noted herein previously. From each of the fractionator, hydrotreater 160 , hydroprocessing unit 108 and Fischer-Tropsch unit 128 , product from each of these operations denoted by 170 or 172 , 184 respectively is introduced to fuel gas 114 . Further, a portion of 172 and 170 rich in hydrogen may be combined with the hydrogen lean syngas at 88 or 91 to enrich this stream for optimum performance of the Fischer-Tropsch unit.
Turning to FIG. 6 , shown in the process flow diagram is yet another variation on the methodology of the instant invention. The overall process in this embodiment is denoted by 180 . Similar unit operations from those established in FIGS. 4 and 5 are applicable in FIG. 6 .
The primary changes with respect to FIG. 5 versus FIG. 6 , includes modification of the XTL, unit 122 and incorporation of hydrogen rich syngas generation and recycle of hydrogen rich syngas generated in the Fischer-Tropsch unit 128 .
In greater detail, the XTL, unit 122 is modified to incorporate a hydrogen rich syngas generator, denoted by 182 . The hydrogen rich syngas generator 182 is typically composed of a steam methane reformer (SMR) (not shown) or an auto thermal reformer (ATR) (not shown) and combinations thereof. Natural gas 188 , Fischer-Tropsch vapours 184 , hydrogen rich fuel gas 174 , etc. from the hydroprocessor 108 and fractionation unit 160 and Fischer-Tropsch naphtha 186 may be supplied individually or in combination to unit 122 to generate hydrogen rich syngas 190 where the ratio between the hydrogen and the carbon monoxide is in range of 2:5 to 6:1. This is an important aspect of the invention and works in concert with the Fischer-Tropsch 128 to provide the effective results realized by practicing the technology as discussed herein with respect to FIGS. 5 through 6 . Natural gas 188 , depending on the current market situation at any location or time, may be used as a primary feedstock to the hydrogen rich syngas generator 182 and the steams 174 , 130 and 184 may be used to maximize upgrader operation. Alternately, if the natural gas market is less favourable, streams 174 , 130 and 184 may be fully utilized to offset the need for natural gas. The hydrogen rich syngas 190 can be introduced in advance of the syngas treatment unit 90 at 190 if treatment is required, or alternately, any portion of the hydrogen rich syngas 190 may be routed directly to the Fischer-Tropsch unit 128 .
In this manner, the hydrogen rich syngas 190 is combined with the carbon rich syngas to create an optimum Fischer-Tropsch syngas where the ratio of the hydrogen to carbon monoxide is preferred 2:1. The combined feed streams to unit 122 reduces the amount of natural gas needed to achieve the optimum Fischer-Tropsch feed stream, thereby offering a commercial advantage of the upgraders dependence on natural gas, but also takes advantage of current low cost supply of natural gas.
Additionally, a portion of the hydrogen rich syngas 190 can be introduced to hydrogen unit 192 where a purified hydrogen stream 164 is generated for use in the hydroprocessing unit 108 and fractionater/hydrotreater 160 . The hydrogen unit 192 may consist of a pressure swing adsorption (PSA), membrane or absorption technology, well known to those skilled in the art.
Turning to FIG. 7 , the process flow diagram illustrates a further variation on the overall concept of the present invention and in this manner, the XTL unit 122 undergoes further variation where the hydrogen unit 192 and hydrogen rich syngas generator 182 inherent in the embodiment FIG. 6 are replaced with a water gas shift (WGS) reaction unit operation. The overall process of FIG. 7 is denoted by 200 . The water gas shift unit is denoted by 202 and is disposed between the syngas treatment unit 90 and the Fischer-Tropsch unit 128 processing at least a portion of the sour or sweet syngas. As is known in the art and particularly by those skilled, the water gas shift reactor is useful to enrich the raw syngas which, in turn, results in optimization of the hydrogen to carbon monoxide ratio for the Fischer-Tropsch syngas. Steam supply for the WGS reaction unit 202 may be provided from the gasifier 86 shown as 204 . Additionally, hydrogen rich gas 171 and 173 from the hydroprocessor units may be combined with the FT vapours 140 to enrich the FT syngas feed.
Referring now to FIG. 8 , shown schematically is an example of a conventional simple low conversion refinery 230 that would receive 30+ API (light crude) crude oil, examples of which include Escravos 34 API and/or Bonny light 35 API at a volume of 100,000 BPD having 1600 ppm sulphur and 1178 ppm N2 with a specific gravity of 0.85, CCR of 1.4% by weight and 11 ppm nickel and vanadium content. This type of refinery targets the production of high value ultra low sulfur (ULSG) gasoline and (ULSD) diesel and produces about 7 vol % of the crude feed as refinery bottoms, denoted as 284 . Such refineries are currently experiencing challenges in maintaining a market for products from low value refinery bottoms and typically convert the bottoms to road asphalt and/or fuel oil. Such refineries are facing continuing economic challenges in accessing low density crude (30+ API) at competitive costs. To maintain commercial viability, these refineries pursue lower value discounted heavy oil (20 to 25 API) feedstocks to blend with conventional light 30+ API crude. The addition of the heavier crude oil increases the production of undesirable refinery bottoms.
The light crude oil is treated in atmospheric distillation unit 82 with 35,010 BPD of atmospheric tower bottoms at 19.6 API being produced referenced by numeral 232 . From the ADU 82 , light straight run oil (LSR) 234 in an amount of 5,370 BPD at 80 API are generated along with 26,000 BPD of heavy straight run (HSR) 236 oil at an API of 48. Kerosene 238 is produced in an amount of 13,510 BPD at an API of 35.7 and diesel 240 at 31 API in an amount of 20,110 BPD.
The LSR 234 is then treated in a C5/C6 isomerization unit operation with the isomerate 244 collected for the refinery product slate 246 as gasoline blend stock. The HSR 236 is treated in a naphtha hydrotreating unit (NHTU) 248 and then in reformer 250 with the reformate 252 subsequently forming part of the slate 246 , also as gasoline blend stock.
The kerosene 238 is treated in a kerosene Merox unit 254 to remove sulfur with the ultra low sulfur kerosene/jet fuel 256 then forming part of the product slate 246 .
Diesel 240 is generated in an amount of 20,110 BPD with an API of 33. The diesel 240 is treated in a hydrotreating unit 258 to form (ULSD) ultra low sulfur diesel 260 , then forming part of the product slate 246 .
Returning to the atmospheric tower bottoms 232 , the material is treated in the vacuum distillation unit 110 to yield 19,330 BPD of 23 API light vacuum gas oil 262 and 8,990 BPD of 19 API heavy vacuum gas oil 264 . Each of these products is then treated in hydrotreating unit 266 to yield distillate 268 forming part of the product slate 246 with a portion of the naphtha formed from treatment in unit 266 passed into NHTU 248 . A further portion, namely gas oil 272 is treated in a (FCC) fluid catalytic cracking unit 274 for production of gasoline blends.
Unconverted light cycle oil (LCO) 276 exiting the FCC unit 274 is further blended and treated in unit 258 to synthesize further ultra low sulfur diesel 260 for slate 246 . Alkylates 278 , light gasoline 280 and heavy gasoline 282 are then passed into gasoline pool of the product slate 246 .
A portion 284 of the vacuum bottoms from unit 110 at 6,690 BPD and API density of 10.7 and containing 121 ppm (nickel and vanadium), together with 80 million standard cubic feet per day (MMSCFD) of natural gas 286 and oxygen 288 in an amount of 1400 tons per day (TPD) is treated in the Fischer-Tropsch unit, described as FTCrude unit to formulate synthetic hydrocarbon byproducts.
Such processing has been discussed herein previously. The resulting product streams of liquid petroleum gas (LPG) 292 , FT naphtha 294 , synthetic jet fuel 296 and synthetic diesel 298 are passed into the isomerisation unit 242 , unit 248 and product slate 246 , respectively. Slate 246 accepts both steams 296 and 298 , while stream 294 is optionally blended into feed to unit 248 , then reformer 250 prior to passage to gasoline pool in product slate 246 .
A supply of hydrogen in an amount of 40 MMSCFD also is produced from unit 122 for use in the hydroprocessing units.
A sulfur recovery unit 302 recovers 21.8 TPD of sulfur.
Subsequent to all of the operations, the slate 246 results in 1,500 BPD of C3/C4 liquid petroleum gas (LPG) 304 , 61,800 BPD of regular/premium gasoline (ULSG) 306 having an API of 55 and specific gravity of 0.76, 13,500 BPD of jet fuel 308 having an API of 36 and a specific gravity of 0.84, 38,400 BPD of ultra low sulfur diesel (ULSD) 310 having an API of 41 and a specific gravity of 0.82. The volume % yield is 115% and the weight % yield is 100%.
Beneficially, the process results in:
a) significant high product yield supporting much improved refinery economics; b) full utilization of the heavy crude resources; c) lower refinery capital and operating costs; d) reduced environmental impact, lower GHG, eliminates heavy metals, sulfur, petcoke, heavy sour fuel oils, etc.; e) a refinery configuration which can handle heavier crude assay; and f) synthetic diesel quality of greater than 55 cetane, meeting most efficient diesel specification for high performance and high efficiency diesel engines.
In summary, the addition of a FTCrude unit receives the additional vacuum residue without the need to form undesirable fuel oil, petcoke or road asphalt and converts it to high value synthetic fuels such as synthetic diesel and synthetic jet fuel. Significant benefits are realized in that greater than 110 vol % product yield or more specifically greater than 115 vol % product yield can be achieved, without the production of unmarketable byproducts and with a 40 to 80% GHG reduction.
Turning to FIG. 9 illustrates an example of a typical medium conversion refinery that receives the entire crude feed as heavy oil (18 to 22 API) crude oil and targets production to ULSD diesel/jet fuel with the option for naphtha sales or further conversion to ULSD gasoline. FIG. 9 also illustrates the addition of a FTCrude or hydrocarbon synthesis unit to receive additional vacuum residue (approximately 24 vol % of the crude slate) and convert it to high value synthetic fuels such as synthetic diesel and synthetic jet fuel. Significant benefits are realized in that greater than 120 vol % product yield result or more specifically, 130 vol % product yield results, without the production of undesirable byproducts and with a 40 to 80% GHG reduction.
In greater detail of FIG. 9 , the overall process is denoted by numeral 312 . The refinery process uses a heavy crude oil as an initial feedstock, the heavy crude oil being denoted by numeral 314 in a volume of 100,000 BPD. In this example, the crude is Angola crude having an API of 22 with 0.7 weight percent sulfur with a specific gravity of 0.92 and a metal content of 94 parts per million (ppm) of nickel and vanadium. The heavy crude oil 314 is introduced into ADU unit 82 for processing. The processing steps are well known to those skilled in the art and will not be discussed herein. Subsequent to processing in the ADU unit 82 , the result is a stream of sweet fuel gas 316 , as well as a stream of straight run naphtha and light gas oil in a combined volume of 42,900 BPD with a specific gravity of 0.82 and an API of 41. The straight run naphtha and light gas oil is denoted by numeral 318 . A further stream of product is atmospheric bottoms in a volume of 57,100 BPD having an API of 19. This is denoted by numeral 320 . The atmospheric bottoms 320 are introduced into a vacuum distillation unit 110 with the result being vacuum gas oil 322 in a volume of 33,300 barrels per day (BPD) having a specific gravity of 0.92 and an API of 19 with 0.8 weight percent of sulfur and a CCR equivalent to 0.9 weight percent. Both the straight run naphtha and light gas oil 318 and the vacuum gas oil 322 are subsequently introduced separately or combined into the hydro-processing unit 108 . In the example, the hydro-processing unit 108 includes unit operations directed to hydrocracking and hydrotreating. This has been generally discussed herein previously with respect to the other embodiments. Subsequent to treatment in hydro-processing unit 108 , the naphtha that is produced, denoted by numeral 324 is introduced into a naphtha recovery unit 326 for stabilization and sulphur removal, where light vapour is subsequently passed into the fuel gas stream 316 for removal of further removal of sulfur (H2S) and use as refinery fuel. Similarly, second sour vapour stream 328 from the hydroprocessor units 108 is passed directed to the fuel gas stream 316 . All the LGO and VGO is converted and sweetened to primarily produce stream 330 exiting hydro-processing unit 108 as (ULSD) ultra-low sulfur diesel in a volume of 72,800 BPD at 33 API with less than 15 parts per million of sulfur and a specific gravity of 0.86. This is passed into the refinery product slate 246 . Similarly, stream 332 exiting naphtha recovery unit 326 comprises sweet, stabilized naphtha in a volume of 9,900 BPD having an API of 55 and a specific gravity of 0.76 and less than 30 parts per million of sulfur. This is also passed into the refinery product slate 246 or can be further processed by reforming to gasoline (not shown) as shown in FIG. 8 as unit 250 .
Returning to the vacuum distillation unit 110 , a stream 334 comprising a vacuum resid bottom volume of 23,800 BPD at an API of 5 and a specific gravity of 1.04 with a CCR equivalent to 19 weight percent and a sulfur content of 1.3 weight percent is introduced together with process oxygen 288 in an amount of 4,100 TPD and natural gas 286 in an amount of 300 MMSCFD into the FTCrude unit 122 . As has been delineated previously in the specification, the FTCrude unit involves XTL operations which include, but are not limited to gasification, syngas generation, the Fischer-Tropsch process unit and the Fischer-Tropsch upgrader. The FTCrude further provides through unit 122 a hydrogen stream 336 in the amount of 80 MMSCFD for use in the hydro-processing unit 108 . Product streams exiting the processing unit 122 include the FT LPG (not shown), FT naphtha 294 in an amount of 5,200 BPD having an API of 72 and a specific gravity of 0.69, FT diesel 298 in an amount of 43,400 BPD having an API of 53 and a specific gravity of 0.77, as well as FT process carbon dioxide in an amount of 2,700 tones per day as denoted by numeral 338 , FT sulfur in an amount of 51 TPD and FT process water in an estimated amount of 50,000 BPD.
As is illustrated in the flow diagram, the FT diesel 298 and FT naphtha 294 are passed to the product slate 246 . FT LPG is generally integrated into the refinery fuel supply.
The result of the refinery products stated in accordance with this embodiment of the present invention includes naphtha 344 in an amount of 15,100 BPD and an API of 60 and a specific gravity of 0.72 with less than 30 parts per million of sulfur, ultra-low sulfur (ULSD) diesel 346 in an amount of 69,700 BPD with an API of 43 and a specific gravity 0.81 with less than 15 parts per million of sulfur and optional ultra-low sulfur jet fuel 348 in an amount of 46,500 BPD with an API 50 and a specific gravity of 0.84 with less than 15 parts per million or ppm of sulfur. The volume percent yield for this process is 132% and the weight percent yield is 100%.
FIG. 10 illustrates an example of a deep conversion refinery that receives the entire crude feed as extra heavy oil (12 to 18 API) crude oil and/or bitumen (6 to 11 API) crude oil and primarily targets production of ULSD diesel and naphtha, with the option to further convert to ULSD gasoline. Extra heavy crude oil and bitumen are typically received at the upgrader as diluted crude referred to as DilBit. The diluent is recovered at the upgrader and returned to the crude provider. FIG. 10 also illustrates the addition of a FTCrude or hydrocarbon synthesis unit to receive the significant additional vacuum residue (approximately 60 vol % of the crude slate) and converts it to high value synthetic fuels such as synthetic diesel and synthetic jet fuel. As shown in FIG. 10 , it is preferred to further treat the vacuum residue with a solvent deasphalting unit, (SDA), capable of producing a clean deasphalted oil (DAO) for further hydroprocessing into high value diesel/jet products. A host of benefits are realized in that greater than 120 vol % product yield result or more specifically 137 vol % product yield results, without the production of undesirable byproducts and with a 40 to 80% GHG reduction. Generally, the increased product yield represents about 65+% product yield increase over conventional carbon rejection technologies, such as coking, and a 35+% product yield increase over conventional hydrogen addition technologies such as heavy reside hydrocracking.
In greater detail, in this embodiment the ADU unit 82 may receive an initial feedstock of dilbit 315 in an amount of 142,800 BPD with an API 21 and a specific gravity of 0.93, which contains bitumen 352 in an amount of 100,000 BPD having an API of 8.5 and a sulfur content of 4.5% by weight and a specific gravity of 1.02. Subsequent to treatment in the ADU unit 82 , the light vapours is taken off as stream 316 and subsequently treated for use a fuel and stream 318 comprises the combined straight run naphtha and light gas oil in an amount of 18,804 BPD at 44 API. In one embodiment of this invention, atmospheric bottoms is processed directly in a Solvent Deasphalting Unit (SDA) 84 , whereby deasphalted oil (DAO) 354 in an amount of 57,862 BPD at an API of 14 with a sulfur content of 4% by weight and a metals content of less than 20 ppm (nickel and vanadium) having a specific gravity of 0.97 and CCR equivalent of 3.3% by weight is produced as idea feed to a conventional hydrocracker unit. Streams 318 and 354 are optionally passed into the hydro-processing unit 108 with the produced naphtha 324 being stabilized and treated in naphtha recovery unit 326 and the vapours subsequently passed into sweet fuel gas 316 . In this embodiment, the naphtha stream 332 coming from naphtha recovery unit 326 is in the amount of 8,300 BPD at an API of 55 having a specific gravity of 0.76 with less than 30 ppm of sulfur which can optionally be further processed in a Reformer to produced into gasoline, as previously discussed. The ultra-low sulfur (ULSD) diesel/jet fuel in a volume of 73,150 BPD having an API of 33 with a sulfur content of less than 15 parts per million (ppm) and a specific gravity of 0.86 is primarily produced from the hydroprocessing unit 108 . Both streams 332 and 330 are passed into a refinery product slate 246 .
In this embodiment, the arrangement includes a deasphalting unit 84 into which a stream 356 from unit 82 is introduced. The stream 356 comprises atmospheric bottoms in a volume of 85,092 BPD having an API of 7 with a 4.6 weight percent content of sulfur and a metals content of 340 ppm (nickel and vanadium) with a specific gravity of 1.02 and a CCR equivalent of 16.7 weight percent. In another embodiment of the present invention, the atmospheric bottoms can optionally be feed a vacuum distillation unit (VDU) and the subsequent vacuum bottoms can feed the SDA unit. From the SDA unit 84 , the stream 358 therefrom together with process oxygen 288 in an amount of 4,700 TPD and natural gas 286 in an amount of 370 MMSCFD is introduced into FT Crude unit 122 . Stream 358 comprises liquid asphaltene stream in an amount of 27,229 BPD having an API of −6 with a sulfur content of 6.2 percent per weight and a metals content of 730 ppm (nickel and vanadium) with a specific gravity of 1.4 and a CCR equivalent of 37 percent by weight. Subsequent to the treatment in unit 122 , the result is the production of, similar to the embodiment in FIG. 9 , the FT LPG (not shown), FT naphtha with a volume of 6,050 BPD at an API of 72 and a specific gravity of 0.69 as well as FT diesel 298 in an amount of 49,500 BPD having an API of 53 and a specific gravity of 0.77. To reiterate, streams 298 , 294 , 330 and 332 form the refinery product slate 246 and are blended or sold separately aa high value refined products. The result of this is a naphtha content of 14,350 BPD with a 60 API and a specific gravity of 0.72 together with a sulfur content of less of 30 ppm, this being denoted by 344 , which may be optionally further reformed to produce gasoline or marketed as petrochemical feedstock. The slate also includes ultra-low sulfur (USLD) diesel 346 and a volume of 73,590 BPD with an API of 43 and a sulfur content of less than 15 ppm with a specific gravity of 0.81. The slate can further optionally include ultra-low sulfur jet fuel 348 in a volume of 49,060 BDP having an API of 50 and a sulfur content of less than 15 ppm with a specific gravity of 0.84. The volumes of diesel and jet fuel can be further optimized as is well known by those skilled in the art. In this process, the results of streams 338 , 340 and 324 are 2,700 TPD, 270 TPD and an estimate of 50,000 BPD, respectively.
It will be appreciated by those skilled in the art that the processes described herein provide a variety of possibilities for refining, partial upgrading or full upgrading, owing to the fact that the unit operations can be reconfigured to achieve the desired result. As an example, the bottoms fraction that is sent to the syngas generating circuit described herein previously can be used for formulating a hydrogen lean gas stream via a partial oxidation reaction. The reaction may be catalytic or non-catalytic. This reaction product can be then treated in a Fischer-Tropsch reactor to synthesize hydrocarbon byproducts while at least a portion of synthetic hydrocarbon byproducts can be removed for commercial market distribution.
While the preferred embodiments of the invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the invention. Reactor design criteria, hydrocarbon processing equipment, and the like for any given implementation of the invention will be readily ascertainable to one of skill in the art based upon the disclosure herein. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention. Use of the term “optionally” with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the claim.
Accordingly, the scope of protection is not limited by the description set out above, but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present invention. Thus the claims are a further description and are an addition to the preferred embodiments of the present invention. The discussion of a reference in the Background of the Invention is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications and publications cited herein to the extent that they provide exemplary, procedural or other details supplementary to those set forth herein. | A bitumen and heavy oil upgrading process and system is disclosed for the synthesis of hydrocarbons, an example of which is synthetic crude oil (SCO). The process advantageously avoids the waste attributed to residuum and/or petcoke formation which has a dramatic effect on the yield of hydrocarbon material generated. The process integrates Fischer-Tropsch technology with gasification and hydrogen rich gas stream generation. The hydrogen rich gas generation is conveniently effected using singly or in combination a hydrogen source, a hydrogen rich vapor from hydroprocessing and the Fischer-Tropsch process, a steam methane reformer (SMR) and autothermal reformer (ATR) or a combination of SMR/ATR. The feedstock for upgrading is distilled and the bottoms fraction is gasified and converted in a Fischer-Tropsch reactor. A resultant hydrogen lean syngas is then exposed to the hydrogen rich gas stream to optimize the formation of, for example, the synthetic crude oil. | 2 |
BACKGROUND OF THE INVENTION
The present invention arose in the particular context of vendors for bottles and/or cans of beverages such as soft drinks and, while it is disclosed herein primarily in relation to that context, it should be clearly understood that the principles of the invention have broader applicability and may be used with other articles having sufficiently similar dynamics, as will be appreciated by those skilled in the article vendor art.
Of the several types of mechanized article-vendors which have been devised, one which is in particularly widespread use, especially for vending rollable generally cylindrical bottles and/or cans of beverages such as soft drinks is the so-called column vendor.
In a rudimentary or architypical form a conventional column vendor comprises an enclosure, often called a cabinet or box, having a principal face, generally its front, which usually features in a lower region at least one outlet port for vended articles, a control panel which generally includes at least one site where the intending user may insert some form of credit or payment such as coins, a sheet of paper money or a credit card, at least one selector usable for selecting among two or more different brands, flavors, sizes or other characteristics of the articles available for vending, and one actuator (which may be combined with the selector) for initiating operation of the vendor to vend a selected article for which a form of payment has been inserted. Often the control panel as well as other panels on the principal face, and other faces of the column vendor bear logos or other indicia indicative of and/or tending to promote the selection of one or more of the brands and/or flavors of articles usually contained in the vendor. Any of a whole host of other features may be provided on the prinicpal face of the box, including without limitation change-making devices, slug-bent coin rejectors, light and/or sound emitting sales-promotional devices and the like.
Within the cabinet of such a typical column vendor are a plurality of vertical columns generally in one rank which extends transversally of the principal face, but sometimes two or more ranks deep front-to-back. At a minimum, each column includes wall means for confining and supporting a stack of articles, means for permitting articles to the stack, and means operatively connected between a mechanical, electro-mechanical or fully electronic `brain` housed in the cabinet, and an outlet port for abstracting an article from the stack and supplying it to the outlet port upon receipt of a signal which in effect indicates that an intending user has inserted a sufficient payment, has selected an article contained in that column and has requested actuation of the vendor to furnish such an article to the outlet port.
In the typical column vendor, at least for beverages, the space within the cabinet is refrigerated so that the bottles or cans of beverage, when vended, are cold and ready to provide cool refreshment.
Quite frequently in column vendors, the stack of articles in a column is one-article wide (although there may be zig-zag staggering of the articles in order to maximise use of space in the cabinet) and the stack is supported from below by a conventional arrangement which includes a device to temporarily transfer the site of application of stack support to the next-to-lowest article as the lowest article is vended to the outlet port, e.g. by rotation of a cradle portion of a principal support, after which the application of stack support is retransferred to the principal support permitting the stack to correspondingly lower.
The vendor cabinet has a lockable door through which access may be gained to the cabinet interior only by authorized maintaince and service personnel, e.g. for making repairs and adjustments, collecting accumulated forms of payment and refilling the columns with articles to be vended. Often, the principal face of the vendor is provided on that door or at least on the same side of the vendor as is that door. And usually, the individual columns are designed to be refilled from the front, or from the top by starting from the existing lowermost article (or from the principal support if the particular column is completely empty) and building the stack article by article until the particular stack is full or the service person has exhausted his or her supply of the article belonging in that stack.
Over the years, knowledge and lore has accumulated in the article vending trade as to the relative popularity generally, regionally and locally of various brands and flavors of articles to be vended, for instance, soft drinks. A typical route person who has serviced a particular soft drink vendor for an extended period can forecast with a respectable degree of confidence the ratio of cans of cola to orange soda to lemon-lime soda that will have been vended from that machine since his or her last visit and so be able to load up his or her hand-truck with a corresponding profile of cases of warm soft-drink for refilling the machine. It is a knack born of necessity, since the person who is poor at such forecasting will be found lugging much more merchandise both to and from the delivery truck and having to make more second trips to the delivery truck, both of which act as drags on efficiency.
In order to accomodate some of the disparity in brand/flavor popularity, many different tricks-of-the -trade and machine design features have been devised. Perhaps most rudimentary of these practices, often used on machines where each column has its own stack support cradle and each selector button or position on the vending panel is connected to a distinct stack support cradle, is to fill the stacks for slow-selling brands/flavors only part-way full, but the stacks for fast-selling brands/flavors all of the way full (and often also to devote more than one column to the fast-selling brands/favors). Then, the service person may fill the empty spaces in the respective columns above the stacks of slow-selling brands/flavors (and perhaps other spaces within the refrigerated cabinet) with containers of the faster-selling brands/flavors of product. In this manner an advantage can be gained, since, at the time of the next refilling of the machine the service person can manually transfer already cold containers of the fast-selling brands/flavors from the `wrong` to the `right` columns, after which the remaining column space can be filled with warm containers of product as before. In this manner, a service person can restock the machine with somewhat less frequency than if only the `right` containers were ever placed in the respective columns, and yet be assured that customers will neither find the machine to be `out` of their desired beverage or the like, nor that can or other container when received from the vending machine to contain warm beverage or the like due to insufficient time of residence of the respective container in the vendor cabinet prior to its being vended. Of course, if the vendor was used abnormally frequently, and/or the service person was delayed abnormally long from one visit to the next, the intending user could still find his or her brand/flavor sold out or, what is worse, could deposit his or her money, make a selection, and instead of a container of the selected brand/flavor of product, receive one of the containers that the service person had sandbagged in a `wrong` column in anticipation of his or her next restocking of the machine.
At the vendor designer/manufacturer level, the various equipment modifications that have been deivsed for accomodating disparity of brand/flavor popularity have included (in addition to the aforementioned provision of more than one column and thus more than one selector or selector position devoted to a popular brand/flavor), some other doubling-up or column transfer techniques such as connecting two or more columns to the same selector or selector position on the selector panel in such a manner that containers are vended alternately or in some established pattern of succession from the functionally interconnected columns. Another technique which has been devised is to interconnect two columns at some point above the bottom in such a manner that containers can transfer from one column to an adjacent column as that adjacent column tends to become empty.
In a typical such arrangement of the latter type, one column may be provided at half-height with an elevated floor, and above that floor a `trap-door` leading to an adjoining column, for effectively converting two adjoining columns into a half-column for a less-popular brand/flavor of product and a one-and-one-half column for a more-popular brand/flavor of product. Such arrangements are shown in the following U.S. patents:
______________________________________Patentee U.S. Pat. No. Issue Date______________________________________Donaldson 2,399,105 Apr. 23, 1946Johnson et al 3,169,621 Feb. 16, 1965Thompson 3,561,640 Feb. 9, 1971______________________________________
Other arrangements for causing a container which is stored in one column to be dispensed from a port which serves another column, e.g. by bodily shifting all or part of that column are shown in the following U.S. patents:
______________________________________Patentee U.S. Pat. No. Issue Date______________________________________Fry 2,205,192 Jun. 18, 1940Greene et al 2,255,007 Sep. 2, 1941Salisbury 2,913,142 Nov. 17, 1959______________________________________
Quite often the aforementioned prior art vendor structural arrangements were for accomodating space-to-sales were adjustable and/or reversible which is considered to be an attractive feature, inasmuch as it provides a means for being flexible, within a given vending machine, so as to permit the operator to tailor the columns to allot more space to faster-selling items, and less space to slower-selling ones. This need is particularly strong in an age where brand segmentation is producing a proliferation of beverages under the same brand, a growing number of new strongly-promoted beverages e.g. teas, fruit juices, and soft drinks containing some proportion of real fruit juice, and in an age where some changes in ownership of brands may result in unaccustomed realignments of varieties of soft drinks expected to be vended from the same machines. It is also important where the machine over its expected lifetime, is expected to be in service at a succession of locations where different profiles of brand/flavor preference are likely.
The present inventor and his associates have experimented with various configurations of the active `trap-door`-type of column transfer mechanism which has been referred to above, only to find the usefulness of such mechanicsms to be overly limited, in that, if the `trap-door` is not near the top of a column, the weight of the cans or bottles being held back will push out the door and, in essence, both stop downward travel of the principal stack in the principal column and also inhibit transfer of the auxiliary stack to the principal column. More complex active gates provided at lower levels of the columns also have proved to be a disappointment. Although they may eliminate the problem of `fighting` or precedence between the stack in the principal column and the stack in the auxiliary column, when the complex active gate is finally released the sudden cascade of cans or bottles into the principal column causes many complications that have proved difficult to solve.
The present invention was devised in order to provide the advantages of prior art column transfer devices, without the drawbacks which have been described.
SUMMARY OF THE INVENTION
A column vendor for articles such as generally cylindrical containers of beverage typified by cans or bottles of soft drinks is provided with an inexpensive and reliable way of being reconfigured to fit the particular distribution of popularity of brands/flavors or the like of articles, as experienced by the operator for the particular vendor. Openings are provided through intercolumn divider walls. In use, these openings are either closed by closure members, or fitted with shunt, cam or floor plates for effecting particular column transfers. In use, these members are static; adjustment can involve rearrangement, substitution, augmentation and removal of these members which preferably are hooked in place either on edges of the openings or in slots or other securement features provided on the intercolumn divider walls.
The principles of the invention will be further discussed with reference to the drawings wherein preferred embodiments are shown. The specifics illustrated in the drawings are intended to exemplify, rather than limit, aspects of the invention as defined in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings
FIG. 1 is a somewhat schematic fragmentary front elevational view of the column and stack support portions of a beverage can vendor provided with adjustable column transfer features according to principles of the present invention. (Structure omitted from this view may be utterly conventional; e.g. the cabinet may be one as shown in the Steeley, U.S. Pat. No. 3,680,937, issued Aug. 1, 1972; the stack support/article vendor cradles may be constructed and operated as disclosed in the Oden, U.S. Pat. No. 4,509,658, issued Apr. 9, 1985; and the general arrangement of the vendor may be as disclosed in any of a number of prior U.S. patents exemplified by those listed as references in the above-mentioned patents of Steeley and Oden, as well as in other prior U.S. patents, the Gale, U.S. Pat. No. 3,158,247 issued Nov. 4, 1964 being selected as a particular example in an illustrative, non-limiting sense and the Johnson, U.S. Pat. No. 2,988,246 issued June 13, 1961 being selected as another such example.)
FIG. 2a is a fragmentary view showing the portion encircled by dash-dot lines in FIG. 1 at a different stage in a typical vending cycle; and
FIG. 2b is a similar view showing the same portion at yet another stage.
FIGS. 3a, 3b and 3c are somewhat schematic front elevational views showing three alternate arrangements of two side-by-side double (i.e. `tandem`) columns using the adjustable column transfer features according to principles of the present invention.
FIGS. 4a, 4b and 4c are somewhat schematic front elevational views showing three alternate arrangements of the columns of an eight column vendor using the adjustable column transfer features according to principles of the present invention.
DETAILED DESCRIPTION
FIG. 1 shows in simplified form what a column vendor 10 might look like to a person who has opened its front door (not shown) and is looking at the front of the set of columns 12A-12H of the vendor. Structure not depicted in this view may be conventional, as indicated hereinabove with reference to disclosures of typical conventional vendors. This vendor happens to be one for vending cylindrical cans of soft drink, which will be used in the ensuing description by way of example.
The vendor 10 is an eight column vendor, which is a typical layout, the columns 12A-12H being arranged side-by-side transversally of the front of the vendor 10. The columns 12A-12H are vertical, and each is bounded at its two laterally opposite sides by respective sidewalls 14. In instances where a colunm 12A or 12H is at the extreme left of right of the bank of columns, its laterally outer wall 14 is unshared, but in other instances, each sidewall 14 is a dividing wall between two neighboring columns e.g. between 12A and 12B.
Each column 12A-12H is designed to be filled from the front and/or from the top by a succession of articles, in this instance cans C lying on their sides.
In the instance depicted in FIG. 1, which is a preferred arrangement, columns 12A, 12B, 12G and 12H are wide columns, i.e. so-called tandem columns which are slightly less than two cans wide, in order to accomodate a deeply-folded stack of cans C in which alternate cans rest in engagement with opposite sidewalls 14 of that column. In this instance, columns 12C-12F are narrow columns, each of which is only slightly wider than a single can, in order to accomodate a substantially unfolded, or only slightly folded stack of cans C, in which alternate cans rest in engagement with one or the other of the opposite sidewalls 14, although not necessarily with the absolutely regular alternation which is depicted. (Regular alternation maximizes the packing density, i.e. the space utilization of the columns.)
In viewing FIG. 1, it is possible that what is seen is all that there is, in terms of depth of the vendor, but it is also possible, even likely, that behind the stacks of cans which can be seen is one or more additional ranks of stacks of cans, and the present invention is equally applicable to either situation. In any event, the sidewalls 14 are generally vertically oriented, are of metal sheet material or the like, as is conventional, with their thickness oriented transversally of the front of the vendor 10, and extending to a rear wall 16 from which they may be supported in whole or in part. Other structure which may be provided to strengthen the walls 14 and/or to help support them from other elements of the cabinet have been omitted for the sake of clarity.
Each column is shown served at its otherwise open bottom outlet 18 by a respective conventional mechanism 20 or 22 for supporting the respective stack of cans C and for, upon command, abstracting the lowermost can from the stack and delivering it to the outlet 18, while permitting the remainder of the respective stack to correspondingly lower, as the can delivered to the outlet 18 conventionally descends a chute (not shown) to an outlet port (not shown) from which it can be withdrawn by the intending customer.
Because some of the columns, for instance 12A, are almost double the width of others, for instance 12C, the vendor 10 is already conventionally suited to stock more of fast-selling brands/flavors of soft drink than of slow-selling brands/flavors. And that capability can be conventionally enhanced by providing more than one selector button or selector position on the selector panel (not shown) for fast-selling brands/flavors, thus giving the intending consumer a second chance for a popular drink should one of the columns containing cans of that drink become empty.
However, in addition to, or instead of the conventional techniques for customising the capacity of the vendor 10 to the locally prevalent popularity profile, the present invention provides convenient, highly-adaptable, rugged, relatively trouble-free and inexpensive means for transferring articles, e.g. cans, laterally from column to column at one or more sites above the level of the lowermost can in the respective stack.
In FIG. 1, as well as the other drawing Figures, the particular arrangements of the structures provided in accordance with the principles of the invention, while certainly possible ones, are not necessarily the ones that would be most typical or most usually encountered. Rather, in these views, the structures have been shown in positions calculated to help the interested viewer and reader to more easily understand the range of possibilities for adjustment using the apparatus and method principles of the invention.
The apparatus of the invention is shown including a number of preferably mountable/demountable elements, as well as certain modifications to the sidewalls 14, as will now be described.
The sidewall modifications include the fact that at least one of the sidewalls which also acts as an intercolumn divider is provided with an opening 24 which is at least slightly taller than the diameter of a can C and which is at least slightly deeper than the height (when upright) of a can C. Each of the openings 24 may extend completely to an adjacent front and/or rear edge of the respective sidewall C, or it may be formed as a slot through a central part of such sidewall.
The sidewall modifications also include a plurality of anchor sites, e.g. slots 26 for permitting the preferably removable attachment of the elements which are further described below. These slots 26 preferably are provided not only in the intercolumn divider walls 14, but also in the laterally outermost sidewalls 14.
The mountable/demountable elements are shown including cams 28, ramps 30, slanted floors 32 and closure plates 34. (In any particular installation more or less than all of these elements may be used, and more or less than any one of them than has been illustrated may be used.)
Each closure plate 34 is designed to hook into one or more slots 26 above an opening 24 and to hook onto the ledge 36 of the respective opening, using its hooks 38 so as to effectively close that opening for so long as the machine is configured in the particular manner, i.e. the plate 34 does not intermittantly or periodically open or act as a gate during use of the vendor as depicted.
Each cam 28 comprises a sheet that is bent back on itself so as to provide an oblique declining surface 40 having a hook 42 at the top by which that cam 28 is mounted in the slot or slots 26 of a respective sidewall, and a foot 44 which engages the same sidewall in order to cause the lower edge of the oblique declining surface 40 to stand off from that respective sidewall by a fixed distance amount.
In the instance depicted, the cams 28 are provided for use in the wide columns, the foot 44 causes the lower edge to stand out nearly to the diameter of a can C from the respective sidewall, the surface 40 is about three can diameters in length, and the foot 44 angles upwards from horizontal so that when a cam 28 is used in juxtaposition with an underlying slot 26 in the same sidewall 14, the foot 44 engages that sidewall immediately over the respective opening 24.
The ramps 30 are designed to be used with taller ones of the openings 24, i.e. ones substantially taller than the diameter of one can, e.g., without limitation, ones which are 2-6 cans in height. A ramp 30 has a hook means 46 at the top for hooking into one or more slots 26 in one sidewall 14 across from an opening 24 in the opposite sidewall 14 of the same column, and a hook or ledge means 48 at the bottom for lapping over the lower lip of the opening 24 in that opposite wall of the same column. The main portion of the ramp slants between the hook means and ledge means thereof fully across the respective column.
Each of the slanted floors 32 is cantilevered upwards and across at a slant from an inverted channel 50 which embraces a lower lip of a respective opening 24. The lateral extent of a slanted floor is the full width of a narrow column and somewhat more than half the width of a wide column.
The structures may be used in conjunction with one another in the various combinations and juxtapositions shown, and in others also.
An overview of the provision of the structures in the various positions and combination shown in FIG. 1 will now be provided.
As a basis of comparison, it may be noted first that single column 12D is neither closed-off height-wise nor ported to an adjacent column at any place throughout its height, as an illustration that some of the columns in the set may be utterly conventional. The same effect can be achieved even for a column which has openings 24 in either or both of its sidewalls, by closing those openings with respective closure plates 34. The sidewalls 14 of the column 12D may nonetheless be provided with slots 26 at various levels, as may the sidewalls of all of the columns, both for use by structures mounted in the adjoining columns for which these walls are party walls, and also for use by structures which may be mounted at other times in the particular column in question.
The wide columns 12A and 12B and the narrow column 12C are shown set-up to shunt all of the cans in columns 12A and 12B and the cans from the top half of column 12C to the stack support 20 for the outlet 18 of column 12A. Typically, these two and one-half columns would hold cans of a comparatively fast-selling soft drink, such as regular Coke® or regular Pepsi®. The bottom half of column 12C is set to dispense cans of a comparatively unpopular soft drink via the stack support 22 and outlet 18 of column 12C. Typically, this half-column would hold cans of a comparatively slow-selling soft drink, such as generic grape soda.
Narrow columns 12E and 12F are shown set-up to vend all of column 12F and the top one-quarter of column 12E via the stack support 22 and outlet 18 of the column 12F, but the contents of the lower three-fourths of column 12E via the stack support 22 and outlet 18 of the column 12E.
Columns 12G and 12H, both wide columns are shown set-up to vend all of the contents of column 12G and the contents of the upper half of column 12H via the stack support 20 and outlet 18 of the column 12G, and the contents of the lower half of column 12H via the stack support 20 and outlet 18 of the column 12H.
All of the bracket-like members 28, 30, 32 which shunt the cans from one column to an adjacent column and/or isolate an upper part of a column from the lower part of that column, and the bracket-like members 34 which close-off openings 24 between adjoining columns by preference are simple brackets, shelves or the like, e.g. made of sheet metal or molded engineering plastic material, with the hooks or grooves shown being fabricated or molded into them for permitting them to be mounted, preferably removably mounted to the sidewalls of the columns.
It is very important to notice that the structures and method of the present invention facilitate use of old product before new in each column, i.e. inventory management on a first-in/first-out basis. In addition to the benefits mentioned above, the problem of first-in/first-out is of prime importance to the syrup companies because they do not want old product to stay in the machines. With the apparatus of the present invention, no matter how far the columns have been emptied, one simply places the new product at the top of the primary and secondary columns and the new product will take its turn being vended out. In the vendor of the Thompson, U.S. Pat. No. 3,561,640 or any gate concept, even the shifting column concepts shown in Green, U.S. Pat. No. 2,255,007 or Fry, U.S. Pat. No. 2,205,192, such a problem is present. If one comes back to the machine to reload it when the primary column has been vended down approaching the gate but has not opened the gate, one will be adding product back into the prime column and the secondary column will just rest there. If this happens too many times, one will have stale product in the secondary column. If one approaches the machine after the primary column has passed the gate and part of the secondary column has been vended out, one will have to manipulate the structure in order to get the gate closed and load both the primary column and secondary column. The proper way would be to unload the secondary column into the primary column and then load fresh product into the secondary column, but in practice, one cannot depend on service personnel taking the time to do this in the field.
Where the vendor 10 is a double-depth or other multiple-depth vendor, the structures of the invention may be independently provided and used at any and all of the levels, i.e. front and rear, or front, middle and rear, etc.
In concept, a column having an operative support 20 or 22, i.e. one which is connected with a selector button or selector position on the selector panel of the vendor via the control mechanism of the vendor, may be considered to be a `primary column`, and a column or column portion which originally contains a can that must transfer to another column in order to be vended may be considered to be a `secondary column`.
By strong present preference, the present invention as put to use involves no active gates for achieving secondary column to primary column transfer, i.e. no gate which pivots, slides, swings, deflects or otherwise must move from one position to another in order to permit the column-to-column transfer to take place. The cans siimply flow from the secondary column to the primary column as suggested in the circled region 60 of FIGS. 1, 2a and 2b, which has been found in practice so far to be more reliable than waiting for a primary column to become empty down to the level of a closed, active gate which then releases and lets cans from the secondary column into the primary column through the opened gate.
Taking a parting look at FIG. 1, when a wide column, such as column 12H is transferring to a wide column such as column 12G, a small shelf-like bracket 34 is clamped on the lower lip of the opening 24 in the wall 14 between columns 12G and 12H and two diversion devices 28 are hung on the walls so that the nested cans C in these wide columns form relatively unfolded single stack segments which neatly nest as a highly folded stack in wide column 12G below the respective opening 24. Not only is the need for working gates eliminated, but also, freedom is gained as to where to provide the opening or openings 24 in each cloumn-divider wall 14, because there is no longer a question of pressure on a necessarily active gate. In fact, one can go to the extreme which is depicted near the bottoms of columns 12A and 12B, where all of columns 12A and 12B, and an upper part of column 12C are devoted to one fast-selling product. In a modular vendor, this permits the drive motor for the support 2 of column 12B to be omitted (or, if already installed, removed and used elsewhere) with corresponding savings.
Other arrangements using the structures and method of the present invention are depicted in FIGS. 3a-3c and 4a-4c. Supports such as 20 or 22 which would be provided as is described above in relation to FIG. 1 are simply omitted from FIGS. 3a-3c and 4a-4c. Other elements are given numerals corresponding to those used in FIG. 1, and redescription is omitted here. The different types of shading used on the various cans C is intended to permit the viewer to readily distinguish cans of three different brands/flavors of soft drink from one another. These FIGS. 3a-3c and 4a-4c do depict a preferred placement for openings 24 i.e. three vertically spaced ones in each column divider wall which is a party wall for a wide column and another column.
Assuming the vendor depicted in FIGS. 3a-3c is a double-depth vendor of which only the frontal bank is visible, the capacity of the vendor with the set-up shown in FIG. 3a is twenty of the non-stippled variety of cans and one hundred-sixteen of the heavily stippled variety of cans. The comparable figures for the set-up shown in FIG. 3b are thirty-two non-stippled cans and one hundred-four heavily stippled cans, and for the set-up shown in FIG. 3c are forty-four non-stipppled cans and ninety-two heavily stippled cans.
The column capacity (in number and percent) of the vendor of FIGS. 4a, 4b and 4c and with all of the openings 24 closed and the other brackets of the invention removed (i.e. of a conventional eight column vendor for comparison) are shown in the following table:
TABLE 1__________________________________________________________________________ COLUMNSET UP 12H 12G 12F 12E 12D 12C 12B 12A TOTAL__________________________________________________________________________Conventional 72(16%) 38(9%) 38(9%) 38(9%) 38(9%) 72(16%) 72(16%) 72(16%) 440FIG. 4a 82(19%) 22(5%) 38(9%) 38(9%) 22(5%) 32(8%) 20(5%) 168(40%) 422FIG. 4b 82(19%) 22(5%) 38(9%) 38(9%) 38(9%) 32(8%) 20(5%) 152(36%) 422FIGS. 4C 82(16%) 22(5%) 38(9%) 38(9%) 38(9%) 72(17%) 20(5%) 116(27%) 426__________________________________________________________________________
In FIGS. 4a-4c, the three different degrees of stippling are intended to illustrate cans of three respectively different brands/flavors of soft drink.
For the sake of clarity, it should be noted that in their current form, FIGS. 3a-4c are computer-generated schematic views, in which the relationships of the cans to the sidewalls of the banks of columns is not shown as accurately as in FIGS. 1-2b, in that, in practice the sidewalls are actually engaged by the cans at opposite sides of the stack.
It should now be apparent that the article vendor with adjustable column transfer provision for accomodating locally-prevalent space-to-sales ratio as described hereinabove, possesses each of the attributes set forth in the specification under the heading "Summary of the Invention" hereinbefore. Because it can be modified to some extent without departing from the principles thereof as they have been outlined and explained in this specification, the present invention should be understood as encompassing all such modifications as are within the spirit and scope of the following claims. | A column vendor for articles such as generally cylindrical containers of beverage typified by cans or bottles of soft drinks is provided with an inexpensive and reliable way of being reconfigured to fit the particular distribution of popularity of brands/flavors or the like of articles, as experienced by the operator for the particular vendor. Openings are provided through intercolumn divider walls. In use, these openings are either closed by closure members, or fitted with shunt, cam or floor plates for effecting particular column transfers. In use, these members are static; adjustment can involve rearrangement, substitution, augmentation and removal of these members which preferably are hooked in place either on edges of the openings or in slots or other securement features provided on the intercolumn divider walls. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to synthesized messaging and real-time consumer contextual information. The present invention more specifically relates to synthesizing messaging to automate advertising processes.
BACKGROUND OF THE INVENTION
[0002] Online advertising has seen phenomenal growth over the last few years, growing hand-in-hand with the expansion of the Internet. It has evolved from randomly displayed, passive advertisements to advertisements targeted to specific individuals based on their demographic and psychographic profile. Examples of such technologies are given by U.S. Pat. No. 7,062,466, U.S. Pat. No. 7,007,074 and US Patent Applications 20050216335, 20070038500, 20080243480, 20080228568 and 20090070219. What all these approaches to advertising hold in common is establishing the appropriate context for the advertisement. This context is established by matching a specific individual or consumer group with the media or content that provides the context for the advertisement. Broadly, contextualizing is known as relevance matching. It is apparent that online advertising is struggling to resolve the problem of matching the message of the advertisement with the context of media placements such as web pages.
[0003] Relevance matching, however, is only one small portion of a much larger advertising process. The typical advertising process is complex and time-intensive. As a result, it excludes many small businesses and individuals who lack the professional expertise. Some of the essential elements of the typical advertising process comprise:
recognizing an audience by identifying prospects of unmet needs and evaluating the environment within which the audience exists; evaluating and identifying market segments; developing a strategy to target audiences by positioning and developing messaging as well as choosing appropriate media placement and buys; developing and managing an advertisement campaign; developing and executing sales-related feedback; performing analysis on sales-related data; and making necessary corrections to the whole process in light of campaign performance.
[0011] This cumbersome situation has only become more complex with the advent of online advertising and the evolution to context-generated advertisements. These approaches represent technical improvements, but are still rooted within the conventional process; the advertiser must still perform the demanding tasks of market analysis, segmentation, messaging, and campaign management. Other companies are already using keywords and semantic technology to improve the matching of existing advertiser-created messages with target segments, but the segmentation must be determined in advance by the advertiser. Analyzing a web page for its meaning allows them to better determine whether to target it with a given message, but the targeting is based on many difficult and expensive decisions on the part of the advertiser. Again, these examples represent technical improvements within the existing conventional process for advertising.
[0012] There is presently no technique directed to the over-riding process for advertising, to enable the discovery of the optimal market segmentation and messaging for promoted content; to identify and generate relevant relationships and messaging between an advertiser's content and an individual consumer that can be beneficially utilized by a consumer in response to a consumer action.
SUMMARY OF THE INVENTION
[0013] The present invention provides a computer network implementable method for synthesizing relevant messaging from a domain of information, underpinned by promoted content and optionally non-promoted content, using a consumer-generated context, the method comprising: (a) obtaining promoted and optionally non-promoted content, wherein the promoted content and optionally the non-promoted content are associated with at least one promoter; (b) receiving a consumer-generated context; and (c) semantically analyzing and synthesizing, or facilitating the semantic analysis and synthesis, by one or more computer processors, relevant messaging based on the promoted and optionally non-promoted content and the consumer-generated context, wherein the relevant messaging is traceable to the at least one promoter.
[0014] The present invention also provides a computer system for synthesizing relevant messaging from a domain of information, underpinned by promoted and optionally non-promoted content, using a consumer-generated context over a computer network linked to a plurality of computing devices, the system comprising: (a) a first set of computing devices, and a second set of computing devices for obtaining promoted content and optionally non-promoted content associated with the first set of computing devices, wherein the promoted content and optionally the non-promoted content is linked to at least one promoter; (b) a third set of computing devices for obtaining, receiving or generating the consumer-generated context and providing the consumer-generated context to the second set of computing devices; and (c) a semantic analyzing means and a semantic synthesizing means linked to the second set of computing devices for synthesizing relevant messaging based on the promoted and optionally non-promoted content and the consumer-generated context, wherein the relevant messaging is traceable to the at least one promoter.
[0015] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 illustrates relevance matching between promoters' messaging and media placements.
[0017] FIG. 2 illustrates a comparison between a prior art approach and the present invention where the present invention makes a promoter's content available through dispersed concepts.
[0018] FIG. 3 illustrates bypassing of the process where a promoted message is matched to media placement.
[0019] FIG. 4 illustrates a process where promoted content is a processed integral output.
[0020] FIG. 5 illustrates an analysis stage where a message is grouped with non-promoted content as part of the concept definition generated by various algorithms.
[0021] FIG. 6 illustrates a synthesis stage where a consumer-related input initiates semantic synthesis.
[0022] FIG. 7 illustrates a semantically synthesized web page.
[0023] FIG. 8 illustrates a networked implementation in accordance with the present invention, in one aspect thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Definitions
[0025] The following words, when used in the present specification, have the following meanings:
[0026] “concepts” means content constituting abstract thoughts, ideas, conceptualizations, and semantics that may or may not be associated with other content;
[0027] “consumer” includes any entity to whom synthesized messaging created in accordance with the present invention is directed; it may be a person, a collection of people, or in other system integration scenarios a consumer may be a machine-based consumer of the information in support of further processing;
[0028] “content” includes any data or media content including raw data, information, text, documents, images, or multimedia, more complex content such as web pages or websites, documents, advertisements, market analytics, etc. “content” includes information that describes other content, such as semantic data, metadata, and information that describes abstract “concepts”;
[0029] “domain” means a source of content that is made available to the present invention;
[0030] “domain administrator” includes any entity that makes available to the present invention one or more domains; domain administrators may be “promoters” but may also be service operators of the present invention, or non-affiliated individuals or organizations within the broader value chain (such as public website operators);
[0031] “media representation” provides the container for the promoted message or messaging, which may take different forms across different media, such as text, audio, video, etc., so that the same message or messaging may be represented in different forms to suit the media;
[0032] “message” or “messaging” includes the synthesized content created in accordance with the present invention and directed to a consumer;
[0033] “non-promoted content” has the meaning provided in the Overview, below;
[0034] “promoted content” has the meaning provided in the Overview, below;
[0035] “promoter” includes an entity that wishes to benefit from the present invention by directing messaging, whether for promoting specific content, seeding concepts or content, or influencing a consumer to read or view content, think about ideas, take an action (such as visit a website), etc.; and
[0036] “seed” or “seeding” includes directing “concepts” or other high level content to consumers in order to identify reaction of consumers with such concepts or other high level content in order to gather information regarding consumers, such as their interests, requirements, intentions, or otherwise.
[0037] Overview
[0038] The present invention provides a computer system, computer implemented method, and computer program, to create messaging based on, or informed by, one or more domains of content and to direct a consumer of the domain to, or present to a consumer of the domain, messaging comprising relevant content from one or more domains. Content can be utilized for a wide range of purposes as outlined below, whether for a specific commercial purpose such as generating messaging such as advertising, or influencing the creation of new content by presenting ideas from a domain that embody “looser” associations to encourage lateral thinking by the consumers. The created messaging provides advertising process automation.
[0039] In accordance with the present invention, the domain may be semantically analyzed, and a means of semantic synthesis may be used for generating or creating a semantic network to represent the domain. The semantic network may be a thought network, in accordance with that disclosed in PCT/CA2009/000567, however, it should be understood that other means for generating or creating a semantic network may be used.
[0040] In order to aid in the understanding of the invention the operation of the invention is explained from the perspective of the varying purposes of interacting with the present invention, and the different processes for creating and displaying messaging that are enabled by the functionality of the present invention. The present invention includes interaction between a promoter and the functionality of the present invention, and the messaging created by the present invention may be based on (i) promoted content; (ii) promoted content and additionally non-promoted content; or (iii) non-promoted content.
[0041] By operation of the invention, a promoter is able to direct a consumer to messaging comprising the content from the domain by seeding “concepts” or other content in the domain (a specific example of “seeding” is provided below under the heading “Providing a Domain of Information and a Semantic Representation of the Domain”. The present invention discovers relations between the seeded concepts or content and the promoted or non-promoted content within the domain of information. The promoter may supply the concepts or other content directly to the domain to use as an underpinning for the domain as promoted content or may direct a domain administrator to use as underpinning for the domain, non-promoted content that are already part of the domain. The present invention could automatically provide the relations, however a promoter or domain administrator may leverage their knowledge of the relations that may be made in order to appropriately seed concept and/or content. Connections can be created or inferred (for example, hyperlinks that encode links between data, documents, semantics, or other informational entities) between the non-promoted content and the particular concepts or other content. The promoted content and non-promoted content that comprises the underpinning of the domain is combined, integrated or blended prior to a consumer interaction with the domain.
[0042] A consumer can interact with the semantic network representing the domain. When the consumer interacts with the semantic network, consumer interaction information (which provides a context) interacts with this combined, integrated or blended content and delivers messaging comprising content derived from the underpinning of the domain, which may include promoted content, non-promoted content, or new content, to the consumer based on the concepts and content and the connections between the concepts or other content and the domain. The consumer perceives the message, for example, as part of a consumer experience but in fact is receiving a specific message tuned to the specific consumer interaction (consumer input or other consumer action) at hand by operation of the present invention. Also, the combination, integration or blending by semantic analysis and/or synthesis can be used to position the message in an association that is close to the consumer interaction occurring in that instant.
[0043] This integration and interaction approach displaces the current practice of matching a message, for example to a consumer based on media placement, in a way that it is believed will be of interest to the consumer. The integration and interaction approach is responsive to actual consumer interaction rather than consumer interaction that is likely in relation to a particular media placement location, therefore enabling more targeted messaging (such as advertising). In addition, the promoter need not incur the time and cost of creating relatively complex messaging such as advertisements, or multiple versions of advertisements for different consumer contexts, but rather may simply provide the underpinning of the domain by integrating content with many different consumer contexts by leveraging the creation of, through the operation of the present invention, messaging closely associated with such different consumer contexts.
[0044] Furthermore, the promoter is able to direct the consumer to the messaging by leveraging the domain and the connections between the concepts or other content represented by the domain and the consumer.
[0045] The promoted content may be created or generated from a number of sources. For example, the promoted content may be any content created by or for a promoter, or collected by or for a promoter, whether for monetary or non-monetary purposes. This may include content for which the promoter is willing to pay for distribution to a consumer. An example of such content is advertising that includes hyperlinks to a related website, wherein the promoter is interested in ensuring that advertising reaches a target audience.
[0046] The non-promoted content may be content that exists in the domain without any current contribution or collection by or on behalf of the promoter. The non-promoted content could relate to previously contributed information (for example, advertisements that were used in previous advertising campaigns), contributions by others not associated with the promoter, or generally available content (e.g. content obtained from public domains).
[0047] A domain administrator administering or facilitating the use of the present invention may create or facilitate the creation or inference of connections between the non-promoted content and concepts or other content of interest to the promoter. The domain administrator has knowledge of the connections in the domain and can target particular consumer contexts to the concepts or other content of interest to or desired by the promoter. Thus, the consumer experiences an automated process whereby it receives messaging desirable to the promoter. The promoter can direct the messaging to a consumer without being required to provide promoted content.
[0048] It should be understood in the present invention that the functions provided herein may be performed by different entities. For example, the domain administrator may facilitate the selection or accumulation of non-promoted content, whereas another entity may determine what consumers are interested in, and yet another may allow the connection or inference between the content and the consumer interest. The entity can use automated means for performing these processes. Additionally, the various functionalities of the present invention can be distributed across a plurality of different computer systems.
[0049] It should also be understood that promoted content and non-promoted content in certain cases are not mutually exclusive. For example, a promoter may want to promote specific content within a domain of publicly available content made available by the promoter. The specific content may be put forward by the promoter (promoted content), and also be represented in the broader domain of publicly available information used as the underpinning for the promoted information objects (i.e. non-promoted content).
[0050] To enable the directing of a consumer to the messaging or presenting of the messaging to a consumer, the present invention comprises a computer network implemented method to create or generate a semantic network, including receiving promoted or non-promoted content, semantically analyzing the content and combining, integrating or blending the content by generating semantic representations of concepts (hereafter, “concept definitions”), such that a media representation of the relevant promoted or non-promoted content within the generated concept definitions is traceable to the promoter.
[0051] The generated concept definitions are compared to consumer interaction information, and relevant concept definitions may be semantically synthesized along with the consumer interaction information into consumer concept definitions with promoted and non-promoted content, such that a media representation of relevant promoted or non-promoted content within the synthesized consumer concept definitions is traceable to the promoter and is provided to the consumer.
[0052] It should be understood that the sequence of the steps performed in carrying out the invention are not essential to the operation of the invention. For example, the system can obtain a consumer interaction information before, concurrently, or after obtaining promoted and optionally non-promoted content. For clarity, it will generally be the case that the promoted and optionally non-promoted content is obtained prior to the consumer interaction information, but the order can be changed without affecting the invention.
[0053] The present invention also comprises a computer-network-based implementation that includes simultaneously receiving promoted content and non-promoted content, semantically analyzing the promoted content with the non-promoted content and combining, integrating or blending the promoted content with the non-promoted content at a consumer interaction stage, such that such that a media representation of relevant promoted or non-promoted content within the combined, integrated or blended content is traceable to a promoter. The consumer interaction, with the semantically analyzed content, results in messaging that is a semantic synthesis of the relevant semantically analyzed content to be displayed as part of a network web page, for example, such that the combined, integrated or blended content is in a hypertext format.
[0054] The present invention further comprises a computer-network-implementable method to combine, integrate or blend consumer interaction information with promoted and non-promoted content by semantically synthesizing all content with the consumer interaction information into consumer concept definitions, such that a media representation of relevant promoted or non-promoted content within the synthesized consumer concept definitions is traceable to a promoter.
[0055] The present invention still further comprises a system for executing a computer-network-implementable method to combine, integrate or blend promoted and non-promoted content before a consumer interaction with the network, the system comprising a computer network, means to receive content, means to perform semantic analysis, and means to output combined, integrated or blended synthesized content on the network, the system operable to receive promoted and non-promoted content, semantically analyze the content and combine, integrate or blend the content by generating concept definitions, such that a media representation of relevant promoted or non-promoted content within the generated concept definitions is traceable to a promoter.
[0056] In the present invention, the full implementation of the invention is operable on a distributed and networked computing environment. This includes implementation of the invention based on Internet-based technology development and service development wherein users are able to access technology-enabled services “in the cloud” without knowledge of, expertise with, or control over the technology infrastructure that supports them (“cloud computing”). Internet-based computing further includes software as a service (“SaaS”), distributed web services, variants described under Web 2.0 and Web 3.0 models, and other Internet-based distribution mechanisms. In order to illustrate the implementation of the present invention in such distributed and networked computing environments, including through cloud computing, the disclosure refers to certain implementations of the invention using multiple sets of computers. It should be understood that the present invention is not limited to its implementation on any particular computer system, architecture or network. It should also be understood that the present invention is not limited to a wired network and is implementable using mobile computers and wireless networking architectures, for example by linking wireless devices to the system by a wireless gateway.
[0057] Typically, at least one set of computing devices would generate or retrieve and send the promoted or non-promoted content (or both) over the network to a second set of computing devices to stage, semantically analyze and synthesize relevant content to provide a domain of information, and at least a third set of computing devices from which the consumer interaction information originates sends the consumer interaction information to the second set of computing devices, where it is received. The third set of computing devices also receives the messaging provided by the second set of computing devices over the network and displays the messaging to the consumer.
[0058] The present invention may include a feedback loop from the output to the analysis stage (or to the synthesis stage). This represents a feedback report on the performance of promoted or non-promoted content that comprise the message displayed within the output, as well as a mechanism for revealing to the promoter the market segmentation and other market analytics discovered by the system. The semantic analysis and synthesis processes are adaptive to the performance report, with resulting adjustment to more optimally integrate the promoted or directed content into the messaging over time.
[0059] Providing a Domain of Information and a Semantic Representation of the Domain
[0060] As earlier stated, the present invention provides a system, computer network implementable method and computer program to create or generate messaging based on, or informed by, a domain of information and direct a consumer of the domain to the messaging, which comprises relevant content.
[0061] A promoter of the particular information is able to direct the consumer to the messaging by seeding concepts or other content in the domain to provide the underpinning of the domain. The seeded concepts or other content may relate to promoted or non-promoted content within the domain of information. For example, the promoter may supply the concepts directly to the domain as promoted content or may direct a domain administrator to mine or create non-promoted content that is already part of the domain and create or facilitate the creation or inference of connections by automated means between the non-promoted content and the concepts desired by the promoter. The promoted and non-promoted content are combined, integrated or blended prior to a consumer interaction with the domain.
[0062] For clarification purposes, the domain comprises either or both of promoted or non-promoted content.
[0063] It should be understood that promoted content need not be created by the promoter. It could instead comprise non-promoted content that is collected and contributed by the promoter to the domain, or this could be done on the promoter's behalf. The promoter, or an entity on its behalf, creates or collects content that creates or facilitates the creation of connections between a particular context and the message to which the consumer is directed.
[0064] Non-promoted content, on the other hand, may be content that exists in the domain without any current contribution or collection by the promoter. The non-promoted content could relate to previously contributed information (for example, advertisements that were used in previous advertising campaigns), or contributions by others not tied to the promoter. A domain administrator can mine this information to create or facilitate the creation or inference of connections by automated means between the non-promoted content and concepts or other content desired by the promoter. The non-promoted content may also consist of publicly available information (public domains) that by operation of the invention can provide the underpinning for the creation of content.
[0065] The domain administrator may have knowledge of the connections in the domain and can target particular consumer contexts to the concepts or other content desired by the promoter. Thus the promoter can direct a consumer to the messaging without being required to provide promoted content.
[0066] For example, the domain administrator may compile a list of keywords or terms that relate to other keywords or terms. A promoter can consult with the domain administrator regarding non-promoted content to which it desires connections and can engage the domain administrator to create or discover connections between keywords and terms, relevant to a given context, on such a list with other terms of relevant non-promoted content. These new connections, when semantically analyzed with the domain and when the semantic network is created or generated, enable a consumer to be directed to messaging comprising the content when a given context is provided by the consumer.
[0067] The domain, comprising either or both of promoted or non-promoted content, may be semantically analyzed and a means of semantic synthesis may be used for generating or creating a semantic network to represent the domain. The semantic network may be a thought network, in accordance with that disclosed in PCT/CA2009/000567, as previously described.
[0068] A consumer can interact with the semantic network representing the domain. When the consumer interacts with the network, consumer interaction information (which provides a context) interacts with this combined, integrated or blended content and delivers a directed message to the consumer based on the concepts and the connections between the concepts and the domain. The consumer is provided with a media representation of the directed message as part of a consumer experience. The combination, integration or blending by semantic analysis and synthesis can be used to position the message as close as possible to the consumer interaction tasks at that instant.
[0069] The consumer interaction information may be consumer driven or machine driven. For example, consumer interaction information may include consumer input provided via a user interface, consumer demographic information, consumer browsing information, machine generated data, GPS data, sensor data, or any combination thereof. The consumer input may be provided in response to a web based search query. The consumer browsing information can also be analysed to determine a major theme or themes of consumer browsing (such as one that recurs or is dominant relative to other themes).
[0070] Alternatively, the consumer may store information, for example thoughts, gathered during the course of one or more consumer interactions. Further still, the consumer may select content for gathering of consumer interaction information, for example by selecting part of a web page, document or email. The thoughts or selection can be set aside by the consumer, or by the present invention as so configured, and later provided as the consumer interaction information. A tool could be provided for enabling the consumer to set aside these thoughts and selections and provide them as the consumer interaction information by a consumer action or on an automated basis.
[0071] Additionally, the consumer interaction information can be provided in real-time, on a delayed basis, or in a collective set. A collective set of consumer interactions which, for example, may consist of a set built up over time and processed on a set frequency or a set built up to a threshold number of consumer interactions, can be processed together by the system. The collective set can be parsed prior to its use with the system.
[0072] This integration and interaction approach displaces the current practice of matching message to media placement. The promoter, therefore, does not have to incur the time and expense of creating and disseminating several complex and intricate promoted materials since the promoter can simply use the present invention to automatically integrate content with many different consumer contexts. Through the present invention, the promoter is able to direct the consumer to the messaging by leveraging the underpinnings of the domain and the connections between the concepts represented by the domain and the consumer.
[0073] To enable the directing of a consumer of the domain to the messaging, the present invention comprises a computer network implementable method to create or generate a semantic network, including receiving promoted or non-promoted content, semantically analyzing the content and combining, integrating or blending the content by generating concept definitions, such that a media representation of the relevant promoted or non-promoted content within the generated concept definitions is traceable to the promoter. The generated concept definitions are compared to a consumer interaction information, and relevant concept definitions are semantically synthesized along with the consumer interaction information into consumer concept definitions with promoted and non-promoted content, such that a media representation of relevant promoted or non-promoted content within the synthesized consumer concept definitions is traceable to the promoter and is provided to the consumer.
[0074] Combining, Integrating or Blending Promoted and Non Promoted Content
[0075] The present invention provides an interactive consumer experience wherein shaping of messaging that is consumer directed information is based substantially on consumer participation. The consumer may be an existing or potential customer or existing customer or end-user of a product or service. The messaging may include promoted and non-promoted content. The promoted content may be, for example, any content that are desired by a promoter to be included in the consumer directed information for a consumer, as previously described. For example, the promoter may be an advertiser promoting the sales of a product or service, a political advocacy group promoting a particular cause, a government body distributing information into the public domain, a community or social group distributing information to its members, among many other use cases. The messaging may include advertisements and/or other communications directed to a consumer, or an information product, for example information created specifically for the consumer and based on a consumer interaction. The messaging may also include non-promoted content, for example publicly provided content or content enabling the creation or inference of connections to the consumer interaction.
[0076] Messaging may be created by inferring connections between a consumer context and the promoted content, non-promoted content and related content. The connections may be inferred using a means of semantic synthesis. The resulting consumer directed content are conceptually relevant to the consumer context.
[0077] The interactive consumer experience could also be implemented by utilizing the information source of promoted content (for example, a promoted communication), for example an advertisement or other message, to bypass the relevance matching process by performing an information process on not just the consumer-related or created content, but also on the information source. This approach enables consumers, through their own activity, to automatically find and interact with conceptually relevant promoted or non-promoted content and enables these consumers to shape in real-time both the consumer context and the messaging.
[0078] Where the promoted content consist of advertising-related content, an approach to processing the information source of promoted content with non-promoted content may disrupt much of the onerous practices of conventional advertising at the process level. With it, consumers, not promoters, can shape both the consumer context and the messaging, allowing advertisers to bypass much of the hard work in such areas as market analysis, strategy development and positioning steps that are generally required to effectively direct messaging to consumers with a particular purpose in mind. Further, there is no longer a need for expensive and time-consuming communication development, audience segmentation, or complex media buying and placement activities, thus dramatically lowering the cost of advertising and promotion. Additionally, the messaging and associated relevant promoted or non-promoted content, and an effective context for their presentation, are defined by the consumer, not the promoter, increasing the overall effectiveness of the messaging. Another major advantage is that properly targeted and timed messages are perceived by consumers as useful information, not an annoyance (unlike most advertising as delivered under the conventional process). Moreover, market feedback and analysis are greatly simplified by displacing traditionally laborious upfront activities with market analytics that are automatically discovered and reported through the operation of the present invention. The present invention thus provides a discovery-based mode of advertising and promotion, since the promoters do not need to precisely define and target their audiences. Broader and unanticipated audiences are another advantage of this discovery-based approach. Since the requirements of market analysis and segmentation are diminished or displaced entirely, promoters can promote activities without a precise definition of their audience and in turn learn what are the optimal audiences and markets for their promotional needs. Further, advertisers can discover what aspects of their content resonate with the market, enabling them to make appropriate adjustments to their content.
[0079] Semantic synthesis may be provided for performing synthesis on a lexicon of terms provided by the results of a semantic analysis on a domain of information. A means of semantic analysis may optionally be provided for generating consumer concept definitions that are input for semantic synthesis. In one particular implementation of the present invention, semantic analysis and synthesis are applied to the problem space of promoting content to consumers. It simplifies and disrupts the conventional approach by displacing many of the conventional activities altogether. The present invention may be enabled by a process such as that illustrated in FIG. 4 , which is more fully described below. The system enabled by the present invention, in accordance with this aspect, may include the steps of staging, analysis, synthesis, generation of consumer concept definitions, output, and feedback, as is more fully described below. This process could furthermore be made dependent on limitations to achieve real-time process efficiency. In other words, a consumer interaction in accordance with the present invention can result in meaningful output within particular constraints to provide a more cost-effective result. The constraints may be provided for optimizing the system based on physical limitations presented by the system or environment. For example, the limitations may include staging, analysis or generation time limits based on processing time, available CPU cycles or maximum CPU cycles desired to be used, limits on the volume of data to be occupied, bandwidth limitations, or any other meaningful limitation that can impact the performance of the system.
[0080] Alternatively, instead of requiring staging and semantic analysis of the domain, a domain of already analysed content can be provided. For example, an annotated domain or structured domain providing a semantically analyzed domain can be used by the system.
[0081] In addition, the means for semantic analysis, if provided, could be provided by a third party and/or at a remote location. Input to the semantic synthesis stage could be provided by obtaining or receiving semantic analysis rather than generating it.
[0082] The system may load, retrieve or otherwise be provided with content from sources the promoter creates or collects and provides or identifies, and it may deconstruct this content to an elemental level. In response to a consumer action, the system may create messaging, for example advertisements assembled from those elements, using information about consumer context to ensure that the messaging is relevant and appropriate. The content could be created or derived by an entity based on the consumer's interests, which could be based on indirect means, for example, websites the consumer is visiting, profiling data such as social networking profiles, or service usage analytics and logs. Another entity could process promoted content, while a third entity could manage the connection between the information and the promoted content. The third entity can provide the messaging to the consumer's computing device for output. The system may collect data regarding the nature and volume of the messaging it creates. From this, it may create reports that the promoter can use to make adjustments to its source content and to monitor its promotion.
[0083] The system may be implemented using a distributed and networked computing environment comprising, for example, at least three sets of computing devices including devices associated with the source promoted content, the consumer, and the processing engines described herein. The consumer may provide inputs and receive outputs from the computing devices using a consumer interface, or the consumer information could be provided by other means, such as tracking of demographic information or browsing information related to the consumer.
[0084] Matching Advertisement to Consumer
[0085] The following describes an implementation of the present invention wherein the underpinning of the domain is promoted content consisting of advertising. The non-promoted content in this example consists of content available in the public domain. Optimally, a domain administrator enables or facilitates the creation or inference of connections between the non-promoted content and the domain of information.
[0086] The present invention provides a computer-implemented method and system to match advertisement source content in a media representation (such as a web page) with a consumer-generated input on a network such as the Internet. The domain of information could comprise all or a subset of media representations (such as web pages and other digital media) on the Internet.
[0087] In contrast to the practice common in conventional prior art given by FIG. 1 , where consumer-generated information is matched with an advertisement, the present invention uses advertisement source content to match to a consumer. This can be implemented by deconstructing the advertisement source content to an atomic level (that is, deconstructing many different concepts that taken together comprise the meaning of the advertisement) and synthesizing messaging leads that are associated with the atomised concepts. The advertisement source content is semantically analyzed with the domain of information, or provided to the system, and a means of semantic synthesis of the collection of atomised concepts provides a semantic network for representing the domain (including the source content). Possible methods for semantic analysis and synthesis are more fully described below.
[0088] The atomised concepts here refer to elemental concepts that may be progressively broken down further into increasingly narrow meaning. Correspondingly, while the messaging leads as a whole casts a wide net around consumer-generated information, they can further get matched individually to measurable semantic differences of consumer interests within a unique topic. This micro-level matching bypasses the whole process of relevance matching, by combining, integrating or blending consumer interests with advertisement source content that has already been combined, integrated or blended with relevant public and/or private domain information.
[0089] A comparison between prior art approaches and the present invention is illustrated by FIG. 2 , where the prior art advertisement is conveyed to a consumer in whole. In contrast, as shown in the lower part FIG. 2 , the present invention makes promoted or non-promoted content available by attaching them to concepts dispersed across an output, wherein the output is a result of consumer-defined context, which forms the basis for one or more messages.
[0090] As shown in FIG. 3 , by semantically engineering the context of a message into messaging leads, it is possible to match the message to context from consumers (in this case web users) at a very refined level, thus bypassing media placement altogether. This is achieved by staging content from various sources. Staging of content refers to a phase where external content (from various sources, including the domain of information, promoted content, and non-promoted content) are mapped to the system schema. The external content may be identified based on criteria including the nature of the content that can be processed. For example, content from a selectable domain may include all content that is operable to be processed by a means of semantic analysis (including approaches such as natural language processing of unstructured text, named entity extraction, mapping to linked data through open standards for semantic representation, and many other approaches that are well known in the art).
[0091] External content may also be provided by other structured domains of information, for example semantically annotated web content or a thought network from one or more consumers. A tool may be provided for enabling a thought network to be provided as external content to be staged. It should be understood as well that other forms of external content can be provided.
[0092] Subsequently, staged content is deconstructed into semantically analyzed and annotated content that is then synthesized into a message that matches a consumer context created by consumer information. The semantic analysis of content refers to a phase where content from all sources has been deconstructed to an elemental level (atomised concepts) and is ready for semantic synthesis. The content may include promoted content, either directly disclosed or collected by the promoter, and non-promoted content, either from public websites or non-public sources, such as an intranet, RSS feeds, private blogs or any sources of network-available private content.
[0093] After the staging and analysis of content, the processed advertisement source content may include messaging leads synthesized using the atomised concepts or elemental content from the content source of the advertisement message. The source of this content may be any source linked to a promoter including, for example, an advertiser's web page, a third-party web page containing an advertisement for the promoter, direct content disclosed by the promoter, content linked by a promoter, content related to a promoter's product, technical content relating to advertiser promoter or its products, etc. An additional source for content may be provided by facilitating promoters with a self-service utility having a user interface. This self-service utility would allow promoters to register and disclose, online, their information source, whether it be a link to a website or direct material submission. The promoters would be able to choose from a selectable options list to enter into a commercial transaction for the service with which they would be provided. Once the synthesized messaging is positioned within the consumer-generated context, the promoter's interactive information may be made available to consumer interactions. This enables the promoter to enter into transactions with consumers in a way that is more conceptually relevant to the consumer context.
[0094] For example, a promoter might register through the self-service utility to identify one or more domains as a source for consumer interactions. A website or an online store are examples of this type of domain. Consumers that are existing users of these domains, such as customers at a store, may elect to include these domains as a source of their synthesized information and messaging. In one example, a customer of an online electronics store may wish to be informed of related products from this store as they are exploring subjects related to electronics. There are numerous monetization and revenue models to support this type of promoter-consumer interaction, including affiliate models, transactional advertising models, sponsorship models, and many others.
[0095] With reference to FIG. 4 , FIG. 5 and FIG. 6 , the advertisement information source, such as a public website, may be provided as input to staging to prepare it for generation or creation of semantic representation along with the public and other related content, which for example may be processed by semantic analysis. The means for generating or creating semantic representation may produce consumer concept definitions relevant to the consumer context.
[0096] Semantic analysis, as one example of a means for generating or creating these consumer concept definitions, can be performed using a number of approaches including, but not limited to, schema mapping, statistical clustering, natural language processing, entity extraction and facet analysis. In the semantic analysis stage, the advertisement information is processed along with non-promoted information and is tracked. The information generated through the analysis stage may be stored in the form of semantic representations such as concept definitions, where the advertiser information is grouped with relevant subjects.
[0097] An example is:
Concept definition C: {domain advertisement 1, Subjects k1, k2} Concept definition C1: {Sunrise Apple Farms, Apple, Farm} Concept definition C2: {Great Furniture Co, Chair, Table, Wood}
[0101] As previously mentioned, instead of requiring staging and semantic analysis of the domain, a domain of already analysed content can be provided.
[0102] The semantic analysis stage may be followed by a semantic synthesis stage where consumer interaction information is submitted to generate or create semantic representations, such as consumer concept definitions. The consumer interaction information may be consumer-provided information, including search queries, semantic networking creation information or consumer-related collected information, such as demographic information, content of a third-party website that has been browsed by the consumer or a browsing history that is submitted to construct consumer concept definitions. The semantic network to be created could, for example, be a thought network, wherein the consumer interaction information is part of building the thought network and the output is a web page with content organized and collated by the resulting thought network.
[0103] The semantic synthesis may be performed using any number of semantic synthesis approaches, including but not limited to, faceted classification, semantic reasoners, formal concept analysis, multi-document summarization or a hybrid semantic synthesis protocol that combines many such approaches. Consumer concept definitions are concepts made from relevant concept definitions related to consumer-submitted information as shown in FIG. 6 . The consumer concept definitions are created by applying semantic synthesis rules, which might be dependent on the type of algorithm being used. At all phases of semantic processing, promoted or non-promoted content in a media representation can be traceable to a promoter (such as an advertiser). Making promoted or non-promoted content in a media representation traceable to a promoter could be implemented, for example, by providing a unique identifier (ID) for each promoted or non-promoted content. The media representation generated by the semantic synthesis may also be linked to the ID so that the media representation is linked to the promoter. This traceability enables not only the identification of the promoter for specific represented content, but also the feedback loop described herein.
[0104] The combined, integrated or blended output of promoted and non-promoted content essentially complete the process whereby the combined, integrated or blended semantically synthesized content are now ready to be utilized as a base for a wide range of applications including developing knowledge-bases, displaying search results, creating automatically-generated documents such as a web page as displayed by FIG. 7 , or any other customized application taking a consumer input and displaying an output result. These applications will combine, integrate or blend the synthesized content within the media representation. One example of a media representations is shown in FIG. 7 , wherein a web page being accessed by a consumer is modified by embedding the promoted content using the messaging leads.
[0105] As shown by FIG. 4 , there could be a feedback loop from the output to the analysis stage and/or the synthesis stage. This represents a feedback report on the performance of the message within the media representations. By semantically processing the feedback report, the promoted or non-promoted content may be deconstructed and recombined, reintegrated or reblended into a variety of different messages and consumer-generated contexts. This feedback report is thus able to inform the promoter (an advertiser for example) as to the messaging and content that is resonating with consumers. It allows the promoter to avoid trying to predict and measure this effectiveness in advance, and rather discover the messaging and content that should be targeted. Metrics that may be used to inform this feedback report may include information about the number of times particular promoted content is clicked or followed-up (accessed), the followed-up/times-displayed ratio over all consumer contexts, and the followed-up/times-displayed ratio within each different consumer context.
[0106] The semantic processing of the feedback report can be at the analysis stage and/or the synthesis stage.
[0107] This performance report may be fed into the analysis stage, which may be automatically configured to adjust the display priority for promoted or non-promoted content. These display priorities may include removing or re-ordering a promoter's content from a certain consumer context, where it has a low followed-up/times-displayed ratio, to replace it with another promoter's content within the same consumer context. This process ensures a redistribution of promoted and non-promoted content takes place within a given consumer context. The redistribution may be further enhanced by automatically replacing optimally successful promoters for a given consumer context with other promoters after a certain definable or arbitrary time limit or for a trial basis. This step would make way for the exposure of new promoters testing their content.
[0108] The performance report may also or alternatively be fed back to the synthesis stage. The synthesis stage could adapt to those metrics which can be processed by the synthesis stage such as discontinuing a promoter and bringing in a new promoter or shuffling the priority of a promoter based upon feedback data, where the analysis need not be changed, just the priority.
[0109] A higher display priority for a promoter can also be used to assign a higher probability that the promoter's content will be displayed and/or to assign a higher number in an order sequence for display.
[0110] Content from a third-party website that is browsed by the consumer can also act as a context generator (providing consumer interaction information as well as the non-promoted content from which to generate messaging leads). A promoter can direct a domain administrator to enable or facilitate the creation or inference of connections between the content from the third-party website and the consumer context. The content from the third-party website would provide both context and non-promoted content that will be semantically processed along with promoted content. The semantic process may begin with staging, shift to analysis and eventually synthesize messaging based upon consumer context that is inferred or implied by the subject matter of the page. This aspect would support a distributed content network and would effectively outsource management of non-promoted content in a conventional promoter-publisher model. This distribution model would, for example, support the operations of advertising networks, affiliate networks, or similar multi-party promotion models.
[0111] Once the media representation is ready to be displayed, there are issues to deal with regarding placement of the number of messages suitable for the same place or page in the output. One way to deal with this issue is to make a simple adjustment affecting the display priority of messages by using a single parameter or a combination of parameters. Examples of parameters include, but are not limited to, relevancy, higher fees, and IP address locality of the consumer and/or GPS coordinates of the consumer for providing locally-relevant messages. Another plausible way of placing more promoted and/or non-promoted content in the messages is to time slice the results by updating the output in order to accommodate more than one promoter or message.
[0112] Monetization may take place upon display of a message within a media representation. Once the media representation is displayed, monetization may also take place after the consumer clicks the message or after an actual purchasing action takes place. Monetization may depend on a combination of transactions or interactions. Monetization may also depend, in portion, on the service of processing of promoted content at the semantic analysis stage. Another form of monetization would be by a CPM model, which refers to advertising bought on the basis of impressions. Further, another form of monetization could come from forwarding performance results and feedback reports to the promoter.
[0113] It should be understood that the present invention also provides matching of messaging (for example, advertising) to consumers based on only non-promoted content, i.e. without promoted content, without need for a promoter to provide any source domain information. In this example, the promoter may provide concepts only, without specifying content on which messaging created by operation of the invention will be based.
[0114] There are two main modes of operation of the invention for non-promoted content based messaging: ( 1 ) promoters influence the analysis and synthesis operations by manipulating parameters for creating content rather than providing promoted content other than the concepts; and ( 2 ) promoters take a “passive” approach to creation of messaging that is similar to “seeding” concepts as described above.
[0115] In the first mode of operation, a user interface provided by operation of the system can expose parameters within the system's analysis and synthesis methods to promoters. The promoters can use these parameters to bring about different outcomes in the analysis and synthesis of concepts and connections. Tuning these parameters can create a different consumer experience in relation to the created messaging, which can in turn be tied to specific promoter goals or objectives. For example, if the promoter wants to create a conservative impression in keeping with their brand, they can tighten the parameters to reduce the variability in the concepts and connections produced Similarly, if a promoter wants to make more of a freewheeling, creative impression, the parameters can be tuned to increase the variability of concepts and connections produced. There are many ways to tie promotional objectives (such as marketing and branding objectives) to optimal system parameter configurations, simplifying operations for non-technical promoters.
[0116] In the second mode of operation, the promoter takes a passive role and does not try to influence the operations of the system through domain information or method parameters. Instead, the promoter selects from one or more possible promotional goals which a service design implemented by the system of the invention provides. These goals may include activities such as directing consumers to a specific website or supporting messaging for specific branding programs. As with the first mode, the system can align these goals to specific configurations of method parameters and community (public or shared) domains. In both modes of operation, the system can evolve and optimize advertising campaigns over time via the feedback loop described above.
[0117] For example, communities of users may represent the market as a whole. These communities may be an aggregation of consumers providing interactions, a focus group providing aggregate consumer interaction information, or a combination of the two wherein individual consumer interactions are first aggregated and then provided to the system. The community need not be structured, as individual consumers can be placed in a community by the system, based for example on shared interests of the consumers.
[0118] The community may create or add to the domain by contributing content or by linking to content external to the domain.
[0119] The system of the present invention can combine these modes of operation with other embodiments of the invention. For example, promoters may take a largely passive role, but still provide promoted content. Promoters may also provide promoted content implicitly by providing a website address as a goal. The system can then automatically harvest the website for particular promoted content. It should be understood that in this last example, by providing the website address, the advertiser will have still provided promoted content by putting forward a location where these can be found.
[0120] Implementation
[0121] FIG. 8 illustrates a networked implementation in accordance with the present invention. The present invention should not be considered to be limited to the particular network implementation illustrated. The present invention may be implemented using a distributed and networked computing environment comprising at least one computing device. In a particular implementation, at least three sets of computing devices may be provided. Each set of computing devices may comprise one or more computing devices linked by a network. Typically, at least one set of computing devices would generate and send the promoted and/or non-promoted content over the network to a second set of computing devices. The second set of computing devices receives the content, and may combine, integrate or blend the content. The second set of computing devices would stage, semantically analyze and synthesize relevant content. However, it should be understood that the generation of the content, the combination, integration or blending of content, and the analysis and synthesis of content may be processed on any number of computing devices from one to many.
[0122] At least a third set of computing devices may be used to obtain or receive or be the source of the consumer interaction information also sent to the second set of computing devices for further staging, analysis, and synthesis. Again, the consumer interaction information could be provided on the same computing devices as described above, or any number of other computing devices. The consumer interaction information may be consumer generated or machine generated. For example, the consumer interaction information may be generated by the consumer using an interface, which may be operable to receive queries or other contextual input from the consumer, may be generated using demographic information or browsing information related to the consumer, or may be provided as any other consumer interaction as described above. Machine generated consumer interaction information may be based on, for example, GPS data, other sensor data, etc. The third set of computing devices would also receive the resulting content and information over the network and display to the consumer the output that has been semantically customized by the second set of computing devices. The means for displaying the output could be a monitor or other display device linked to the third set of computing devices. In particular, where the third set of computing devices includes a wireless gateway and one or more wireless devices for displaying the output, the wireless devices may be equipped with video/image stabilizers, for example accelerometers, to enhance the user experience.
[0123] The consumer may be associated with a consumer profile linked to the third set of computing devices. The profile may be operable to link consumer information to the consumer each time the consumer interacts with the network. The consumer information can be provided back to the consumer as it is generated or created.
[0124] The second set of computing devices may be linked to a staging engine, analysis engine, and synthesis engine. The staging engine extracts, transforms, and loads content from the promoted content sources into the system for analysis. The system may maintain promoted content separately from non-promoted content, such as that from public sources. This may enable both tracing of the promoted content to a promoter and the ability to process promoted content differently than non-promoted content. The analysis engine deconstructs all the staged content, including promoted content, to an elemental level, extracting semantic data and compressing it into a semantic kernel. After analysis, promoted and non-promoted content may be maintained as separate data sources. The synthesis engine synthesizes the relevant promoted or non-promoted content into messaging leads that the system dynamically assembles into messages, which are the output of the system. The output may be provided to the consumer using the applications described above. In one aspect of the invention, the output is displayed in one or more web pages containing links in hypertext or hypermedia format. The links may be embedded based on the messaging leads linked to the promoted content, such as the promoter's website or other content provided by the promoter, as described above, or non-promoted content including public content linked to a promoter.
[0125] In a further implementation, synthesis could be provided on a computing device either local to or under the control of the consumer. The relevant messaging provided by the synthesis could, therefore, be kept under more private control of the consumer.
[0126] A utility may be provided wherein the engines can be configured to process promoted content and non-promoted content differently, so that it is more or less likely that promoted content will surface in the output to the consumer.
[0127] Furthermore, a facility may be provided for direct or indirect configuration of the ratio of promoted to non-promoted content placed in the output. The ratio may be determined based on the likelihood of particular promoters or classes of promoters having their content used. This content could be collected based on offline statistical analysis or real-time automated analysis. The facility could also be used to configure monetization as described above, or to configure the appropriate actions to be taken with respect to the performance report (for example, the display priorities) described above or the metrics described above.
[0128] It should be understood that further enhancements to the disclosed system, method and computer program are envisioned, and without limiting the generality of the foregoing, the following specific enhancements are envisioned.
[0129] Optionally, an additional initial step may be provided for performing a synthesis of a portion of the domain to enhance the performance of delivering relevant messaging to the consumer. For example, a portion of the domain can be input to the analysis and/or synthesis engine along with the consumer interaction information to provide relevant messaging faster than would otherwise be possible.
[0130] In addition, a pre-analysis stage could be provided to enhance the functionality of the invention, for example summarizing particular content prior to analysis and/or synthesis of the domain. For example, already existing semantic databases or already completed semantic representations may be input. The annotated web is a particular example of this type of content.
[0131] Furthermore, optionally a specific level of the domain could be defined for limiting the amount of the domain to interact with, for increasing performance.
[0132] Further enhancements may be provided wherein one or more of the computing devices are mobile devices or wirelessly networked devices. For example, the network may be or include a wireless network, the wireless network including a wireless gateway for linking the wireless network to the Internet. The first set of computing devices may include or be linked to a wireless gateway, the wireless gateway being linked to the Internet so as to enable one or more wirelessly networked devices to access the Internet. One or more of the second set of computing devices could similarly be provided as wirelessly networked devices linked to the Internet by a wireless gateway. The third set of computing devices may include for example wireless smartphones, wireless computers or computers linked wirelessly to the Internet by a wireless computer network or cellular network, for example. The wireless networked devices described may include a browser for obtaining, receiving or being the source of consumer interaction information and for displaying or otherwise providing output to the consumer. The wirelessly networked devices could also be equipped with additional functionality for providing consumer interaction information, including for example a GPS receiver operable to provide GPS location information as part of the consumer interaction information and/or one or more accelerometers or other movement sensors operable to provide movement-based or gesture-based information. Thus the messaging to be returned to the consumer may include location, movement and/or gesture relevant content. | The present invention provides a computer network implementable integration of promoted content with non-promoted content before a consumer interaction with the network, such that when the consumer interacts with the network, a consumer generated context interacts with this integrated content to deliver a message to the consumer such that the consumer visualizes this message as part of consumer experience without distracting from the network interaction task at hand. The integration is facilitated by semantic analysis and synthesis to naturally position the promoted content as close to the consumer interaction tasks as possible at that instant. This approach displaces the current practice of matching message to media placement while further enabling a promoter to evaluate and respond to feedback data depicting the efficacy of the sponsor message. The network in question is any computer network such as the Internet or intranet. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus and method for the delivery of supplemental oxygen gas to a person combined with the monitoring of the ventilation of the person, and more particularly to an apparatus and method where such delivery of oxygen and monitoring of ventilation is accomplished without the use of a sealed face mask.
2. Description of Related Art
In various medical procedures and treatments performed on patients, there is a need to deliver supplemental oxygen (O 2 ) gas to the patient. In procedures involving the delivery of anesthesia or where a patient is otherwise unconscious and ventilated, the delivery of oxygen (and other gaseous drugs) is typically accomplished via a mask that fits over the patient's nose and mouth and is sealed thereto or by a tracheal tube. In other procedures, however, for example, where a patient may be sedated, but conscious and breathing on their own, the delivery of supplemental oxygen gas may be accomplished via a mask or by nasal cannulae (tubes placed up each nares of a patient's nose), connected to a supply of oxygen.
The primary goal of oxygen supplementation (whether mask-free or otherwise) is to enrich the oxygen concentration of the alveoli gas, namely, the mixture of gas in the alveoli (microscopically tiny clusters of air-filled sacs) in the lungs. In a person with normal lung function, the level of oxygen in the deepest portion of the alveolar sacs is essentially reflected at the end of each “tidal volume” of exhaled gas (the volume of gas in one complete exhalation). The gas sample measured at the end of a person's exhalation is called the “end-tidal” oxygen sample.
So, for example, if a person breathes room air, room air contains 21% oxygen. When the person exhales, the end tidal gas will have about 15% oxygen; the capillary blood has thus removed 6% of the oxygen from the inhaled gas in the alveoli, to be burned by the body in the process of metabolism. Again, a simple goal of any form of oxygen supplementation is to increase the concentration of oxygen in the alveolar sacs. A convenient method of directly measuring or sampling the gas in alveolar sacs is by continuously sampling the exhaled gas at the mouth or nose and identifying the concentration of oxygen at the end-tidal point, a value that is reasonably reflective of the oxygen concentration in the alveolar sacs. Thus, one can compare the effectiveness of oxygen delivery systems by the amount that they increase the end tidal oxygen concentration.
If a person breathes through a sealing face mask attached to one-way valves and inhales a supply of 100% oxygen, the end tidal concentration of oxygen goes up to 90%. More specifically, once inert nitrogen gas has been eliminated from the lungs (after pure oxygen has been breathed for several minutes), alveolar gas will contain about 4% water vapor and 5% carbon dioxide. The remainder (about 90%) will be oxygen. Thus, the best oxygen delivery systems typically increase end tidal oxygen from a baseline of 15%, when breathing non-supplemented room air, to 90% when breathing pure oxygen. Although sealed face-masks are relatively effective oxygen delivery systems, conscious patients, even when sedated, often find masks significantly uncomfortable; masks inhibit the ability of a patient to speak and cause anxiety in patients.
Nasal cannulae, on the other hand, do not typically cause the level of discomfort or anxiety in conscious patients that masks do, and thus, from a patient comfort standpoint, are preferable over masks for the delivery of oxygen to conscious patients. Nasal cannulae are, however, significantly less effective oxygen delivery systems than sealed face masks. Nasal cannulae generally increase the end tidal oxygen concentration to about 40% (as compared to 90% for a sealed mask). Nasal cannulae are less effective for at least two reasons.
First, when a person inhales, they frequently breathe through both nasal passages and the mouth (three orifices). Thus, the weighted average concentration of inhaled oxygen is substantially diluted to the extent of mouth breathing because 21% times the volume of air breathed through the mouth “weights down the weighted average”.
Second, even if a person breathes only through their nose, the rate of inhalation significantly exceeds the supply rate of the nasal cannula (typically 25 liters/min.) so the person still dilutes the inhaled oxygen with a supply of 21% room air. If the nasal cannula is flowing at 2 liters per minute and a person is inhaling a liter of air over 2 seconds, the inhalation rate is 60 liters per minute, and thus, most of the inhaled volume is not coming from the nasal cannula, but rather from the room. Increasing the oxygen flow rate does not effectively solve this problem. First, patients find increased flow very uncomfortable. Second, increased oxygen flow dilutes (washes away) the exhaled carbon dioxide, then carbon dioxde cannot be sampled as a measure of respiratory sufficiency.
There is also a need in various medical procedures and treatments to monitor patient physiological conditions such as patient ventilation (the movement of air into and out of the lungs, typically measured as a volume of air per minute). If the patient does not move air into and out of the lungs then the patient will develop oxygen deficiency (hypoxia), which if severe and progressive is a lethal condition. Noninvasive monitoring of hypoxia is now available via pulse oximetry. However, pulse oximetry may be late to diagnose an impending problem because once the condition of low blood oxygen is detected, the problem already exists. Hypoventilation is frequently the cause of hypoxemia. When this is the case, hypoventilation can precede hypoxemia by several minutes. A good monitor of ventilation should be able to keep a patient “out of trouble” (if the condition of hypoventilation is diagnoses early and corrected) whereas a pulse oximeter often only diagnosed that a patient is now “in” trouble. This pulse oximetry delay compared to ventilatory monitoring is especially important in acute settings where respiratory depressant drugs are administered to the patient, as is usually the case during painful procedures performed under conscious sedation.
Ventilatory monitoring is typically measured in terms of the total volumetric flow into and out of a patient's lungs. One method of effective ventilatory monitoring is to count respiratory rate and then to measure one of the primary effects of ventilation (removing carbon dioxide from the body).
There are a variety of ventilation monitors such as 1) airway flowmeters and 2) capnometers (carbon dioxide detectors). These monitors are used routinely for patients undergoing general anesthesia. These types of monitors work well when the patient's airway is “closed” in an airway system such as when the patient has a sealing face mask or has the airway sealed with a tracheal tube placed into the lungs. However, these systems work less well with an “open” airway such as when nasal cannulae are applied for oxygen supplementation. Thus, when a patient has a non-sealed airway, the options for tidal volume monitoring are limited. With an open airway, there have been attempts to monitor ventilation using capnometry, impedance plethysmography, and respiratory rate derived from the pulse oximeter's plethysmogram. The limitations of each are discussed below.
Nasal capnometry is the technique of placing a sampling tube into one of the nostrils and continuously analyzing the carbon dioxide content present in the airstream thereof. Nasal capnometry is relatively effective provided that 1) the patient always breathes through his/her nose, and 2) nasal oxygen is not applied. More specifically, if the patient is talking, most of the exhalation is via the mouth, and frequent false positive alarms sound because the capnometer interprets the absence of carbon dioxide in the nose as apnea, when in fact, it is merely evidence of talking. A couple of devices in the prior art have tried to overcome this problem by: manual control of sampling from the nose or mouth (Nazorcap); supplementing oxygen outside of the nose while sampling for CO 2 up inside the nose (BCI); providing oxygen in the nose while sampling CO 2 from the mouth (BCI); and supplying oxygen up one nostril and sampling for CO 2 Up inside the other nostril (Salter Labs). None of these already-existing systems provide oxygen to both the nose and mouth or allow automatic control of sampling from either site. Further, if nasal oxygen is applied to the patient, the carbon dioxide in each exhalation can be diluted significantly by the oxygen supply. In this case, the capnometer may interpret the diluted CO 2 sample as apnea (stoppage in breathing), resulting once again, in frequent false positive alarms.
Impedance plethysmography and plethysmogram respiratory rate counting also suffer drawbacks as primary respiratory monitors. Impedance plethysmography is done via the application of a small voltage across two ECG electrode pads placed on each side of the thoracic cage. In theory, each respiration could be detected as the phasic change of thoracic impedance. Unfortunately, the resulting signal often has too much noise/artifact which can adversely effect reliability. Respiratory rate derived from the pulse oximeter's plethysmogram may not diagnose apnea and distinguish it from complete airway obstruction, thus misdiagnosing apnea as a normal condition (a false negative alarm state).
In view of the above drawbacks to current systems for delivering supplemental oxygen gas and monitoring ventilation, there is a need for an improved combined system to accomplish these functions.
SUMMARY OF THE INVENTION
One of the purposes of the current invention is to increase the alveolar oxygen concentration without the requirement for a patient to wear a mask.
This is done by:
1) Delivering a higher flow of oxygen (e.g. 10-15 liters per minute) 2) Making this higher flow of oxygen acceptable to patients by providing it only during the inhalation part of the respiratory cycle (so the patient does not get a continuous sensation of high flow oxygen) 3) Making the higher flow of oxygen acceptable to the patient by opening a variable orifice for oxygen supply slowly rather than going to immediate full-open or otherwise diffusing the oxygen supply, which minimizes the sensation of a rapid burst of oxygen beginning with each inhalation. 4) Providing oxygen flow to all three respiratory orifices (i.e., provide flow over both nostrils and the mouth) during the inhalation cycle. Thus, inhaled gas is not diluted at any inhalation portal by pure room air.
5) The supply source for oxygen is a multiplicity of holes rather than single lumen cannula. This decreases the Bernoulli-effect of air entrainment that occurs when a high velocity of gas is delivered through a single cannula.
The invention thus increases end tidal oxygen concentrations from the baseline 15% (breathing room air) up to 50-55%. Whereas this is not as effective as face mask oxygen supplementation, it is significantly better than the prior art for open airway oxygen supplementation devices.
A second purpose of the invention is to more effectively monitor patient ventilation in combination with mask-free delivery of oxygen gas to the patient.
In this aspect, the invention includes placing pressure lumens inside one of a patient's nostrils and in front of the patient's mouth. The pressure lumens are connected to pressure transducers which in turn are connected to a processor running software. A carbon dioxide sampling tube accompanies each pressure lumen. The nasal and mouth pressure samples from the respective lumens are continually compared with one another to determine the primary ventilatory path i.e., whether the nose or mouth is the primary respiratory site. That is, whichever orifice is experiencing greater pressure swings is selected as the location of the primary ventilatory path. The carbon dioxide sampling tubes continuously sample gas from the nose and mouth and are connected to a solenoid valve which is in turn connected to a capnometer. Once the comparators (pressure transducers) determine the primary ventilatory path, the solenoid valve is opened so that only the sample from the primary path is run to the capnometer.
The software also analyzes the pressures sampled from each orifice to determine whether the patient is inhaling or exhaling. The software opens a solenoid valve connected to an oxygen source so that oxygen flow is high only during the inhalation phase of the patient's breathing.
In addition to being connected to pressure transducers, each pressure lumen is also connected to a microphone that amplifies the patient's respiratory sounds so they may be heard by a care giver in the room.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side, cut out view of the disposable portion of the apparatus placed on a patient in accordance with the invention.
FIG. 2 shows a perspective exterior view of the disposable portion of the apparatus in accordance with the invention.
FIG. 3 is a blow-up view showing the lower, middle and cover portions of the disposable portion of the apparatus in accordance with the invention.
FIG. 4 shows an embodiment of the disposable portion of the apparatus with an oral collection chamber in accord with the invention.
FIG. 5A is a schematic diagram of an oxygen delivery and ventilatory monitoring system in accordance with one embodiment of the invention.
FIG. 5B is a schematic diagram of an oxygen delivery and ventilatory monitoring system in accordance with an alternative embodiment of the invention.
FIG. 6 is a schematic diagram of pressure transducer circuitry in one embodiment of the invention.
FIG. 7 is a diagram of the pressure wave form during a respiration cycle used in the method of the invention.
FIG. 8 is a flow chart of a preferred embodiment of the method of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a cut-out view of the disposable portion 4 of an apparatus in accordance with the invention placed on a patient 10 .
The apparatus provides for the mask-free delivery of supplemental oxygen gas to the patient combined with the monitoring of patient ventilation. Oxygen gas is supplied to the patient from an O 2 supply tube 12 and exits portion 4 from a diffuser grid 14 in housing 16 (shown in more detail in FIG. 2 ). Diffuser grid 14 blows diffused oxygen into the immediate area of the patient's nose and mouth. Two thin lumens (tubes) are mounted adjacent one another to portion 4 and placed in one of the patient's nostrils (nasal lumens 18 ). Another two thin lumens are also mounted adjacent to one another to portion 4 placed in front of the patient's mouth (oral lumen's 20 ).
Of nasal lumens 18 , one lumen is a pressure lumen for sampling the pressure resulting from a patient's nose breathing and the other lumen continuously samples the respiratory gases so they may be analyzed in the capnometer to determine the concentration of carbon dioxide. This arrangement is essentially the same for oral lumens 20 , namely, one lumen is a pressure lumen (samples pressure in mouth breathing) and the other lumen continuously samples the respiratory gases involved in mouth breathing. Nasal lumens 18 and oral lumens 20 are each connected to their own pneumatic tubes, e.g., 22 , which feed back the nasal and oral pressure samples to pressure transducers (not shown) and which feed back the nasal and oral gas samples to a capnometer (not shown). All of portion 4 ; lumens 18 , 20 ; oxygen supply tubing 12 and feedback tubing 22 are disposable (designed to be discarded after every patient use), and preferably constructed of pliable plastic material such as extruded poly-vinyl chloride.
As shown in FIG. 2 , lumens 18 , 20 and tubings 12 and 22 , although shown as a portion cut-out in FIG. 1 in a preferred embodiment, are housed in cover 30 . Also, in FIG. 2 , nasal lumens 18 (including pressure lumen 28 and CO 2 lumen 26 ) are formed from a double-holed, single-barrel piece. Oral lumens 20 (which include pressure lumen 32 and CO 2 lumen 34 ) are preferably formed from a double barrel piece. Diffuser grid 36 is formed in cover 30 and functions as an oxygen diffuser which releases a cloud of oxygen into the immediate oral and nasal area of the patient 10 .
FIG. 3 shows disposable portion 4 including cover 30 in more detail in cut-out fashion. Specifically, lower portion 110 , formed from a suitably firm, but not rigid, plastic, has an opening 112 for insertion of oxygen supply tube 12 . Slot 114 in portion 110 receives the oxygen gas from the tube 12 , retains it, and forces it up through opening 148 in middle portion 112 . Middle portion 112 is affixed to lower portion 110 lying flat on portion 110 . From opening 148 , the oxygen gas travels into cover 130 (affixed directly onto middle portion 112 ) and travels lengthwise within cover 130 to diffuser portion 135 , whereupon the oxygen exits cover 130 through diffuser grid 136 into the immediate vicinity of the patient's nose and mouth in a cloud-like fashion. It is preferable to supply oxygen flow to all three respiratory orifices (both nostrils and mouth) to increase the concentration of oxygen provided to the patient. By providing flow to all three orifices inhaled gas is not diluted at any inhalation portal by pure room air. Also, a diffused stream such as that created by grid 136 is a preferred embodiment for the oxygen stream delivered to the patient. This is because a stream of oxygen delivered through a single lumen cannula is typically uncomfortable at the higher flow rates necessary for sufficient oxygen delivery. Further, at those flow rates, a single lumen can create an undesirable Bernoulli effect. It is noted that an alternative to the diffuser grid 136 is a cup-shaped or other chamber which receives the O 2 jet-stream and includes a foam or filler paper section for diffusing the jet stream of O 2 .
As is also shown in FIG. 3 , feedback tubing 22 enters lower portion 110 at openings 122 . At one opening 122 begin grooves 146 and 140 formed in lower portion 110 each for receiving the feedback pressure sample from lumens 128 and 132 . At the other opening 122 begin groves 144 and 142 , formed in lower portion 110 each for receiving the feedback CO 2 sample from lumens 126 and 134 . Grooves 146 , 144 , 140 and 142 , all formed in lower portion 110 , connect at one end to their respective sampling lumens ( 128 , 126 , 132 and 134 ) and at their other end to feedback tubing 22 ; middle portion 112 lies flat on and affixed to portion 110 such that the grooves 146 , 144 , 140 and 142 form passageways for the respective feedback samples. As can be seen, when assembled portions 130 , 112 and 110 together form whole disposable piece 4 , shown perceptively in FIG. 2 .
FIG. 4 shows a preferred embodiment of disposable portion 4 (here portions 110 and 112 are shown affixed to one another) with an oral sample collection chamber 210 fitting over oral lumens 220 (nasal lumens are shown) at 218 and the opening for the oxygen supply tube is shown at 212 ). Oral sample collector 210 is preferably constructed of plastic and creates a space in chamber 214 that collects a small volume of air the patient has breathed orally. That volume of air is then sampled by lumens 220 and fed back for analysis through the respective pressure and CO 2 feedback tubing to pressure transducers and the capnometer described above. Collector 210 thus acts as a storage container for better sampling of the oral site. It also serves as a capacitor for better monitoring of oral site pressure (exhalation contributes to volume and pressure increases, while inhalation removes air molecules from volume and pressure decreases).
In one preferred embodiment, collector 210 is provided in a variety of sizes and shapes to collect different volumes of air or to facilitate different medical procedures which may be performed in or near the mouth. In another preferred embodiment collector 210 is adjustable in that it is capable of sliding over lumens 220 to enable positioning directly over the mouth's airstream. In a further embodiment, lumens 220 are themselves also slidably mounted to portion 222 so as to be extendable and retractable to enable positioning of both the lumens and collector directly in front of the oral airstream.
FIG. 5A shows a schematic circuit diagram of a preferred embodiment of the oxygen delivery and ventilatory monitoring system of the invention. As described above, disposable portion 304 includes nasal lumens which sample a nasal (nares) volume 318 of air breathed through the patient's nostril; an oral sample collector which creates an oral volume of air 320 effecting sampling of air breathed through a patient's mouth; and an oxygen diffuser 336 which enriches the immediate breathing area of a patient with oxygen, increasing the patient's fraction of inspired oxygen and thereby increasing the patient's alveolar oxygen levels. The diffuser 336 ensures that a high rate of oxygen flow is not uncomfortable for the patient.
Oxygen gas is supplied to diffuser 336 from an oxygen supply (O 2 tank or in-house oxygen). If the supply of O 2 is from an in-house wall source, DISS fitting 340 is employed. The DISS fitting 340 (male body adaptor) has a diameter indexed to only accept Compressed Gas Association standard oxygen female nut and nipple fitting. A source pressure transducer 342 monitors the oxygen source pressure and allows software running on processor 344 to adjust the analog input signal sent to proportional valve 346 in order to maintain a user-selected flow rate as source pressure fluctuates. Pressure relief valve 348 relieves pressure to the atmosphere if the source pressure exceeds 75 psi. Proportional valve 346 sets the flow rate of oxygen (e.g. 2.0 to 15.0 liters per minute) through an analog signal and associated driver circuitry (such circuitry is essentially a voltage to current converter which takes the analog signal to a dictated current to be applied to the valve 346 , essentially changing the input signal to the valve in proportion to the source pressure, as indicated above). Downstream pressure transducer 350 monitors the functionality of proportional valve 348 . Associated software running on processor 344 indicates an error in the delivery system if source pressure is present, the valve is activated, but no downstream pressure is sensed.
As described above, the nares volume 318 and oral collection volume 320 are fed back to the capnometer 352 via a three-way solenoid valve 354 . The capnometer 352 receives the patient airway sample and monitors the CO 2 content within the sample. Software associated with capnometer 352 displays pertinent parameters (such as a continuous carbon dioxide graphic display and digital values for end-tidal CO 2 and respiration rate) to the user. A suitable capnometer may be that manufactured by Nihon Kohden (Sj5i2). Three-way solenoid valve 354 automatically switches the sample site between the oral site and the nasal site depending on which site the patient is primarily breathing through. This method is described in more detail below, but briefly, associated software running on processor 344 switches the sample site based on logic that determines if the patient is breathing through the nose or mouth. It is preferable to have a short distance between the capnometer and valve 354 to minimize dead space involved with switching sample sites.
Also as described above, the nares volume 318 collected is fed back to a nasal pressure transducer 356 and nasal microphone 358 . Transducer 356 monitors the pressure in the nares volume 318 through the small bore tubing described above. Associated software running on processor 344 determines through transducer 356 if the patient is breathing primarily through the nose. Associated offset, gain and temperature compensation circuitry (described below) ensures signal quality. Nasal microphone 358 monitors the patient's breath sounds detected at the nasal sample site. Associated software allows the user to project sound to the room and control volume. Output from microphone 358 may be summed with output of the oral microphone 360 for a total breath sound signal. In an additional embodiment the breath sound signals are displayed to the user and/or further processed and analyzed in monitoring the patient's physiological condition.
Oral pressure transducer 362 monitors pressure at the oral collection volume 320 through the small bore tubing described above. Associated software running on processor 344 determines via monitor 362 if the patient is primarily breathing through the mouth. Offset gain and temperature compensation circuitry ensure signal quality. Oral microphone 360 operates as nasal microphone 358 described above to project breath sounds to the room.
Dual chamber water trap 364 guards against corruption of the CO 2 sensors by removing water from the sample volumes. Segregated chambers collect water removed by hydrophobic filters associated with the nasal and oral sites. This segregation ensures that the breathing site selected as the primary site is the only site sampled.
FIG. 5B shows an additional embodiment of the system circuit of the present invention, including a sample bypass circuit which keeps the sample sites flowing at the same rate, regardless of whether the site is being sampled by the capnometer or bypassed. Specifically, nasal diverter valve 555 switches the nasal sample between the capnometer for CO 2 sampling and the bypass line. Activation of the valve 555 is linked to activation of oral diverter valve 557 in order to ensure that one sample is connected to the bypass line while the other sample is connected to the capnometer. This allows two states: 1) the oral site fed back to the capnometer, with the nasal site to the bypass; and 2) the nasal site fed back to the capnometer with the oral site on bypass. As described above, the control software switches the sample site based on logic that determines if the patient is breathing through the nose or mouth. Oral diverter valve 557 switches the oral sample between the capnometer for CO 2 sampling and the bypass line and operates as described with respect to nasal diverter valve 555 .
Bypass pump 559 maintains flow in the bypass line 561 that is equivalent to flow dictated by the capnometer (e.g., 200 cm/min.). The pump 559 also ensures that the sample sites are synchronized with one another so that the CO 2 waveform and respiration rate calculations are not corrupted when sample sites are switched. Flow sensor 563 measures the flow rate obtained through the bypass line 561 and provides same to electronic controller 565 necessary for flow control. Controller 565 controls the flow of pump 559 .
As can be seen from FIG. 5B , balancing the flow between the active sample site and the bypass (e.g., maintaining a flow in the bypass equivalent or near equivalent to the flow within the CO 2 sampling site, e.g., 200 cc/min) is desired. This prevents corruption of the CO 2 waveform and respiration rate calculations in the event one site became occluded such that the bypass and capnometer lines flowed at different rates.
FIG. 6 shows a schematic of the electronic circuitry associated with pressure transducers 356 and 362 . Such circuitry includes a pressure sensor 402 , a hi-gain amplifier 404 , a temperature compensating zeroing circuit 406 and a low pass filter 408 . This gain and temperature zeroing circuitry ensure signal quality for the pressure transducers.
FIG. 7 is a diagram of the pressure reading (oral or nasal) during a typical respiration cycle with thresholds A, B, C and D identified in accordance with the preferred method of the invention. As is shown, as exhalation begins, the pressure becomes positive, eventually reaching a peak then dropping back to zero as the exhalation completes. The beginning of inhalation is indicated by the pressure becoming negative. The pressure will become more negative during the first portion of inhalation then trend back towards zero as inhalation ends.
The control software of the present invention defines an upper and a lower threshold value 702 , 704 , respectively. Both are slightly below zero, with the lower threshold 704 being more negative than the upper threshold 702 . During each respiration cycle the software determines when the thresholds 702 , 704 are crossed (points A, B, C, and D, FIG. 7 ) by comparing the pressures to one of the two thresholds. The crossings are expected to occur in sequence, i.e., first A, then B followed by C, and finally D. An O 2 source valve is turned up (e.g., to 10-15 liters/min of flow) when point A is reached and turned down (e.g., to 2-3 liters/min of flow) when C is reached, thus providing the highest oxygen flow during the majority of the inhalation phase.
To determine when the threshold crossings occur, the software examines the pressures from the oral and nasal pressure sensors at periodic intervals, e.g., at 50 milli/seconds (e, FIG. 8 ). During each examination the software combines the oral and nasal pressures then compares the combined pressure to one of the two thresholds as allows.
As shown by the flowchart of FIG. 8 , when the software begins execution, it awaits a combined pressure value less than the upper threshold (point A). When this condition is met, the software turns up the O 2 valve to a higher desired flow (e.g., 10-15 liters/min) then begins looking for a pressure value less than the lower threshold (point B). When this occurs the software waits for a combined pressure value that is greater than the lower threshold (point C). When this value is read, the O 2 is turned down to the lower desired flow rate (e.g., 2-3 liters min) and the software awaits a pressure value that exceeds the upper threshold (point D). Once this value is read, the cycle begins again for the next breath.
As described above, a capnometer is used to provide information such as EtCO 2 and respiration rate by continually sampling the level of CO 2 at a single site. Since breathing can occur through the nose, mouth, or both, the software must activate valves 354 (FIG. 5 ), that switch the capnometer-sampling site to the source providing the best sample, i.e., mouth or nose.
As is also shown in FIG. 8 , the software accomplishes this by examining the oral and nasal pressure readings at periodic intervals. During each examination, the current and prior three oral pressure values are compared to the corresponding nasal pressure values. If the combined nasal pressures exceed the combined oral pressures by more than a factor of three, the capnometer sample is obtained at the nose. If the combined oral pressures exceed the combined nasal pressures by more than a factor of three, the sampling occurs at the mouth.
The above-described system and method thus provides improved delivery of supplemental O 2 gas and ventilatory monitoring without use of a face mask. The system and method are particularly useful in medical environments where patients are conscious (thus comfort is a real factor) yet may be acutely ill, such as in hospital laboratories undergoing painful medical procedures, but also in the ICU, CCU, in ambulances or at home in for patient-controlled analgesia, among others. It should be understood that the above describes only a preferred embodiment of the invention and other equivalent embodiments are contemplated. | Disclosed is an apparatus and method for the delivery of supplemental oxygen gas to a person combined with the monitoring of the ventilation of the person with both being accomplished without the use of a sealed face mask. Preferred embodiments of the present invention combine an oxygen delivery device, a nasal airway pressure sampling device, an oral airway pressure sampling device, and a pressure analyzer connected to the sampling devices to determine the phase of the person's respiration cycle and the person's primary airway. The oxygen delivery device is connected to a controller such that it delivers a higher flow of oxygen to the person during the inhalation phase of the person's respiratory cycle. The invention thus increases end tidal oxygen concentrations with improved efficiency comparative to known open airway devices. Embodiments of the invention can include carbon dioxide sampling tubes that continuously sample air from the nose and mouth to determine carbon dioxide concentration during exhalation. | 0 |
BACKGROUND OF THE INVENTION
The original Kroyer process and Kroyer machine are disclosed in the U.S. Pat. Nos. 3,581,706 and 4,014,635 to Karl Kristian Kobs Kroyer. In those prior art patents, fiber is passed through a static wire screen by using downward air flows and rotating paddles or impellers in an enclosed distributor or distributor head. After the fiber has passed through the static wire screen, it is formed on a moving forming-wire screen. The fiber is directed to the moving forming-wire screen by producing a suction under the forming-wire screen and particularly directly beneath the distributor. The front end of the distributor is the end which receives the moving forming-wire screen and the back end of the distributor is the end which delivers the moving forming-wire screen with fibers forming a web thereon. The forming area is closed off by sealing rolls on the front and back ends of the distributor and by side seal deckles.
As the forming-wire screen speed of a Kroyer machine increases, the sealing rolls build up electrostatic charges causing the fibers to stick to the rolls which disrupts the already-formed web. The sealing rolls perform well at screen speeds up to about 200 feet per minute, but their performance degrades as the speed increases so that by the time the moving forming-wire screen is moving between 500 and 700 feet per minute the formed web is totally disrupted by the sealing rolls.
Gaps between the sealing rolls and the side deckles also allow air to pass into the forming area from the outside atmosphere, disrupting the web edges. The disrupted edges then jam the next sealing roll with fiber locking into the gap between the sealing roll and the side seal deckle.
When two or more distributors, each having a pair of sealing rolls, are used, the fiber web or mat lifts off the wire at higher speeds because of windage and the fact that there is no vacuum under the moving forming-wire screen between the exit sealing roll of one distributor and the entrance sealing roll of the next distributor to hold the web down.
In a patent application filed concurrently herewith by Dennis L. Mielke, entitled APPARATUS FOR THE DEPOSITION OF DRY FIBERS ON A FORAMINOUS FORMING SURFACE, there is disclosed and claimed the concept of using a common tunnel for the forming area of two Kroyer type machines with a space between the machines. Perforations are made in the top of the tunnel between the machines to minimize turbulence in that region and in the baffle below the moving forming-wire screen in the region between the Kroyer machines to hold the web on the forming-wire screen. Such a design has run successfully at 1,000 feet per minute with good web formation. However, in the areas between the distributors there occurred some air turbulence which resulted in fiber building on the sides. In unperforated areas of the top of the tunnel, when the build-ups became large enough they fell onto the web producing localized spots of high basis weights and high opacity which were readily noticeable. In addition, such localized spots were proved to pick in the embossing process leading to a poorer running sheet.
Further, the pulling of air through the web to hold it down in the areas between distributors is an energy wasteful process.
The following issued patents in addition to the above-mentioned Kroyer patents, are representative of the state of the art:
Austrian Pat. No. 220,446 to Weyerhauser Timber Co. teaches a plurality of non-Kroyer type distributors for laying fibrous material.
U.S. Pat. No. 3,825,381 to Danning teaches a plurality of non-Kroyer type distributors for forming airlaid wood fiber webs.
U.S. Pat. No. 3,645,457 to Greten, et al teaches two non-Kroyer type distributors depositing wood chips on a belt.
U.S. Pat. No. 3,598,680 to Lee teaches two non-Kroyer type distributors depositing fibers on a belt.
U.S. Pat. No. 3,080,617 to Lytton teaches a plurality of non-Kroyer distributors depositing consecutive layers of fibers on a belt.
U.S. Pat. No. 3,071,822 to Meiler teaches a plurality of non-Kroyer felters delivering fibers to a belt.
U.S. Pat. No. 2,165,280 teaches a plurality of non-Kroyer blowers delivering fibers to a belt.
BRIEF DESCRIPTION OF THE INVENTION
A multi-distributor head is contemplated by this invention wherein Kroyer type distributor heads are positioned side by side with a common tunnel therebeneath in the forming region. All of the sealing rolls are eliminated except those at the entrance and exit of the common tunnel. Further, the sealing roll at the entrance may readily be eliminated, and that entrance end may be closed, leaving a small slot through which the forming-wire screen enters the tunnel. The degree of suction under the forming-wire screen is such that horizontal components of air at the ends of the tunnel are insignificant.
The use of a plurality of smaller distributor heads lays down a more uniform mat or web of fibrous material than one very large machine.
It is therefore an object of this invention to produce a more uniform fibrous web or mat of air laid dry fibrous material on a foraminous forming-wire screen.
It is another object to this invention to produce such a uniform web or mat with a minimum of power or energy use.
It is another object to this invention to minimize fiber build up in regions other than on the moving foraminous wire screen.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects will become apparent from the following description taken in connection with the accompanying drawings in which
FIG. 1 is a vertical side view of a plurality of distributor heads for delivering air laid dry fibers to a foraminous forming-wire screen in a common tunnel having common side deckles; and
FIG. 2 is a top view of the apparatus of FIG. 1, partly in section, and showing portions of the distributor heads in dashed outline.
DETAILED DESCRIPTION OF THE INVENTION
The distributor heads include housings 10 and 12 each having inlet conduits 14, 16, 18, 20 for delivering fibrous material thereto. The exit housings are provided with conduits 22, 24, 26, 28, 30, 32, 34 and 36 for retrieving fibrous material which is excessive in size and for returning it to a reservoir or hammermill. Within the housings 10 and 12 are a plurality of impellers 38, 40, 42, and 44 which are rotatably driven on vertical shafts 46, 48, 47 and 49. The motive means is not shown. More than one impeller may be positioned on each of the shafts, and more than two shafts may be used. Typically the impellers turn in the same direction. Only half of the exit conduits 22, 24, 26, 28, 30, 32, 34, 36 are used at any one time, depending upon the direction of rotation of the impellers 38, 40, 42, 44. When the impellers 38 and 40 are turning clockwise (i.e. righthand) from the view point of FIG. 2, exit conduits 22 and 28 are used while exit conduits 24 and 26 are blocked. When the impellers 38 and 40 are turning counter-clockwise, the exit conduits 24 and 26 are used while conduits 22 and 28 are blocked.
The bottoms of the housing 10 and 12 are open with a foraminous screen S stretched across the opening. Portions of the opening may be blocked, if desired. The openings of the bottoms of housings 10 and 12, and any additional housings which may be placed side-by-side with the two shown housings, open into a common tunnel having common side deckles such as deckle 50. The tunnels are substantially sealed by rotatable sealing rolls 52, 54 at the ends of the tunnels. Only a small gap 56, 58 is allowed between the sealing rolls 52, 54 and the side deckles 50 and an additional deckle on the backside of FIG. 1 but not shown.
A moving foraminous forming-wire screen 60 upon which a mat or web of fibrous material is formed travels from one end to the other of the tunnel sequentially beneath one then another of the openings and beneath the rolls 52, 54.
The roll 54 helps to compress the mat or web W of fibrous material as it leaves the tunnel. The direction of motion of the forming-wire screen 60 and its supported mat or web is shown by the arrows 62.
A suction box 64 maintains a partial vacuum beneath the foraminous forming-wire screen 60 to cause the descending fibers to form the mat or web (not shown) on the moving screen 60 and to hold the web on the screen.
If desired, in accommodation of movement of screen 60 through the tunnel, the roll seal 52 may be eliminated, and that entrance end of the common tunnel 51 may be partially closed, leaving a slot through which the screen 60 may enter the tunnel.
Thus, the apparatus of this invention lays down a mat or web of fibrous material onto a foraminous forming-wire screen with the distributor housings side-by-side, leaving no gap therebetween and delivering their fibers into a common tunnel 51, whereby fluffing of the mat or web within the tunnel 51 is eliminated, and sticking of the fibrous material to the walls and to the roller seals is minimized.
Although the invention has been described in detail above, it is not intended that the invention should be limited by that description but only by the combination of that description together with the accompanying claims. | Multiple distributor heads of the Kroyer type in side-by-side position over a common suction tunnel for laying fibrous material onto a foraminous forming-wire screen travelling along the tunnel. | 3 |
The instant invention relates to retractable blade arrowheads. The instant application claims priority to U.S. Provisional Patent Application Ser. Nos. 62/285,679; 62/389,059; and 62/392,245 filed Nov. 5, 2015; Feb. 16, 2016; and May 24, 2016 respectively. Broadhead arrowheads are known and comprise either fixed or retractable blades. Fixed blade broadheads are mechanically simple but suffer from relatively high aerodynamic drag from the exposed fixed blades. Fixed blade broadheads also require care in handling and storage to prevent blade dulling and accidental injury. The blades of many retractable blade broadheads do not fully retract into the body of the arrowhead and thus suffer from the same aerodynamic drag and safety problems as fixed blade broadheads.
BACKGROUND OF THE INVENTION
As discussed in U.S. Pat. No. 4,998,738 and U.S. Pat. No. 5,112,063, the objective for any hunting arrow with deployable cutting blades is to have the blades retracted to a more aerodynamic position during the flight of the arrow and to have the blades open to a cutting position which causes maximum hemorrhaging when the arrow strikes its quarry. As discussed above, traditional broadheads have fixed, exposed cutting blades which are subject to wind drag and other adverse wind effects during the flight of the arrow. It has been found that broadheads designed with deployable blades overcome the problems associated with wind effects and are more accurate than traditional fixed blade broadheads.
U.S. Pat. No. 2,859,970 discloses a cone which houses a pair of cutting blades therein where the cutting blades are mounted on a pivot pin. The Doonan device is frictionally fit over the tip of a target arrow. The intended design of the Doonan device is such that during the flight of the arrow, the cutting blades stay within the cone, thereby overcoming adverse wind effects on the flight of the arrow. When the cone strikes the animal, the arrow shaft rams the target tip into the back of the cutting blades such that they open up from the cone by pivoting on the pivot pin. One problem with the Doonan device is that the shaft of the arrow is likely to ram the cutting blades of the cone open just as the arrow is shot because of the inertia of the cone relative to the speed of the arrow. Another problem with the Doonan device is that the frictional engagement of the cutting blades against sidewalls of slots in the cone is not easily controllable.
U.S. Pat. No. 4,932,671 shows a phantom bladed broadhead where the cutting blades remain inside a cylindrical ferrule body during flight and are rammed open by a plunger, positioned to slide rearward from the front of the body, when the plunger impacts against the body of the animal. In Anderson, the cutting blades are not connected to the plunger but are pivotally connected to the cylindrical body by a ring which passes through a forward cut out section of each blade.
U.S. Pat. No. 4,504,063 discloses a broadhead which is designed to have a slimmer profile during flight and a wider, cutting profile upon impact. In LeBus, a plunger, which extends from the front of the broadhead while it is in flight, includes a weight at its rear section that acts against notches formed on the inside surfaces of the cutting blades when the broadhead strikes an animal. LeBus utilizes an O-ring to help hold the cutting blades in their slimmer profile during flight wherein the O-ring fits in a notched portion at the base of each cutting blade and the O-ring expands when the weight at the rear of the plunger forces the cutting blades open. Since the blades of the LeBus broadhead are always slightly open, the archer must be very careful when installing the O-ring so as not to get cut on the sharp blades of the broadhead.
U.S. Pat. No. 5,102,147 and U.S. Pat. No. 8,118,694 disclose broadheads having fully retracting blades. U.S. Pat. No. 7,713,152; U.S. Pat. No. 7,905,802; U.S. Pat. No. 8,905,874; and US Patent Application Publication 2015/0184986 disclose broadheads having partially retracting blades. The instant invention is directed at providing a better retractable blade arrowhead having fully retracting blades.
SUMMARY OF THE INVENTION
The instant invention is an important advance in the art of retractable blade arrowheads. The instant invention is an arrowhead comprising: (a) a cylindrical ferrule; (b) a tip; (c) a first blade; (d) a second blade; (e) a hinge pin; and (d) a shear pin, the ferrule having a longitudinal axis, the ferrule having a passageway thereinto along the longitudinal axis of the ferrule, the tip having a shank dimensioned to pass into the passageway, the ferrule having a first elongated aperture into said passageway on one side of the ferrule into which the first blade is positioned, the ferrule having a second elongated aperture into said passageway on the other side of the ferrule into which the second blade is positioned, the first blade having a first aperture near one end and a second aperture near the other end, the second blade having a first aperture near one end and a second aperture near the other end, the hinge pin positioned through the first aperture of the first and second blades, the hinge pin positioned near the shank of the tip, the ferrule having a bore therethrough transverse to the longitudinal axis of the ferrule, the shear pin positioned through said bore and through the second apertures of the first and second blades so that when the arrowhead strikes a game animal the shank of the tip pushes the hinge pin and blades to move in a direction along the longitudinal axis of the ferrule away from the tip to shear the shear pin so that the blades swing out from the ferrule on the hinge pin.
In another embodiment, the instant invention is an arrowhead comprising: (a) a cylindrical ferrule; (b) a tip; (c) a first blade; (d) a second blade; and (e) a hinge pin, the ferrule having a longitudinal axis, the ferrule having a passageway thereinto along the longitudinal axis of the ferrule, the tip having a shank dimensioned to pass into the passageway, the ferrule having a first elongated aperture into said passageway on one side of the ferrule into which the first blade is positioned within the ferrule, the ferrule having a second elongated aperture into said passageway on the other side of the ferrule into which the second blade is positioned within the ferrule, the first blade having a first aperture near one end and a detent projection near the other end, the first blade detent projection being an interference fit in the first elongated aperture, the second blade having a first aperture near one end and a detent projection near the other end, the second blade detent projection being an interference fit in the second elongated aperture, the hinge pin positioned through the first aperture of the first and second blades, the hinge pin positioned near the shank of the tip so that when the arrowhead strikes a game animal the shank of the tip pushes the hinge pin and blades to move in a direction along the longitudinal axis of the ferrule away from the tip so that the blades swing out from the ferrule on the hinge pin.
In yet another embodiment, the instant invention is a kit of parts packaged for retail sale, comprising: the arrowhead of the instant invention employing a shear pin made of an elastomer; and (b) a plurality of shear pins colored coded to correspond to the durometer value of the shear pin.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of the parts of a highly preferred embodiment of the instant invention;
FIG. 2 is a side view of the assembled arrowhead of FIG. 1 ;
FIG. 3 depicts the arrowhead of FIG. 1 in flight;
FIG. 4 depicts the arrowhead of FIG. 1 upon impact with the target;
FIG. 5 depicts the blades of the arrowhead of FIG. 1 fully deployed after impact with the target; and
FIG. 6 is an exploded view of the parts of another highly preferred embodiment of the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 , therein is shown an exploded view of the parts of a highly preferred arrowhead 10 of the instant invention. Arrowhead 10 includes cylindrical ferrule 13 , tip 11 and tip retraction spring 12 . The term “cylindrical” is defined herein to include a conical shape. Tip 11 has the terminal shape of a three sided pyramid and is notched with notches 11 a . Tip plunger 11 b is passed through spring 12 into ferrule 13 . Set screw 15 retains tip 11 in ferrule by engagement near tip plunger flat portion 11 c . Blade 20 is inserted into elongated aperture 17 in ferrule 13 . Blade 21 is inserted into an elongated aperture (not shown) opposite elongated aperture 17 in ferrule 13 so that pin 24 is passed through aperture 20 b in blade 20 and aperture 21 b in blade 21 . Then pin 24 is slid up elongated aperture 16 in ferrule 13 so that shear pin 18 can be passed through an aperture (not shown) opposite aperture 25 in ferrule 13 , through aperture 21 a of blade 21 , through aperture 20 a of blade 20 and then through aperture 25 of ferrule 13 so that bulbous portion 18 b of shear pin 18 is positioned in aperture 25 with shear pin tail 18 a extending from ferrule 13 . Threaded shank 19 permits arrowhead 10 to be screwed into the shaft of an arrow or into the shaft of a crossbow bolt. A preferred shear pin 18 of the instant invention has a central diameter of 0.093 inches and is molded of an elastomer having a durometer value selected to shear upon impact of the arrowhead with a target. The preferred durometer value for use with a compound bow is a value on the A scale of between 40 and 45. Since a crossbow typically has a higher bolt acceleration upon firing, the preferred durometer value for use with a crossbow is a value on the A scale of between 50 and 60.
Referring now to FIG. 2 , therein is shown a side view of an assembled arrowhead 10 with shear pin tail 18 a shown extending from ferrule 13 . Shear pin tail 18 a is removed before use of arrowhead 10 . Blades 20 and 21 are positioned on top of each other and folded into body 13 as seen through elongated aperture 17 in ferrule 13 .
Referring now to FIG. 3 , tip 11 is shown in its extended position retained by set screw 15 . Shear pin 18 retains the blades of the arrowhead within ferrule 13 . Hinge pin 24 is shown at one end of elongated aperture 16 . FIG. 3 shows arrowhead 10 of FIG. 1 in flight.
Referring now to FIG. 4 , when arrowhead 10 of FIG. 1 strikes a target game animal (such as a deer) tip plunger 11 b is forced into ferrule 13 to force blades 20 and 21 from ferrule 13 shearing shear pin 18 as pin 18 is slid in the direction away from tip 11 along elongated aperture 16 . Notch 20 c in blade 20 and notch 21 c in blade 21 are preferred to better enable blade 20 and blade 21 to fully deploy as shown in FIG. 5 . The spring constant of tip retraction spring 12 and shear strength of shear pin 18 are readily confirmed by experiment. For example, if the spring constant of tip retraction spring 12 and shear strength of shear pin 18 are too low, then blades 20 and 21 will deploy in the air upon firing of the arrowhead thereby increasing the aerodynamic drag of the arrowhead. And, if the spring constant of tip retraction spring 12 and the shear strength of shear pin 18 are too high, the blades will fail to deploy upon striking the target. High power crossbows typically require higher shear strength shear pins while longbows typically require lower shear strength shear pins. Notches 11 a in tip 11 shown in FIG. 1 are highly preferred because the pointed edges thereof increase the initial force of the tip shank 11 b into ferrule 13 when arrowhead 10 strikes a game animal. It should be understood that an arrow tip terminating in a pyramid point wherein the edges of the faces of the pyramid are notched with cylindrical notches transverse to the edges of the pyramid is novel and unobvious as a separate invention disclosed herein. It should also be understood that tip 11 shown in FIG. 1 is not critical in the instant invention and that any tip shape can be used in the instant invention. Preferably, the arrowhead 10 of FIG. 1 is sold in a package that includes spare color coded shear pins of different shear strength together with recommendations for use with different bows, compound bows and crossbows.
Referring now to FIG. 6 therein is shown an exploded view of the parts of another highly preferred arrowhead 30 of the instant invention similar in many respects to the arrowhead 10 of FIG. 1 . Arrowhead 30 includes ferrule 33 , tip 31 and tip retraction spring 32 . Tip plunger 31 b is passed through spring 32 into ferrule 33 . Set screw 35 retains tip 31 in ferrule by engagement near tip plunger flat portion 31 c . Blade 40 is inserted into elongated aperture 37 in ferrule 33 . Blade 41 is inserted into an elongated aperture (not shown) opposite elongated aperture 37 in ferrule 33 so that pin 44 is passed through aperture 40 b in blade 40 and aperture 41 b in blade 41 . Then pin 44 is slid up slot 36 in ferrule 33 . Detent projection 40 a on blade 40 and detent projection 41 a on blade 41 are an interference friction fit in their respective elongated apertures of ferrule 33 and serve to retain blades 40 and 41 in ferrule 33 before arrowhead 30 strikes a game animal or other target. The spring constant of tip retraction spring 12 and the friction of the interference fit of the detent projections 40 a and 41 a on blades 40 and 41 are readily confirmed by experiment. For example, if the spring constant of tip retraction spring 12 and the friction of the detent projections are too low, then blades 20 and 21 will deploy in the air upon firing of the arrowhead thereby increasing the aerodynamic drag of the arrowhead. And, if the spring constant of tip retraction spring 12 and the friction of the detent projections are too high, the blades will fail to deploy upon striking the target. High power crossbows typically require stronger springs and higher detent friction while longbows typically require weaker springs and less detent friction of the detent projections. Threaded shank 39 permits arrowhead 30 to be screwed into the shaft of an arrow or into the shaft of a crossbow bolt.
The tip and blades of the instant invention can be made of any suitable material but preferably are made of a metal such as stainless steel. The ferrule of the instant invention can be made of any suitable material but preferably is made of aluminum shaped by automatic machine tools. The shear pin of the instant invention can be made of any suitable material (such as brass, tin or a thermoplastic) but preferably is made of an elastomer such as silicone rubber.
CONCLUSION
While the instant invention has been described above and claimed below according to its preferred embodiments, it can be modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the instant invention using the general principles disclosed herein. Further, the instant application is intended to cover such departures from the present disclosure as come within the known or customary practice in the art to which this invention pertains. | A broadhead arrowhead having fully retractable blades wherein a plunger of the tip of the arrowhead causes the blades to shear a shear pin and deploy when the arrowhead strikes a target. In an alternative embodiment, the blades are retained in the arrowhead by a friction fit that is overcome to deploy the blades when the arrowhead strikes a target. | 5 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention concerns a circular knitting machine of the kind including a first support knitting implements for making stitches, a second support with implements for making loops, which have elements for handling a ground yarn and a plush yarn, and at least one knitting system which includes a cam part section for control of the knitting implements, a cam part section for control of the loop forming implements, at least one yarn feeder for feeding the ground yarn and at least one yarn feeder for feeding the plush yarn and in which system stitches consisting of the ground yarn and the plush yarn can be formed and loops formed solely from the plush yarn can be formed.
The invention also relates to a sinker with a nose extending in a longitudinal direction and forming with an edge spaced from the underside of the sinker a longitudinal slot likewise extending in the longitudinal direction and forming with its upper edge an middle edge which is spaced from an upper edge of the sinker.
(2) Description of the Prior Art
In circular knitting machines of this kind there is frequently the need to preselect independently the size on the one hand of the stitches formed from the ground and plush yarns and on the other hand of the bows or loops formed from the plush yarn alone, in order to match the kinds of yarn used (thick, thin, crimped yarn, etc.) For this it is known (DE-PS 3 035 562) to associate with the knitting needles two-part sinkers mounted slidably in a sinker ring and to use the magnitude of the advance movement of the one sinker part to adjust the length of the plush yarn loop or bow and the magnitude of the advance movement of the other sinker part to adjust the stitch size. Similar possibilities arise in the use of circular knitting machines with dials, in which special hooks are mounted slidably (DE-AS 1 250 587), which are controlled by adjustable cam parts and serve for the selective adjustment of the lengths of the plush bows or stitches.
The use of two-part sinkers has the disadvantage that with high degrees of gauge or fineness (number of needles per inch) mechanical problems arise and the friction between the two sinker parts is appreciable. If however one-piece sinkers are used to avoid this disadvantage (DE-PS 2 824 314), it is not then possible to adjust the size of the stitches and the plush yarn loops independently of one another.
SUMMARY OF THE INVENTION
The invention is therefore based on the problem of developing the circular knitting machine of the kind initially set forth in such a way that the sizes of the stitches and the lengths of the plush yarn loops are independently adjustable, in spite of the use of one-piece sinkers. The object of the invention is moreover to provide a sinker suitable for such a circular knitting machine.
The circular knitting machine for making plush fabric according to the invention comprises a first support with knitting implements for making stitches; a second support with loop forming implements for making loops, the second support having means for handling a ground yarn and a plush yarn; and at least one knitting system for forming stitches having a size and consisting of the ground yarn and the plush yarn and for forming loops having a length and formed solely from the plush yarn; wherein the at least one knitting system includes at least one yarn feeder for feeding the ground yarn; at least one yarn feeder for feeding the plush yarn; first cam means for controlling the knitting implements having an adjustable cam part for adjusting the length of the plush yarn loops; second cam means for controlling the loop forming implements; and an adjustable cam part for adjustment of the size of the stitches independently from the length of the plush yarn loops.
In a preferred embodiment of the circular knitting machine the loop forming implements each have a drawing edge adapted to form ground yarn loops and becoming active by virtue of a movement of the loop forming implement and the cam part for adjusting the size of the stitches controls the loop forming implements. The loop forming implements can be provided with an upper edge for forming the plush yarn loops, a middle edge for forming ground yarn loops and a lower edge for forming the stitches, support edges for the plush yarn loops being provided at front ends of the upper edges and drawing edges at rear ends of the middle edges.
In another embodiment advantageously a plurality of yarn feeders for feeding the plush yarn are provided in one of the knitting systems and the number of the yarn feeders corresponds to the number of adjustable cam parts in the first cam means.
In the preferred embodiment the first support is a needle cylinder, the second support is a sinker ring and the knitting implements are latch needles. Advantageously the loop forming implements can be clearing and holding down sinkers.
The sinker for a circular knitting machine for making plush fabric according to the invention has an underside; a knocking-over edge spaced from the underside and extending in a longitudinal direction; a middle edge; an upper plush yarn loop forming edge and a nose arranged between the knocking-over edge and the plush yarn loop forming edge, the nose extending in the longitudinal direction and having a lower nose edge and an upper nose edge. The lower nose edge forms a longitudinal fabric holding-down slot with the knocking-over edge and the upper nose edge forming the middle edge at a position between the fabric holding-down slot and the plush yarn loop forming edge;
wherein the middle edge and the plush yarn loop forming edge are connected by a front face having an end adjoining the middle edge formed as a drawing edge for forming ground yarn loops and having a plush yarn loop forming end formed as a support edge for plush yarn loops.
In a preferred embodiment of the sinker the drawing edge is formed by a recess in the front face. Advantageously the upper edge is formed as a support edge for plush yarn loops and this support edge is formed by a recess in the front face.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail below in conjunction with the accompanying drawings of an embodiment of a circular knitting machine. These show:
FIG. 1 a schematic axial section through the circular knitting machine in accordance with the invention for making plush goods;
FIG. 2 shows schematically the lock development of a knitting system of the circular knitting machine according to FIG. 1;
FIG. 3 shows details of the sinker cam part section of the circular knitting machine according to FIG. 1;
FIG. 4 shows details of the cylinder cam part sections of two adjacent knitting systems of the circular knitting machine according to FIG. 1;
FIG. 5 shows a view corresponding to FIG. 2 to a larger scale;
FIGS. 6 to 17 show relative positions of the needles and sinkers at the positions indicated VI-XVII in FIG. 5;
FIGS. 18 and 19 show schematic views of plush goods made with the circular knitting machine according to FIGS. 1 to 17;
FIG. 20 shows a representation corresponding to FIG. 4 of the cylinder cam part sections according to a further embodiment of the invention; and
FIGS. 21 and 22 show schematic views of two further plush goods which can be made with the circular knitting machine according to FIG. 20.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an embodiment of the invention as an example of a circular knitting machine for making plush goods. This circular knitting machine is known in part (DE-OS 3 145 307), so that only parts essential to the invention are explained in detail below.
The circular knitting machine comprises a first support, in the illustrated embodiment a rotatably mounted needle cylinder 1, in which knitting implements, e.g. conventional latch needles 2 with hooks 3 and latches 4 are mounted to move axially, and a second support, here in the form of a sinker ring 5 rotatable with the needle cylinder 1 and in which one-piece loop forming implements, formed in the embodiment as sinkers 6, are mounted for radial movement. The sinkers 6 are arranged in slots of the sinker ring 5 and one such sinker is associated with each needle 2. The needles 2 comprise a butt 9 controlled by cam or lock part sections 7 of a first cam or lock (hereinafter the term "lock" is used instead of "cam" throughout the specification and claims), here formed as a cylinder lock 8, the sinkers 6 each having a butt 10, which is controlled by lock part sections 11 of a second lock formed in the embodiment as a sinker lock 12, which sections engage in a recess 14 formed between the butt 10 and the front side of the sinker. The needle and the sinker lock 8, 12 respectively are components of a lock arrangement, where the needles 2 or other knitting implements and the cylinder lock 8 or other locks serve essentially for the formation of ground and plush yarn stitches and the sinkers 6 or other loop forming implements and the sinker 12 or other locks serve essentially to control the ground and plush yarn loops in the shaping thereof.
For reasons explained further below, the lock part sections 7 are provided with lock parts mounted adjustably in the axial direction on the lock 8 and the lock part sections 11 with lock parts mounted on the lock 12 adjustably in the radial direction. Adjusting screws 15, 16 respectively serve for adjustment of these lock parts, these screws acting through eccentrics or the like in a manner known per se on sliders, not further shown, mounted movably in the lock 8 or 12 and to which the adjustable lock parts are fixed.
The loop forming implements are formed as clearing and holding down sinkers and comprise elements provided for handling a ground yarn and a plush yarn. In particular the sinkers 6 comprise a longitudinally extending lower edge 18 above their lower sides which are guided on the bottoms of the sinker ring grooves, each such edge passing into a longitudinal slot 17 or a throat, and also comprise a nose 19 thereabove, likewise extending in the sinker longitudinal direction and which delimits the slot 17 with its lower edge and which is provided on its upper side with a middle edge 20. This is connected via a short front face 21 projecting in the direction of the front end of the nose 19 and extending substantially perpendicular to the edge 18 to a still higher upper edge 22 running towards the rear, the edges 18, 20 and 22 being arranged substantially parallel to one another. Moreover the nose 19 is shorter than the lower edge 18, measured from the bottom of the longitudinal slot 17 and the upper edge 22 is shorter than the nose 19.
At each of the upper and lower ends of the front face 21 there is provided a recess, the lower recess forming a drawing edge 23 for a ground yarn and the upper recess forming a support edge 24 for a plush yarn.
FIG. 2 shows a view to a smaller scale than FIG. 1 of the lock paths formed by the lock sections 7, 11 of a system I with a movement of the needles in the direction of an arrow v. In the left part of FIG. 2 it is indicated that the upper edges of the hooks 3 are normally guided on a circulation track 27 which-- regarded in the axial direction--runs at the level of the edges 18 of the sinkers 6 shown in a position 6a, this position being for making clear the relative positions of the hooks 3 and the sinkers 6 in the axial direction. From the circulation track 27 the needles 2 can be transferred in the knitting system I shown in FIG. 2 firstly to an intermediate position, namely a tuck position, in which the upper hook end is arranged on a track section 28, in which it is possible to lay in a ground yarn by means of a schematically shown yarn feeder 29. Then the needles 2 can be further raised selectively at two positions such that the upper edges of the hooks 3 are guided on a first or a second triangular track section 30, 31 respectively, which allow like or differently constituted plush yarns to be laid in by means of schematically shown yarn feeders 32, 33. Then the upper edges of the hooks 3 are retracted again along a withdrawal section 34 to the circulation track 27.
In the upper left part of FIG. 2 there is shown schematically a second sinker position 6b. Through this the positions of the front faces 21 of the sinkers 6 relative to the needles 2 are to be shown in the radial direction. Accordingly, the front faces 21 are so guided on a track section 36 when the hooks 3 are in the circulation track that they are arranged substantially in the extension of the longitudinal axes of the needle shanks, i.e. above the hooks 3. From this position the sinkers are first retracted radially from the needle circle along a triangular track section 37, in order to make space for the yarn feeder 29, and are then pushed in again radially in the direction of the needle cylinder up to a track section 38, in which the front faces 21 are arranged somewhat further radially inwards than corresponds to the track section 37. At the end of the system the front faces 21 are pushed first radially outwardly by means of a further triangular track section 39 and then radially in to a track section 40 running at the level of the track section 36, in order to facilitate the formation of the stitches in the region of the withdrawal region 34.
In FIG. 3 the lock part section 11 (cf. also FIG. 1) used to implement the sinker track sections 36 to 40 according to FIG. 2 is shown. The lock part section 11 consists of three lock parts 41, 42 and 43 arranged one after another in the direction of the arrow v, whose support plate 44 has a recess 45 in the region of the track section 37, in which recess is fitted a slide carrying the lock part 42 so as to be radially movable in the direction of a double arrow w. This slide is coupled via an eccentric or the like to the adjusting screw 16 shown in FIG. 1. In order that, in the passage of the sinkers 6 from the lock part 41 to the lock part 42 and from this to the lock part 43 in the direction of the arrow v, there shall be no edges or the like interfering with the sinkers, the width of the lock part 42 is smaller at its left, run-in side and greater at its right, run-out side than the respective adjoining part of the lock part 41 or 43, as can be seen clearly from FIG. 3, whereby the magnitude of the range of adjustment in the direction of the arrow w is also established.
The sinker lock part sections 11 at all knitting systems of the circular knitting machine are moreover preferably formed identically, so that the sinker lock 12 can only be adjusted by means of the adjusting screws 16. A sinker selection mechanism is neither provided nor necessary.
FIG. 4 shows two lock part sections 7a and 7b of the cylinder lock 8 used to implement the needle track sections 27, 28, 30, 31 and 34 according to FIG. 2 of the cylinder lock 8 (cf. also FIG. 1). Although the lock part sections 7a, 7b in all knitting systems of the circular knitting machine can be formed identically, the use of different lock part sections 7a, 7b is preferably also possible, in order to be able to make stitch or colour patterns in a simple manner. Accordingly in FIG. 4 the different lock part sections 7a and 7b of two knitting systems I and II are shown beside each other. The lock part sections 7a, 7b cooperate with needles 2a, 2b having hooks 3a, 3b and which have their butts 9a, 9b respectively distributed at different heights, e.g. in the ratio 1:1 in the grooves of the needle cylinder 1. Accordingly an upper needle path 48 is associated with the needles 2 a and a lower needle path 49 with the needles 2b.
In the region of the knitting system I the lock part section 7a comprises, again regarded in the direction of the arrow v, four lock parts 50 to 53 lying one after another and forming the substantially closed needle path 48 for the butts 9a. The lock part 50 raises the butts 9a firstly into the intermediate or tuck position corresponding to the track section 28 (FIG. 2) for the purpose of receiving a ground yarn and then into the highest position corresponding to the rising part of the triangular track section 30 (FIG. 2), so that the needles 2a in the following retraction to the intermediate position can receive a plush yarn. The retraction is here adjustable in the axial direction by means of the lock part 51, i.e. parallel to a double arrow x, since the lock part 51 is fixed on a slide 54 which is coupled through an eccentric 55 to an adjusting screw 15a corresponding to the adjusting screw 15 of FIG. 1.
The lock part 51 is followed by the fixedly positioned lock part 52 with a track section running substantially in a straight line at the level of the intermediate position. Through this the hooks 3a corresponding to FIG. 2 are held in the intermediate position (track section 64 in FIG. 2) until they have passed the second plush yarn feeder 33 without receiving a plush yarn. The fourth lock part 53 is a retracting lock part which is provided with a upper needle track corresponding to the track section 34 of FIG. 2 and is fixed to a further slide 56, which is coupled through a further eccentric 57 to an adjusting screw 15b and is mounted for movement parallel to the double arrow x.
The likewise substantially closed lower needle path 49 for the butts 9b of the needles 2b is firstly formed by two lock parts 61 and 62 lying one after another in the direction of the arrow v. The lock part 61 is fixed and serves to guide the butts 9b in such a way that the hooks 3b of the needles 2b are firstly raised to the intermediate or tuck position (track section 28 in FIG. 2), in order to receive the ground yarn, but are then retracted to a somewhat deeper lying position (track section 65 in FIG. 2), in order to pass the plush yarn feeder 32 without receiving a plush yarn. At the end of the lock part 61 there is then provided a section leading to the highest needle position, corresponding to the rising part of the track section 31 (FIG. 2), so that the needles 2b can receive a plush yarn at the plush yarn feeder 33.
The adjoining lock part 62 is, like the lock part 51, fixed on a slide 58 with eccentric 59 and adjusting screw 15c and serves so to guide the butts 9b that the hooks 3b are retracted to the intermediate position on a track section corresponding to the falling part of the track section 31 (FIG. 2). A lower track section of the lock part 53 follows on the lock part 62, being likewise formed in correspondence with the track section 34 (FIG. 2). The lock parts 50 to 53, 61 and 62 as well as the lower needle path of the lock part 53 are so formed at their in-feed and out-feed sides that no projecting edges interfering with the butts 9a or 9b occur within the possible range of adjustment of the adjusting screws 15a to 15c.
The lock part section 7b has an upper, substantially closed needle path 66 acting on the butts 9a and a lower substantially closed needle path 67 acting on the butts 9b. The needle path 66 is formed by lock parts 68, 69 and 70 following one another in the direction of the arrow v, which correspond precisely to the lock parts 61, 62 and 53, so that the needle path 66 is formed like the needle path 49. On the other hand the needle path 67 is formed by lock parts 71, 72 and 73 following one another in the direction of the arrow v, which correspond to the lock parts 50, 51 and 52, and a lower needle path of the lock part 70, so that the needle path 67 corresponds precisely to the needle path 48. Accordingly the lock parts 69, 70 and 72 are fixed on slides 74, 75 and 76 and are adjustable by means of adjusting screws 15d, 15e and 15f.
FIG. 5 is an enlarged representation of the track sections shown in FIG. 2 and includes additional section lines VI-XVII for FIGS. 6 to 17, on the basis of which the manner of operation of the circular knitting machine according to FIGS. 1 to 4 will now be explained.
In FIG. 6 all needles 2a and the associated sinkers 6 are in their base or non-knitting position, in which each hook 3a holds a stitch 81 formed in a preceding system. The latches 4 are still closed and the old stitches 81 are so retained in the longitudinal slots 17 of the sinkers 6 that the knitting is held at the level of the lower edges 18 of the sinkers 6 when the needles 2a rise. The needles 2a are firstly raised to the intermediate position according to FIG. 7 from the base position according to FIG. 6 by the lock part 50 according to FIG. 4 (track section 28 in FIG. 4), until their latches 4 are opened by the old stitches 81 and the lower ends of their hooks 3a are sufficiently far above the middle edges 20 of the sinkers 6.
In accordance with FIGS. 3 and 5 the retraction of the sinkers 6 now takes place along the track section 37, in order to make space for the yarn feeder 29, whose outlet end for a ground yarn 82 fed thereby lies closely above the noses 19 of the sinkers 6 (FIG. 8).
After the needles 2a have received the ground yarn 82, the sinkers 6 are advanced again in the direction of the needles 2a in accordance with FIGS. 3 and 5. Through this the ground yarn 82 lies against the drawing edge 23 of the sinkers 6 (FIG. 9), so that, on further advance of the sinkers 6 such as to bring the drawing edges 23 behind needle backs, loops 83 are formed from the ground yarn 82. The length of these loops 83 depends in accordance with the invention on how the lock part 42 (FIG. 3) is adjusted by means of the adjusting screw 16 in the direction of the double arrow w. It results from this that, in accordance with the invention and contrary to the case with other circular knitting machines, the formation (preliminary loop formation) of the loop 83 of the ground yarn 82 is not effected with the aid of an adjustable lock part acting on the needles or knitting implements, but with the aid of an adjustable lock part acting on the sinkers or loop-forming implements. The sinkers 6 can now be retracted somewhat between the section lines IX and X according to FIG. 5, in order to remove tension from the formed loops 83. Then the needles 2a are driven with the aid of the lock part 50 (FIG. 4) from the intermediate position, in which the old stitches 81 still lie on the open latches, up to their highest position (track section 30 in FIG. 5), in which position the lower ends of the hooks 3a are sufficiently far above the upper edges 22 of the sinkers 6. In this the positions of the various edges of the sinkers and the dimensions of the lock parts involved are so selected that, in driving the needles out of the intermediate position (FIG. 9) into their highest position (FIG. 10), on the one hand the old stitches 81 slide below the latches 4 onto the shanks of the needles 2a and on the other hand the newly formed loops 83 still lie on the open latches 4.
With renewed retraction of the needles into the intermediate position, their hooks 3a initially accept a plush yarn 84, which is fed from the plush yarn feeder 32, whose outlet end is arranged closely above the upper edges 22 of the sinkers 6. On retracting the needles 2a the plush yarn 84 is therefore supported on the upper edges 22, so that plush yarn loops 85 from (FIG. 11). The length of these loops 85 depends in accordance with the invention how the lock part 51 is set in the direction of the double arrow x, i.e. on how deeply the needles 2a are retracted in the retraction into the position according to FIG. 11. The length of the loops 85 is adjustable somewhat in a range which results from the needle positions according to FIGS. 10 and 11. Accordingly the invention is especially suited also to making short loop plush goods, in which the length of the plush yarn bows or loops 85 amounts to about 1.0 to 2.0 mm.
FIG. 12 shows finally that the sinkers 6 are firstly retracted somewhat and then advanced somewhat again after the formation of the plush yarn loops 85, along a triangular track section 86 (FIG. 5) of the sinker lock. This serves firstly to allow the loop 85 formed on the uppermost edge 22 to slide onto the support edge 24 and then to tighten again, or remain tight, until the stitch formation operation is started.
The needles 2b are moved in the system I by means of the needle path 49 firstly into the intermediate position corresponding to the track section 28 in FIG. 5, so that, like the needles 2a, they receive the ground yarn 82 (FIG. 8) laid in from the ground yarn feeder 29. The sinker movement is thus precisely as in the case of the needles 2a, i.e. the length of the pre-formed ground yarn loops is dependent on the advance of the sinkers 6 along the lock part 42. Then however the needles 2b are retracted to the intermediate position (section 65 in FIG. 5), so that they pass the plush yarn feeder 32 without receiving the plush yarn 84 there (FIG. 10), i.e. their hooks 3b are sufficiently far below the upper edges 22 of the sinkers 6.
After passing the plush yarn feeder 32 the needles 2b are raised to their highest position along the triangular shaped track section 31 (FIG. 5) in the same way as in FIGS. 10 and 11, so that they firstly allow the old stitches to slide below the latch tips and then in the following retraction by means of the lock part 62 (FIG. 4) receive a plush yarn 87 fed from the plush yarn feeder 33 (FIG. 13) and can shape this into plush yarn loops 88 (FIG. 14) over the edges 22 of the sinkers 6, where the length of the plush yarn loops 88 is adjusted by means of the lock part 62 or the adjusting screw 15c. At the same time the plush yarn feeder 33 is passed by the needles 2a, without these receiving the second plush yarn 87, since the hooks of the needles 2a at this time are guided on the track section 64 (FIG. 5).
After all needles 2a have formed a loop 85 from the first plush yarn 84 in this way and all needles 2b have formed a loop 88 from the second plush yarn 87 and all needles 2a and 2b have formed a loop 83 form the ground yarn 82, retraction of all sinkers 6 follows, to a position lying so far back that firstly the preformed plush yarn loops 85 slide off the support edges 24 and the pre-formed plush yarn loops 88 slide off the upper edges 22, both on to the middle edge 20 of the noses 19 (FIG. 15) and then together with the ground yarn loops 83 also slide off the noses 19 (FIG. 16). Then follows the actual stitch formation (FIG. 17) in a manner known per se, in that the hooks 3a, 3b are retracted below the edges 18 of the sinkers 6, so that stitches are formed from the loops 83, 85, 88 as the case may be and the old stitches are cast off over the hooks 3a,b. The depth of the withdrawal of the needles 2a,b can be adjusted with the aid of adjusting screw 15b acting on the lock part 53 and can be matched to the loop length set with the lock parts 42 (FIG. 3). As shown in FIGS. 5 and 15 to 17, the required sinker and needle movements can take place with small offset in sequence along the track sections 39 and 34. Finally, the sinkers 6 are pushed forward again on the track section 40 while the needles 2a,b are raised somewhat to take the tension out of the stitches, so that the base position according to FIG. 6 again results.
As can be seen especially from FIG. 13, the support edges 24 serve the purpose of disposing the loops 85 formed by means of the needles 2a behind the needle backs, by advance of the sinkers 6, before the needles 2b are driven out, in order to receive the plush yarn 87. In this way damage to or penetration of the loops 85 by the needles 2b is avoided. Accordingly it will be understood that the support edges 24 are not needed if only one plush yarn is fed in at each system.
In the following system II the loop and stitch formation is effected in similar manner to system I but with the difference that the needles 2b now receive a plush yarn at a plush yarn feeder corresponding to the first plush yarn feeder 32 and the needles 2a receive a plush yarn at a plush yarn feeder corresponding to the second plush yarn feeder 33. The described operations are repeated at following systems, not shown. If accordingly at each first plush yarn feeder 32 of a system group formed from two systems a plush yarn with a first characteristic, e.g. colour is fed in and at each second plush yarn feeder 33 of the same system group a plush yarn of a second characteristic is fed in, there results a plush material of which four rows of stitches A to D are shown in FIG. 18. Here the ground yarn 82 is worked into stitches 91 by all needles 2a,b, indicated schematically by a black dot, in all four stitch rows A to D. On the other hand, the needles 2a form a stitch 92 with the first plush yarn 84 indicated in full lines and the needles 2b form a stitch 93 with the second plush yarn 87 indicated in broken lines in the stitch rows A and C while in the stitch rows B and D the needles 2a work the plush yarn 87 to the stitches 92 and the needles 2b work the plush yarn 84 to the stitches 93. Overall a 1:1 plush material thus results with identical stitch rows but offset each time by one stitch, in which each plush loop extends over two needles 2a or 2b.
Through simple alterations to the cylinder lock 8, numerous plush materials different from FIG. 18 can be made with the described circular knitting machine. If for example the lock parts 68, 69 on the one hand and 71, 72 and 73 on the other hand are interchanged in FIG. 4, the needles 2a in each case take up the first plush yarn 84 and the needles 2b the second plush yarn 87 in the systems I and II Accordingly there results the plush material shown in FIG. 19, which differs from that according to FIG. 18 only in that the illustrated stitch rows E to H are not only identical but are also not offset.
A further possible alteration of the cylinder lock is shown in FIG. 20. Here the upper needle path 48 of the lock part section 7a and the lower needle path 67 of the lock part section 7b correspond to those according to FIG. 4. However, the lower needle path 95 is formed by a lock part 96 extending over the width of the lock parts 50, 51, a lock part 97 corresponding to the lock part 52 and the lock part 53, the lock part 96 being fixed in position and raising the associated needles 2b firstly into the position required to receive ground yarn 82 but then retracting them again to an intermediate position, in order to ensure that only the needles 2a receive the first plush yarn 84. An upper needle path 98 of the lock part section 7b is correspondingly formed. As a result of this a plush material (FIG. 21) is obtained in which the ground yarn 82 is worked into stitches 91 by all needles 2a, 2b in stitch rows I to L, while the plush yarn 84 is worked into the stitches 92 in the stitch rows I, K, etc. only by the needles 2a. Similarly a plush yarn 99 is worked into stitches 100 in the stitch rows J, L, etc. only by the needles 2b. In this the plush yarns 84 and 99 can have the same or different characteristics. In each case the plush yarn loops extend over two needles, only every second needle forms a plush yarn stitch and the wales with plush yarn stitches are offset from row to row by one wale.
A further variant results if the first parts of the needle paths 95 and 98 are formed in the way shown in FIG. 20 by a broken line. Then the needles 2b in system I and the needles 2a in system II are raised in each case so little that they cannot receive the ground yarn 82 at the yarn feeders 29. The resulting plush material corresponds to that of FIG. 21 with the difference that, in the stitch rows I, K, etc. the stitches 91 formed by the needles 2b alone and in the stitch rows J, L, etc. correspondingly the stitches 91 formed by the needles 2a alone are missing and are replaced by floats.
Naturally it is also possible with the described circular knitting machine to make the full plush material shown in FIG. 22. The illustrated stitch rows M to P of this plush material are identically formed in each case and are made with plush yarns of the same or different characteristics, while all needles 2a, 2b work the same ground and plush yarns into stitches. Such a plush material is obtained e.g. in that the lower needle path 49 of the lock part section 7a in FIG. 4 is replaced by the lower needle path 67 of the lock part section 7b and all systems are moreover formed identically and provided with identical lock part sections 7a.
The invention is not limited to the described embodiments, which can be modified in numerous ways. This applies above all to the needle paths and lock part sections described with reference to FIGS. 2 to 4 and 20. In particular, more than two plush yarn feeders 32, 33 can be associated with each of the individual knitting systems I, II in order for example to make Jacquard plush material in conjunction with needle selection devices, not shown. Correspondingly, knitting systems or system groups could be provided at which only the ground yarn or only a ground yarn and a single plush yarn are fed in. It is furthermore possible to implement the adjustment of the lock parts 51, 52, 53, etc. with means other than those shown. In particular it would be possible to provide for this so-called central adjusting devices which make possible e.g. a central axial raising or lowering of the needle cylinder and the sinker ring or of the cylinder lock. Furthermore it would be possible to provide the cylinder lock part section 7 with only a single needle path in each case (e.g. 48 or 49) and to use corresponding needles with only one associated butt 9a or 9b. The needles can naturally also be provided with butts serving further, different purposes. Furthermore the invention is not limited to adjusting the length of the ground yarn loops by means of the sinkers 6. It would be fundamentally possible to preform the ground yarn loops in conventional manner such that the ground yarn is laid over the middle edges 20 of the sinkers 6 and the needles are then retracted by means of lock parts (DE-PS 3 145 307). If adjustable lock parts are used for this, the advantage is obtained in this case also that the length of the ground and plush yarn loops can be adjusted individually by different means. In all cases the needles 2a, 2b described with reference to FIG. 4 can be arranged in distributions other than 1:1.
Furthermore the invention is not limited to the use of the illustrated cylinder needles and clearing and holding down sinkers, in the place of which other knitting and loop-forming implements, especially in the form of dial needles, draw hooks or the like with other elements than correspond to the parts 18 to 22, can be provided and which can be mounted in supports other than those described, especially in a dial. Furthermore it would be possible to provide no preliminary loop formation for the ground yarn but to let this pass freely through the longitudinal slots 17 or throats of the sinkers 6 up to the place at which the stitches are formed (e.g. line XVI in FIG. 5), as is basically already known (EP-AS 0 295 703). Also in this case different lock parts could be provided to adjust the length of the plush yarn loops and size of the stitches. Finally the ground yarn could be preformed differently from FIG. 9 with the closed ends of the longitudinal slots 17, in that the sinkers 6 are suitably advanced and the plush yarn loops are merely formed over the edges 20 of the sinkers 6. In this case the edges 22 can be omitted. However the length of the plush yarn loops could again be controlled by a suitable cylinder lock part, the size of the stitches however by a suitable sinker lock part.
While the invention has been illustrated and described as embodied in a large diameter circular knitting machine having knitting needles in the cylinder and sinkers in the sinker ring, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention, particularly with respect to other circular knitting machines. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | The invention concerns a circular knitting machine for making plush fabric. The circular knitting machine has a needle cylinder fitted with knitting needles, a sinker ring fitted with sinkers, wherein the sinkers have edges adapted to handle a ground yarn and a plush yarn, and at least one knitting system. For independent adjustment to the stitch size and the plush yarn loops, a cylinder cam section has an adjustable cam part which serves to adjust the length of the plush yarn loops. A cam part independent therefrom and also adjustable serves to adjust the stitch size. This cam part can be arranged either in the sinker cam or the cylinder cam. | 3 |
TECHNICAL FIELD
[0001] This application relates to remote sensing, and more particularly to an array of distributed sensors for instruction detection.
BACKGROUND
[0002] Security concerns regarding national borders grow ever more urgent. Low-tech solutions such as fences are easily scaled and crossed by illegal aliens, terrorists, or other security threats. In contrast, millimeter-wave motion detectors provide a virtually secure and foolproof method of detecting intrusion by human beings. However, existing millimeter-wave-based sensors are expensive and cumbersome.
[0003] There is thus a need in the art for improved millimeter-wave sensors for intrusion detection.
SUMMARY
[0004] In accordance with a first embodiment, an intrusion sensor for detecting intrusion in a bi-static radar system is provided that includes: a weighted base, the base including a coil; a pivot attached to a the base; a circuit board mounted on the pivot; wherein the circuit board includes: a magnet; a rotation control circuit configured to control a rotation of the circuit board about the pivot through magnetic interaction with the magnet in response to driving a current into the coil; an antenna array; a transmit/receive module for alternating transmitting and receiving a V-band signal through the antenna array, the transmit/receive module being configured to integrate the received signal and to compare the integrated signal to a threshold to make an intrusion detection decision; and a radio circuit for reporting the intrusion detection signal to a user.
[0005] In accordance with another embodiment of the invention, a method of detecting an intrusion is provided that includes: providing an array of paired V-band sensors, arranged from a first pair to an last pair; in a first sensor in a given one of the pairs and an opposing second sensor in an adjacent pair, rotating a circuit board in each sensor to align a contained antenna array to transmit towards the opposing sensor; alternatively transmitting from the first sensor back to the second sensor and from the second sensor back to the first sensor using the aligned antenna arrays, wherein when one sensor transmits, the other sensor receives; during a receiving period, integrating the received signal and comparing the integrated signal to a threshold; and if the integrated signal exceeds a threshold, raising an alarm by transmitting through a separate radio link to a user.
[0006] The scope of the invention is defined by the claims, which are incorporated into this section by reference. A more complete understanding of embodiments of the present invention will be afforded to those skilled in the art, as well as a realization of additional advantages thereof, by a consideration of the following detailed description of one or more embodiments. Reference will be made to the appended sheets of drawings that will first be described briefly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a block diagram for an intrusion sensor.
[0008] FIG. 2 is a plan view of a virtual wall formed by pairs of intrusion sensors.
[0009] FIG. 3 is a perspective view of the virtual wall of FIG. 2 .
[0010] FIG. 4 is a block diagram for an alternate embodiment of the intrusion sensor.
[0011] FIG. 5 is a block diagram for the transmit/receive module for an intrusion sensor.
[0012] FIG. 6 is a graph of detectable radar cross sections as a function of frequency for various power levels.
[0013] Embodiments of the present invention and their advantages are best understood by referring to the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures.
DETAILED DESCRIPTION
[0014] A distributed array of transceivers provides a low-cost yet effective “electronic fence” that detects trespassers. For example, FIG. 1 shows a distributed sensor 100 that includes a base 105 . The base is bottom-weighted to be stable with respect to placing on the terrain to be monitored as will be explained further with regard to FIG. 2 . As seen in FIG. 2 , sensors 100 are paired such that a virtual wall is formed arranged from a first sensor pair (not illustrated) through a last sensor pair (not illustrated). This arrangement may be better understood with respect to an ith pair of sensors as shown in FIG. 2 . A first sensor in the ith pair has a circuit board pivoted to transmit towards a corresponding sensor in an (i−1)th sensor pair. Similarly, a second sensor in the ith pair has its circuit board 110 aligned to transmit towards a corresponding sensor in an (i+1)th sensor pair. In this fashion, each sensor pair aligns with a preceding and subsequent sensor pair (with the exception of the first and last sensor pair unless the virtual wall forms a closed ring). The sensors in any particular pair are placed adjacent to each other such that an intruder could not slip between the paired sensors to elude detection. FIG. 3 shows a perspective view of the resulting virtual wall of FIG. 2 . The virtual wall may complement a physical wall or may be simply placed in unobtrusive locations in open terrain.
[0015] Referring back to FIG. 1 , circuit board 110 is pivotably mounted about a pivot 150 such that its longitudinal axis is orthogonal to the ground surface underneath base 105 . Board 110 includes a magnet 115 so that a magnetic field generated by a wire coil 120 in base 105 can rotate board 110 in the desired direction as controlled by a rotation control unit 145 . Board 110 includes a linear array of antennas 125 such as dipole antennas or other suitable forms to form an antenna beam aligned in a boresight direction (orthogonal) to the array axis. Thus, the antenna beam propagates substantially parallel to the ground surface surrounding sensor base 105 .
[0016] Board 110 is powered by a solar cell 130 , which may be mounted an end of pivot 150 around which board 110 is pivotably mounted. Solar cell 130 not only powers board 110 but also charges replaceable batteries 140 , which provide power to board 110 during nighttime and overcast conditions. A large variety of batteries 140 with suitable size, power and price are conventionally available. For example, occupying a volume of about 1×1×0.5 cm 3 , a rechargeable battery with about 3.5-4 Wh/cell can readily be acquired. Moreover, commercially available and relatively inexpensive solar cells offer about 0.1 W/square inch of power. Thus, if solar cell 130 has an area of just 100 square inches, more than 1 W of power is available for charging batteries 140 and powering board 110 .
[0017] Board 110 includes a transmit/receive radio integrated circuit (IC) 140 to receive and transmit RF energy in the V band (e.g., 77 GHz) through antenna array 125 . Rotation control circuit 145 controls the current driven through coil 120 to point array 125 such that its beam propagates towards a corresponding board 110 in the adjacent sensor pair. Thus, as seen in FIG. 2 , circuit board 110 is actuated so that the plane defined by the circuit board points to the adjacent sensor pair's corresponding circuit board, and vice versa.
[0018] Although distributed sensor 100 is thus inexpensive, the ability to point to just one other receiver requires the sensors to be placed in pairs as discussed with regard to FIG. 2 . An alternative embodiment as shown for sensor 400 of FIG. 4 requires just one sensor 400 per link rather than a pair of sensors. Circuit board 110 is thus fixed in position with regard to a longitudinal axis 405 . Board 110 includes two arrays of antennas such that two opposing beams may be generated. Since one does not know a priori the required alignment for a desired antenna beam in the resulting virtual wall, sensor 400 includes at least two other antenna arrays 125 that are shown in shadow form for illustration clarity. The supporting board for the extra antennas is also not shown but the alignment of the antennas is such that the full circumference of sensor 400 is covered. As will be explained further herein, sensor 400 differs from sensor 100 in that it cannot rotate to align an antenna but instead must include switching circuitry to select the antenna that is most aligned with an opposing sensor 400 .
[0019] Regardless of whether sensor 400 or sensor 100 is used, a sensor alternates between transmitting and receiving. Sensor 100 will transmit V-band energy to only one other sensor whereas sensor 400 transmits to two other sensors. Similarly, sensor 100 will receive a V-band transmission from only one other sensor whereas sensor 400 will receive a V-band transmission from two other sensors. To keep the power costs low, the sensor spacing may be on the order of 100 meters. The resulting virtual wall of sensors thus forms a distributed bistatic radar system.
[0020] It is bistatic because a given sensor does not transmit while it is receiving a transmission from the opposing sensor and vice versa. The duration of a transmission period and a reception period is relatively arbitrary. A given sensor will first transmit during the transmission period to one opposing sensor (for sensor 100 ) or to two opposing sensors (for sensor 400 ). During the reception period, the sensor listens for transmissions from the corresponding opposing sensors. To keep the design costs low, the transmission may be simply continuous wave (un-modulated) during the transmission period. During the reception period, each sensor can thus perform envelope detection on the received continuous-wave transmission and integrate the amount of received energy to make a detection/no-detection decision regarding an intruder. The transmission period duration as well as the reception period duration is an arbitrary design parameter. For example, a one milli-second duration for each period may be implemented.
[0021] Each sensor includes a separate radio 135 (shown also in FIGS. 1 and 4 ) for reporting detection of an intruder. Radio 135 could be cellular such that it transmits to a base station or it could be a ZigBee or other non-cellular protocol. In a ZigBee embodiment, the radios 135 would daisy-chain to report a detection to a central command whereas in a cellular embodiment, a given sensor could directly report an intruder to the central command station through the corresponding base station.
[0022] Each transmit/receive (TX/RX) module 140 may be constructed as seen in FIG. 5 . A phase-locked loop (PLL) 500 generates a sinusoidal output signal operating at about 19.5 GHz based upon a crystal oscillator 505 . A multiply-by-four circuit 510 upconverts the PLL output signal to drive a switched power amplifier 515 . The resulting amplified V-band signal drives antennas 125 of FIG. 1 . During the reception period, the received signal is amplified through a low-noise amplifier, filtered in a band-pass filter 530 , and detected and integrated in a detector/integrator circuit 535 . A threshold detection circuit 540 receives the integrated received signal from integrator 535 and makes an intrusion/no-intrusion decision accordingly. Should there be no detection, sensor 400 or 100 would continue transmitting and receiving to its neighboring sensor(s). Radio 135 of FIGS. 1 and 4 only needs to transmit should an intrusion detection be made, which saves on power consumption.
[0023] Should module 140 be made using conventional 130-nm SiGE-BiCMOS technology, simulation results show that power dissipation will be less than 30 mA using a supply voltage of 3V. The transmitter phase noise is approximately −60 dBc/Hz at 100 KHz. The PLL output power is about −2 dBm with a loss in the multiply-by-four circuit of around 1 dB. The power amplifier gain may be approximately 6 dB. On the receive side, the low noise amplifier noise figure is less than 8 dB with a loss in the BPF of around 1 dB. The resulting processing gain is thus higher than 20 dB assuming an integration period of between 1 ms to 100 ms.
[0024] The following analysis shows that minimum detectable radar cross section (RCS) versus distance in various embodiments. For comparison purposes, several frequencies have been analyzed under different boundary conditions as seen in the following Table 1. This table shows the minimum detectable RCS versus distance. Please note that the minimum detectable RCS calculation is equivalent to the maximum size that can disrupt the link between the two TRX linked nodes.
[0000]
TABLE 1
Various transmission power scenarios
Band
Additional
Carrier Frequency
width
Pt
Pin
Antenna gain
Gain
[GHz]
[GHz]
[dBm]
[dBm]
[dBi]
[dB]
77
1
−4
−84
22 (32 × 1)
20 (30)
77
1
0
−84
22 (32 × 1)
20 (30)
77 + AG + Ag
1
−4
−84
30 (16 × 16)
23
60
7
−4
−75
6
N/A
60 + AG + Ag
7
−4
−75
30 (16 × 16)
23
5
6
−4
−76
6
N/A
5 + AG + Ag
6
−4
−76
12
23
[0025] To calculate input power (Pin) we have added a 6 dB margin to the noise floor set by the system band width. Using the following radar equation, radar cross section (RCS) as function of distance and signal conditions have been studied:
[0000] R max 4 =Pt*G 2 *λ 2 *S /(4π) 3 * P min
[0000] where: Rmax is the range in which the target produces reflections that are detectable by the receiver (Rx noise floor in this case), Pt is the peak transmit power, G is the receive and transmit antenna gain, S is the radar cross section which is the target's cross section surface, and Pmin is the sensitivity of the receiver. We have assumed this number to be equal to the noise floor at the RF front-end of the receiver. For example, assuming 6 GHz of bandwidth, we will have a −76 dBm noise in the detected band, in worst case taking the receiver's NF and the loss in the antenna feed/distribution line, we assumed the sensitivity to be −70 dBm, which is the noise floor at the receiver. FIG. 6 shows the RCS as function of gain and transmitted power.
[0026] FIG. 6 shows that objects with a RCS of less than 1 square meters (10 square ft.) are detectable at 130 (2×65) and 170 (2×85) meters, respectively, with additional gains in excess of 20 dB to 30 dB when a 0 dBm output power is used. Therefore, an antenna gain obtained from spatial combining is needed to provide such a total gain. Observing the curves in FIG. 6 , the alternative interpretation is that between the two TRX linked nodes of 100 (2×50) meters apart, the maximum size that can be undetected is about 10 square ft. for 0 dBm input power with additional need for antenna gain of 20 dB.
[0027] Another important issue in detecting a moving object by the sensors (sudden appearance of new reflective media in the field) is the reflected power as a result of the new reflective medium. Reflections from a human body in the millimeter wave spectrum, especially in the 60-90 GHz bands, have been studied extensively in the past few years. The human body appears to show reflection properties similar to that of a highly conductive material. A preliminary theoretical study of the reflections from a human body and other reflective media has been performed, in order to ascertain whether the resulting disturbance in received power is sufficient for an assured detection. The extinction ratio between received power at the presence and absence of an intrusive object, as well as other stationary cluttering objects was also addressed. The receiver can with high probability sense the distinction between a human target and the absence of a human target, resulting in low probability of false alarm. Our preliminary studies have shown that polarized antenna structures would offer such extinction ratios. It is important to point out that these simulations have been performed at 5 GHz and not 77 GHz. The reason for this simplification was to avoid prolonged simulation times (in excess of few weeks using a quad processor server with 16 G memory) at 77 GHz. Nevertheless, the conclusion is not expected to be different at 77 GHz from the simulation results performed at the 5 GHz. A 1×32 antenna array of dipoles or patches exhibits a gain of about 22 dBi with a 3-dB beamwidth of 3 degree at one plane and 70 degree at the other plane. The actual 1×32 array physical antenna size is about 10 mm×64 mm.
[0028] The above-described embodiments of the present invention are representative of many possible embodiments. It will thus be apparent to those skilled in the art that various changes and modifications may be made to what has been disclosed without departing from this invention. The appended claims encompass all such changes and modifications as fall within the true spirit and scope of this invention. | An array of paired V-band sensors is provided to act as a virtual fence to detect human intrusion. Each sensor includes a rotating circuit board that includes an antenna array. The sensor pivots the circuit board with regard to a weight base to align with an opposing sensor. By alternatively transmitting and receiving with regard to the opposing sensor, a V-band bistatic radar system is enabled that detects human intrusion between the opposing sensors. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 10/412,943, now U.S. Pat. No. 6,776,752 filed on Apr. 14, 2003 entitled, AUTOMATIC TUBE BOWL CENTRIFUGE FOR CENTRIFUGAL SEPARATION OF LIQUIDS AND SOLIDS WITH SOLIDS DISCHARGE USING A SCRAPER, and also claims priority under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 60/372,153 filed Apr. 12, 2002, the whole of which are hereby incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
The present invention generally relates to centrifuges and in particular to a centrifuge enabling automatic discharge of solids that accumulate during separation.
Many different types of centrifugal separators are known for separating heterogeneous mixtures into components based on specific gravity. A heterogeneous mixture, which may also be referred to as feed material or feed liquid, is injected into a rotating bowl of the separator. The bowl rotates at high speeds and forces particles of the mixture, having a higher specific gravity, to separate from the liquid by sedimentation. As a result, a dense solids cake compresses tightly against the surface of the bowl, and the clarified liquid, or “centrate”, forms radially inward from the solids cake. The bowl may rotate at speeds sufficient to produce forces 20,000 times greater than gravity to separate the solids from the centrate.
The solids accumulate along the wall of the bowl, and the centrate is drained off. Once it is determined that a desired amount of the solids has been accumulated, the separator is placed in a discharge mode. In one such discharge mode, a scraper blade extending the length of the rotating bowl is placed in a scraping position against the separator wall and the bowl is rotated at a low scraping speed. Then, a radial-motion scraper scrapes the solids from the sides of the bowl, and they fall toward a solids collecting outlet. However, such a radial-motion scraper does not effectively remove wet or sticky solids which may have a consistency like that of peanut butter. In such instances, the sticky solids remain stuck on the scraper blades or fall from the wall and then reattach to the blades before reaching the collecting outlet. As a result, the solids recovery yield is reduced and the remaining solids undesirably contaminate the separator.
An additional important consideration in the design of centrifugal separators is to minimize vibration and other ill effects of operation at high rotational speeds. The separator bowl and its mounting structure form a mechanical unit having inherent resonant or “critical” speeds which are preferably avoided during operation. An additional consideration is potential for axial movement of the separator bowl, for example in the presence of imbalance or the motion of liquid axial waves in the bowl, which can result in unstable operation.
SUMMARY OF THE INVENTION
In accordance with the present invention, a centrifugal separator is disclosed that includes features addressing the shortcomings of existing centrifugal separators, especially shortcomings associated with solids recovery and mechanical instability.
In one aspect, the disclosed centrifugal separator provides for automatic discharge of solids by means of either an axial-motion scraper or a piston/extrusion assembly with exchangeable parts, having variable speed operation for greater versatility. The axial-motion scraper is used with hard-packed or friable solids, and includes an integral feed liquid accelerator and feed holes. The scraper blades flex outwardly under high centrifugal force to lock the scraper in place against the bowl. This provides a rigid or fixed end condition for the lower end of the scraper shaft to allow for high critical speed of the shaft. The scraper provides less surface area for solids to stick to, and can be used in conjunction with relatively long separator bowls.
The piston/extrusion assembly is used for pasty, sticky solids that can be extruded. A centrate valve at the top of the bowl is used to enable the centrate (separated liquid) to be discharged during a feed mode of operation, and then to close off the top of the bowl for a solids discharge mode of operation. The assembly further includes a piston that sits at the bottom of the bowl during the feed mode of operation. The piston has an integral feed accelerator and feed holes through which the feed liquid passes. These holes also provide exit paths for the solids during the extrusion that takes place in the solids discharge mode of operation. The piston/extrusion assembly can be used with sticky solids that other existing centrifuges cannot discharge efficiently, and provides for nearly complete removal of the solids, which is desirable for example when the solids contain valuable materials.
In another aspect, the disclosed centrifugal separator includes a separator bowl suspension that employs a short, stiff spindle and a spherically mounted bearing housing. Conceptually, the arrangement is analogous to a vertical rotating beam with a simply supported upper end. This arrangement has a very high critical speed as compared to existing centrifuges. It is possible to achieve a critical speed greater than the highest operating speed, so that the critical speed is not encountered during operation. The spherically mounted bearing housing restrains axial motion of the separator bowl and provides for stable operation at higher speeds than prior mounting arrangements. In one embodiment, the bearing housing comprises a semi-spherical portion having an upper semi-hemispherical portion and a lower semi-hemispherical portion, and a cylindrical portion.
In yet another aspect, the disclosed centrifugal separator employs a half-ball-shaped solids discharge valve at the bottom of the case. The discharge valve incorporates respective passages for the feed liquid and for residual liquid being drained from the bowl. The valve rotates between a closed position in which the bottom of the case is closed except for the openings to and from the feed liquid and residual liquid passages, and an open position in which solids being discharged from the separator bowl are able to fall out of the bottom of the case. This arrangement is generally more compact than prior art arrangements for discharge valves, and can be used in sanitary and/or clean-in-place applications.
Other aspects, features, and advantages of the present invention will be apparent from the Detailed Description Of The Invention that follows.
DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood by reference to the following Detailed Description Of The Invention in conjunction with the Drawings, of which:
FIG. 1 is a section view of a centrifuge having a first construction in accordance with the present invention;
FIG. 2 is a detailed section view of a lower portion of a separator bowl in the centrifuge of FIG. 1 ;
FIG. 3 is a section view of the centrifuge of FIG. 1 illustrating operation in feed mode;
FIG. 4 is a section view of the centrifuge of FIG. 1 illustrating operation in residual liquid drain mode;
FIG. 5 is a section view of the centrifuge of FIG. 1 illustrating operation in solids discharge mode;
FIG. 6 is a detailed section view of a lower part of the centrifuge of FIG. 5 , as viewed from a point to the left in FIG. 5 ;
FIG. 7 is a detailed section view of an upper bowl portion of the centrifuge of FIG. 5 ;
FIG. 8 is a section view of a centrifuge having a second construction in accordance with the present invention;
FIG. 9 is a top perspective view of a scraper in the centrifuge of FIG. 8 ;
FIG. 10 is a bottom perspective view of the scraper of FIG. 9 ;
FIG. 11 is side sectional view of the scraper of FIG. 9 ;
FIG. 12 is a section view of the centrifuge of FIG. 8 illustrating operation in feed mode;
FIG. 13 is a detailed section view of a lower part of the centrifuge of FIG. 12 ;
FIG. 14 is a section view of the centrifuge of FIG. 8 illustrating operation in drain mode;
FIG. 15 is a section view of the centrifuge of FIG. 8 illustrating operation in solids discharge mode;
FIG. 16 is a detailed section view of a bowl suspension structure in the centrifuges of FIGS. 1 and 8 ; and
FIG. 17 is a detailed section view of an alternative bowl suspension structure suitable for use in the centrifuges of FIGS. 1 and 8 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a centrifugal separator in vertical section, with a middle portion removed so as to illustrate a horizontal section as well. The centrifugal separator includes a cylindrical separator bowl 10 mounted in a central region 11 of a separator housing 13 . The separator bowl 10 is preferably a tubular type bowl having a relatively small diameter D and a length L such that the ratio of L/D is approximately 5/1 or greater. Mounted within the separator bowl 10 is a piston assembly consisting of a piston head 12 connected to a piston shaft 14 .
A variable speed drive motor 16 is connected to a drive pulley of a spherically mounted bearing and spindle assembly 18 . The connection is made by a drive belt 20 at a collar-like extension 21 of the upper end of the separator housing 13 . The drive motor 16 is controllably operated to rotate the separator bowl 10 at desired speeds for separating the feed liquid. A piston shaft clutch 22 is mounted in a crosshead 24 of a piston actuator which includes two piston actuator plungers 26 mounted in respective piston actuator cylinders 28 . Each piston actuator plunger 26 is operatively connected to the piston shaft 14 via the crosshead 24 and the piston shaft clutch 22 for raising and lowering the piston assembly within the separator bowl 10 in response to compressed air or hydraulic fluid introduced at piston actuator ports 29 . In a discharge mode of operation, the piston shaft clutch 22 is engaged for holding the piston shaft 14 while the piston actuator is raised so that the edges of the piston head 12 scrape solids from the walls of the separator bowl 10 . In other operating modes, the piston shaft clutch 22 is disengaged so that the piston assembly simply rotates with the separator bowl 10 and does not move axially. In these operating modes, a lock ring 31 prevents the piston assembly from falling out of the bottom opening of the separator bowl 10 .
Also shown in FIG. 1 are a centrate case 30 , centrate outlet port 32 , centrate valve 34 and centrate valve actuator 36 , all of which are involved in removing the centrate, or clarified liquid, from the centrifugal separator during operation, as described in more detail below. A solids valve 38 is mounted in a lower end region 39 of the separator housing 13 , below an inward-facing flange 41 . The solids valve 38 incorporates both a feed liquid passage 40 in communication with a feed liquid port 42 , as well as a residual liquid drain passage 44 in communication with a residual liquid drain port 46 . A solids valve seal 48 is disposed on a lower surface of the flange 41 . Additional structural and functional details of the solids valve 38 are described below.
FIG. 2 shows the area of the piston head 12 in detail. The central area 43 of the piston head 12 has an inverted cone-shaped cross section, with openings 45 arranged around the perimeter. In a feed mode of operation, as described below, feed liquid from the feed liquid passage 40 enters the cavity beneath the central area 43 , as indicated at 47 , and is directed out of the openings 45 toward the inner surface of the separator bowl 10 . Due to rotation of the piston head 22 in this operating mode, the openings 45 serve to accelerate the feed liquid and distribute it around the bottom of the separator bowl 10 .
A feed mode of operation of the centrifugal separator is described with reference to FIG. 3 . The piston shaft clutch 22 is disengaged so that the piston shaft 14 is free to rotate at high speed with the separator bowl 10 under the influence of the drive motor 16 . The solids valve 38 is in a closed position in which its outer upper surface rests against the solids valve seal 48 . The solids valve seal 48 is pneumatically or hydraulically inflatable by a solids valve actuator 50 via an inflating passage 53 . In the feed mode, the seal 48 is maintained in an inflated state.
The feed liquid is introduced through the feed liquid port 42 . The feed liquid flows from the feed liquid port 42 into the feed liquid passage 40 , and upon reaching the end of the feed liquid passage 40 continues in a stream 55 toward the bottom of the piston head 12 . As described above, the piston head 12 includes structure that operates to accelerate the feed liquid and direct it toward the inner wall of the bowl 10 as it rotates. Due to the centrifugal force, the liquid flows up the inner surface of the separator bowl 10 forming a pool surface 52 . As shown, the centrate valve 34 is open, so that any overflow liquid decants over a weir 54 as clarified liquid (centrate) at the top of the separator bowl 10 . The centrate then flows into the centrate case 30 and out of the centrate outlet port 32 as shown at 58 . As the liquid flows through the separator bowl 10 , it is clarified of entrained solid particles by the high centrifugal force acting upon the liquid. The solids are forced to settle on the inside wall of the separator bowl 10 and collect as a compressed solids cake 56 as a result of the centrifugal force.
When the separator bowl 10 has been determined to be sufficiently full of solids, for example by sensing the turbidity of the centrate, the centrifugal separator is placed in a bowl drain mode which is depicted in FIG. 4 . The feed liquid is shut off and the driver motor 16 electronically brakes the separator bowl 10 to a full stop. The residual liquid in the separator bowl 10 drains down through the openings in the piston head 12 onto a shaped upper surface of the solids valve 38 , which channels the residual liquid into the liquid drain passage 44 . The residual liquid then exits via the liquid drain port 46 as shown at 60 . The separator bowl 10 may be rotated again to further separate liquid from the solids, depending on the application.
When the separator bowl 10 has been completely drained of residual liquid, the centrifugal separator enters a “piston” mode in which the accumulated solids are forced out of the separator bowl 10 . The piston mode is illustrated in FIGS. 5 and 6 . The solids valve seal 48 is deflated and the upper offset portion 61 of the solids valve 38 is rotated away from the opening defined by the inner edge of the flange 41 . The piston shaft clutch 22 engages the piston shaft 14 , and the centrate valve 34 is closed by action of the centrate valve actuator 36 . Then, by action of the piston actuator including plungers 26 and cylinders 28 , the crosshead 24 is slowly raised, and with it the piston shaft 14 and piston head 12 . As the piston head 12 is drawn upward, the accumulated solids are scraped away from the inner surface of the separator bowl 10 and eventually fill the compressed space 62 above the piston head 12 . Further raising of the piston head 12 results in pressure on the enclosed solids, forcing them to be extruded downward through the openings in the piston head 12 . The extruded solids fall downward through the open bottom of the separator bowl 10 and past the open solids valve 38 , as indicated at 64 . This extruding action continues until the piston head 12 has been raised to its maximum height, at which point substantially all of the accumulated solids have been removed. At this point, the components including piston head 12 , centrate valve 34 and solids valve 38 are returned to their respective positions as shown in FIG. 1 for the next feed/drain/piston cycle. At this point, a cleaning operation may also be performed in preparation for the next operational cycle.
FIG. 7 shows the area of the centrate valve 34 during the piston mode of operation in greater detail. The centrate valve 34 is normally held open by return springs 66 and 68 . Under the action of compressed air or hydraulic fluid 70 , the centrate valve actuator 36 is raised, bringing the centrate valve 34 to a closed position. As the piston head 12 is raised by action of the piston actuator, the soft solids are extruded through openings 70 of the piston head, as indicated at 64 . As shown, several seals including piston shaft seal 72 , piston head seal 74 , and centrate valve seal 76 provide for fluid-tight sealing of the upper part of the bowl 10 in the piston mode, such that the solids are forced only through the piston openings.
FIG. 8 shows a centrifugal separator similar in many respects to the centrifugal separator of FIGS. 1–7 . The primary difference is the use of a scraper having a scraper shaft 78 and scraper head 80 instead of a piston. Also, the centrifugal separator of FIG. 9 does not include the centrate valve 34 and associated apparatus found in the centrifugal separator of FIGS. 1–7 . The centrifugal separator of FIG. 8 employs a helical scraping action on the inner surface of the bowl 10 rather than an extruding action, and can generally be used with accumulated solids that are relatively dense and rigid.
FIGS. 9–11 show different views of the scraper head 80 . Four scraper arms 82 extend from a central body portion 84 , which includes a number of radially directed feed accelerator holes 90 . Alternative embodiments may use fewer or more scraper arms 82 . Each scraper arm 82 has a forward surface 86 with an edge portion 88 that is in close contact with the inner surface of the separator bowl 10 . The forward surface 86 may be integral with the rest of the arm 82 or may be part of a separate hard material that is attached to the arm 82 , such as by welding or brazing. Also shown in FIGS. 9–11 are skirt portions 89 extending downwardly below the arms 82 . The function of the skirt portions 89 is described below.
FIG. 12 shows the centrifugal separator of FIG. 8 in a feed mode of operation, which is substantially the same as the feed mode of operation of the centrifugal separator of FIGS. 1–7 . FIG. 13 shows the area of the scraper head 80 in detail during the feed mode of operation. The scraper head 80 is located at the lower end of the bowl 10 , and rotates with the bowl 10 at high speed. The skirt portions 89 of the scraper head 80 extend into a lower opening of the bowl 10 , and during the high-speed rotation actually flex slightly outward in response to the centrifugal forces to urge against a lower rim 91 of the bowl 10 . By this action, unwanted vibration of the scraper assembly is reduced.
During the feed mode of operation, the feed liquid stream 55 is accelerated radially by action of the scraper head 80 rotating with the separator bowl 10 . Specifically, the feed liquid stream 55 hits the underside 93 of the body portion 84 of the scraper head 80 (see FIGS. 10 and 11 ) and is directed outwardly to the inner surface of the separator bowl 10 through the holes 90 . The solids 56 accumulate near the inner surface of the separator bowl 10 as the centrate flows up the inner surface of the separator bowl 10 and eventually out of centrate port outlet 32 as described above with reference to FIG. 3 .
FIG. 14 illustrates the drain mode of operation of the centrifugal separator of FIG. 8 . Again, operation is similar to the drain mode of operation of the centrifugal separator of FIGS. 1–7 .
FIG. 15 shows a scrape mode of operation of the centrifugal separator of FIG. 8 . The solids valve seal 48 is deflated and the solids valve 38 is rotated away from the bottom of the separator bowl 10 , as shown in FIG. 6 . The scraper clutch 22 is engaged to prevent the scraper shaft 78 from rotating and to lift the scraper shaft 78 as the scraper actuator is lifted. The motor 16 rotates the bowl at a slow speed as the scraper head 80 is slowly raised. This causes the packed solids to be scraped away along a helical path on the inner surface of the bowl 10 . This action continues until the scraper head 80 reaches the top of the bowl 10 , at which point it is slowly lowered, scraping away any residual solids as it does so. When this scraping cycle is complete, the solids valve 38 closes again and the solids valve seal 48 is re-inflated, enabling the next feed/drain/scrape cycle to commence.
Optionally, cleaning and/or rinsing fluid may be introduced through the same fluid feed pathway, with operation of the drive motor 16 enabling complete distribution of the cleaning and/or rinsing fluid. A scrape mode of operation, as discussed above, may then be entered to further clean the interior of the separator bowl 10 .
FIG. 16 shows the area of the spindle and bearing assembly of the centrifugal separator of FIGS. 1 and 8 . A bearing housing has a semi-spherical portion 96 and a short cylindrical spindle portion 98 . In the embodiment shown by FIG. 16 , the semi-spherical portion 96 comprises an upper semi-hemispherical portion and a lower semi-hemispherical portion. Mounted within the spindle portion 98 are a bearing 100 and an extended spindle or hub 102 of the separator bowl 10 . A driven pulley 104 engaged by the drive belt 20 (which extends through a lateral opening 105 of the spherical portion 96 of the bearing housing) attached to the hub 102 . The spherical portion 96 rests against mating surfaces of seats 106 . A clearance adjustment nut 108 is used to retain the seats 106 while providing for a desired amount of clearance between the seats 106 and the bearing housing. As seen in FIG. 16 , the seats 106 each have an arched surface generally conformed to an outer surface of the semi-spherical portion 96 . The arched surfaces of the seats are in substantially compressive contact with and substantially surround or conform to the upper and lower semi-hemispherical portions of the portion 96 . The seats 106 , therefore, substantially stabilize the portion 96 within the separator housing. A damping rubber support ring is secured to the top of the spherical portion 96 . The support ring 107 and a swing-damping rubber ring are retained by a ring compression adjustment nut 112 . A bearing housing anti-rotation pin 114 prevents the bearing housing from rotating. The pin extends through an enlarged opening 115 in the housing 13 .
The structure depicted in FIG. 16 provides a “simple support” for the rotating spindle 102 and cylindrical separator bowl 10 . This simple support permits a limited amount of outward swiveling of the spindle 102 as it rotates about the central vertical axis of the separator at high speed during operation. This helps to reduce vibration associated with the natural frequency of the rotating apparatus, providing for smoother operation and longer life. It will be noted that the anti-rotation pin 114 is fixed with respect to the bearing housing can move within the opening 115 relative to the separator, and therefore does not interfere with this swiveling action.
FIG. 17 shows an alternative scheme for mounting a bearing and spindle assembly 18 ′. The bearing housing has a cylindrical upper portion 96 ′ with notches for receiving two rubber isolation rings 116 . As seen in FIG. 17 , the isolating rings 116 are positioned near the ends of the upper cylindrical portion 96 ′ and disposed within the mounting region of the separator housing. The assembly is held in place by a ring compression adjustment nut 112 ′. In alternative embodiments, the nut 112 or 112 ′ may be replaced by other structure, including a bolted-on ring or disk.
It will be apparent to those skilled in the art that modifications to and variations of the disclosed methods and apparatus are possible without departing from the inventive concepts disclosed herein, and therefore the invention should not be viewed as limited except to the full scope and spirit of the appended claims. | A centrifugal separator provides for the discharge of solids by either an axial-motion scraper or a piston/extrusion assembly. The axial-motion scraper is used with hard-packed or friable solids, and includes an integral feed liquid accelerator and feed holes. The piston/extrusion assembly is used with pasty solids, and includes a piston extending into a separator bowl and having openings permitting fluid communication across the piston. After high-speed separation is complete, a centrate valve closes one end of the bowl, and the piston is moved axially in the bowl by an actuator. Accumulated solids are scraped from the sides of the bowl and extruded out of the piston openings for discharge from the bowl. A bowl suspension employs a spherical mounting structure and a short, stiff spindle. A spherical portion of a bearing housing is mounted in a spherical mounting region at one end of the separator, with a cylindrical portion of the bearing housing extending along the rotational axis. A bearing and the spindle of the separator bowl are mounted within the cylindrical portion of the bearing housing. The suspension is retained by a stiff resilient ring and retaining member secured to the separator in compressive contact with the spherical portion of the bearing housing. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a brake pipe arrangement for an automotive vehicle and more specifically to a brake pipe arrangement which can reduce abnormal oscillation of brake units.
2. Description of the Prior Art
In usual, vehicle brake can be obtained by supplying hydraulic pressure generated from a master cylinder when a brake pedal is depressed to brake cylinders of brake units provided for front and rear wheels. The brake pipe arrangement for supplying hydraulic pressure to the brake units can be classified into two, front-rear split type and diagonal split type. In the above front-rear split type, a front wheel pipe connected to a front hydraulic pressure port of a master cylinder is branched into two, right and left, front wheel brake cylinders, while a rear wheel pipe connected to a rear hydraulic pressure port of the master cylinder is branched into two, right and left, rear wheel brake cylinders.
In the prior-art brake pipe arrangement for an automotive vehicle, the length of the split pipes extending from the split point to each brake cylinder is roughly equal to each other; that is, a difference in brake pipe length between the right and left wheel brake cylinders is relatively small from the vehicle structural standpoint. Therefore, when a wall thickness of a brake rotor is worn away and therefore brake torque of one brake unit varies, hydraulic pressure fluctuates or vibrates, so that the brake system tends to vibrate at a low frequency (e.g. 10 to 15 Hz). The above hydraulic pressure vibration is transmitted from the right brake unit cylinder to the left brake unit cylinder or vice versa via the two split pipes.
FIG. 1(A) shows the prior-art relationship between the frequency and the phase difference in hydraulic pressure between the two right and left brake cylinders, in which the dot-dashed line indicates the phase difference (degree) obtained when the hydraulic pressure changes in the right brake cylinder and then the changed pressure is transmitted to the left brake cylinder, and the dot-dot-dashed line indicates the phase difference (degree) obtained when the hydraulic pressure changes in the left brake cylinder and then the changed pressure is transmitted to the right brake cylinder. The small difference between the two lines results from a difference in length of pipes extending from the master cylinder (or the branch point) to the two right and left brake cylinders.
Further, FIG. 1(B) shows the prior-art relationship between the frequency and the hydraulic pressure change in the two right and left brake cylinders, in which the dot-dashed line indicates the pressure change (dB) obtained when the hydraulic pressure changes in the right brake cylinder and then the changed pressure is transmitted to the left brake cylinder, and the dot-dot-dashed line indicates the pressure change (dB) obtained when the hydraulic pressure changes in the left brake cylinder and then the changed pressure is transmitted to the right brake cylinder. Further, in FIG. 3(B), the dashed line indicates the relationship between frequency and torque change in one brake cylinder obtained when torque changes in the other brake cylinder.
With reference to FIGS. 1(A) and (B), since the phase difference between the two cylinders is about 90 degrees at 10 Hz (brake cylinder hydraulic pressure vibration frequency), the pressure change is relatively low. However, when the vibration frequency increases from 10 Hz to 20 Hz, since the phase difference increases from 90 to 180 degrees, the pressure change also increases up to the peak resonant point R 0 as shown in FIG. 1(B).
On the other hand, since this hydraulic pressure vibration frequency range from 10 to 18 Hz corresponds to the frequency range during which brake shimmy (an abnormal oscillation in the front wheels of a motor vehicle reinforced by resonance at critical speeds) is generated, there exists a problem in that the brake shimmy phenomenon is accelerated and therefore there exists a need of eliminating hydraulic pressure fluctuations or torque vibration; that is, it is necessary to strictly match the thickness of one side brake rotor to that of the other side brake rotor. In other words, in the prior-art brake units, it has been necessary to often replace the brake units with a new set of brake units, thus resulting in poor workability and higher cost.
SUMMARY OF THE INVENTION
With these problems in mind, therefore, it is the primary object of the present invention to provide a brake pipe arrangement for an automotive vehicle which can shift the peak (resonant) frequency of hydraulic pressure vibration within the brake cylinder caused by changes in brake rotor wall thickness, for instance away from the brake shimmy frequency range (10 to 18 Hz) in order to minimize brake unit vibration.
To achieve the above-mentioned object, a brake pipe arrangement for connecting a master cylinder to right and left brake unit cylinders for an automotive vehicle, according to the present invention, comprises: (a) a first pipe, connected between the master cylinder and the right brake unit cylinder, for supplying hydraulic pressure generated by the master cylinder to the right brake unit cylinder; (b) a second pipe, connected between the master cylinder and the left brake unit cylinder, for supplying hydraulic pressure generated by the master cylinder to the left brake unit cylinder; and (c) an auxiliary pipe, connected between said first and second pipes in the vicinity of the two right and left brake unit cylinder, for reducing an equivalent vibration mass of a brake system including the master cylinder and the two brake unit cylinders.
The diameter of the automotive pipe is equal to or larger than that of the first and second pipes. When the diameter of the auxiliary pipe is equal to that of the first and second pipes, the length of the auxiliary pipe is determined shorter than a sum of lengths of both the first and second pipes.
In the brake pipe arrangement of the present invention, since an auxiliary pipe is additionally connected between the two right and left brake unit cylinders near the two cylinders, it is possible to reduce an equivalent mass of the brake pipe arrangement and therefore to increase the hydraulic pressure peak (resonant) frequency from a point R 0 to a point R 1 (both shown in FIG. 1B) away from the brake shimmy generation range, thus minimizing the brake unit vibration.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1(A) is a graphical representation showing the relationship between phase difference in hydraulic pressure between two, right and left, brake cylinders and hydraulic pressure vibration frequency, in which the prior-art relationship is shown by dot-dashed and dot-dot-dashed lines and the relationship of the present invention is shown by a solid line;
FIG. 1(B) is a grapical representation showing the relationship between hydraulic pressure change and hydraulic pressure vibration frequency, in which the prior-art relationship is shown by dot-dashed and dot-dot-dashed lines and the relationship of the present invention is shown by a solid line, togther with torque change within one cylinder caused by hydraulic pressure change within the other cylinder.
FIG. 2 is a perspective view showing an embodiment of the brake pipe arrangement for an automotive vehicle according to the present invention, which is provided for a pair of front wheel brake units;
FIG. 3 is a simplified diagrammatical illustration showing the brake pipe arrangement shown in FIG. 2;
FIG. 4 is an equivalent vibration circuit corresponding to the brake pipe arrangement shown in FIG. 3;
FIG. 5(A) is a vibration circuit diagram showing a delta-shaped inductance (equivalent mass) circuit structure;
FIG. 5(B) is another vibration circuit diagram showing a pi-shaped inductance (equivalent mass) circuit structure; and
FIG. 6 is a graphical representation for assistance in explaining the effect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 shows a brake pipe arrangement according to the present invention, which is applied to a pair of front wheel brake units. In the drawing, a pair of front wheel, left and right, brake units 10 and 12 are of disc brake type, in which each caliper 18 or 20 is provided so as to sandwich the circumferential edge portion of each brake rotor 14 or 16 and each brake cylinder 42 or 44 is provided for each caliper 18 or 20 to actuate it. When hydraulic pressure is applied from a master cylinder 22 to the brake cylinder 42 or 43, two brake pads attached to the caliper 18 or 20 are brought into pressure contact with the brake rotor 14 or 16 for generating frictional braking force, respectively.
In FIG. 2, a brake pedal 24 is linked with a master cylinder 22. Therefore, when the brake pedal 24 is depresed, a braking hydraulic pressure is generated within the master cylinder 22. The master cylinder 22 is provided with a front hydraulic pressure port 22a and a rear hydraulic pressure port 22b. The front hydraulic pressure port 22a is connected to a proportioning value 32 via a pipe 28 and then to the two front brake units 10 and 12 via two front (left and right) pipes 34a and 34b, separately.
On the other hand, the rear hydraulic pressure port 22b is connected to the proportioning value 32 via pipe 30 and then to two rear brake units (not shown) via a rear pipe 36.
This front pipe 34 is branched at a branch point D near the proportioning value 32 into two front (left and right) pipes 34a and 34b and then connected to two rubber hose 38 and 40 near two suspensions S, separately. These two rubber hoses are connected to two brake cylinders 42 and 44 of the brake units 10 and 12 separately, as shown in FIG. 2. Further, in FIG. 2, an auxiliary pipe 50 is connected between the two front (left and right) pipes 34a and 34b near the two rubber hoses 38 and 40 or the two brake units 10 and 20.
FIG. 3 is a more simplified representation of the brake pipe arrangement shown in FIG. 2, in which the same reference numerals as in FIG. 2 are used. In FIG. 3, the reference numeral 44 denotes the right side brake cylinder; 42 denotes the left side brake cylinder; and 50 denotes the auxiliary pipe 50.
In FIGS. 2 and 3, the feature of the brake pipe arrangement according to the present invention is to connect the two front pipes 34a and 34b by an auxiliary pipe 50 near each brake cylinder 42 or 44 or each rubber hose 38 or 40 in order to increase the equivalent mass of the brake unit vibration system, that is, to shift the resonant frequency of the pipe arrangement away from the brake shimmy generation range. In FIG. 3, l R denotes a right side pipe length from the master cylinder 22 to the rubber hose 40; l L denotes a left side pipe length from the master cylinder 22 to the rubber hose 38; and l H denotes an auxiliary pipe length.
The resonant (peak) frequency characteristics R 1 (shown in FIG. 1B) of the brake pipe arrangement of the split-type front wheel brake units 10 and 12 are subjected to the rigidity of the calipers 18 and 20, the rigidity of brake pedal 24, equivalent masses of brake oils within various pipes, and equivalent stiffness of the various pipes, etc. The equivalent mass and the equivalent stiffness of the pipe including brake oil are determined by the pipe dimensions (e.g. pipe diameter and pipe length).
FIG. 4 shows an equivalent vibration circuit roughly corresponding to the brake pipe arrangement shown in FIG. 3, in which L L denotes an equivalent mass of the left pipe 34a extending from the branch point D to the rubber hose 38; C L denotes an equivalent stiffness of the left pipe 34a; L R denotes an equivalent mass of the right pipe 34b extending from the branch point D to the rubber hose 40; C R denotes an equivalent stiffness of the right pipe 34b; C R denotes an equivalent stiffness of the right pipe 34b; L P denotes an equivalent mass of the master cylinder side pipe; C P denotes an equivalent stiffness of the master cylinder side pipe; and L H denotes an equivalent mass of the auxiliary pipe 50. Further, in FIG. 4, a constant current source i 0 indicates that a hydraulic pressure change is assumed to be produced on the right side brake unit 20.
When taking into consideration of only the masses, the equivalent vibration circuit shown in FIG. 4 can be simplified into a delta-shaped inductance connection circuit as shown in FIG. 5(A). This delta-shaped circuit can further be transformed into a pi-shaped circuit as shown in FIG. 5B in accordance with a transformation formula as follow: ##EQU1## where L L , L R and L P denote equivalent masses of right side pipe, left side pipe, and master side pipe, respectively all including the mass L H of the auxiliary pipe 50.
Here, assumption is made that both pipes 34a and 34b are the same in length (as L L =L R ) and the auxiliary pipe is arranged along the pipes 34a and 34b (as L H =2L L =2L R ).
Then, the following relationship can be obtained from the expressions (1) and (2) as
L.sub.L =L.sub.R =L.sub.L /2=L.sub.R /2
Here, if the length of the auxiliary pipe 50 is determined to be equal to that of the pipe 34a or 34b (as L H =L L =L R ), the following relationship can be obtained from the expressions (1) and (2) as
L.sub.L =L.sub.R =L.sub.L /3=L.sub.R /3
When the diameter of the auxiliary pipe 50 is two times larger than that of the pipe 34a or 34b (as L H =L R /4), the following relationship can be obtained from the expressions (1) and (2) as
L.sub.L =L.sub.L /9 L.sub.R =L.sub.R /9
Here, when the diameter of a pipe is increased by n times, the mass of oil within the pipe is increased by n 2 times. However, since the impedance Z 0 when seen from the brake cylinder side is reversely proportional to the fourth power of the diameter (d 4 ), the impedance is increased by n -4 times. Therefore, the equivalent mass of the pipe is increased by n -2 times in total.
In summary, when the length of the auxiliary pipe 50 is determined shorter than the total length of the two branch pipes 34a and 34b or when the diameter of the auxiliary pipe 50 is increased, it is possible to reduce the equivalent mass of the vibration system of the brake pipe arrangement, so that the resonant (peak) frequency R 1 of the hydraulic pressure vibration is increased in FIG. 1(B) away from the brake shimmy generation range (e.g. 10 to 18 Hz) for prevention of brake pipe vibration caused when the wall thickness of the disk rotor is worn away.
In FIG. 1(A), the solid line indicates the relationship of the present invention between the frequency and the phase difference in hydraulic pressure between the two right and left brake cylinders when hydraulic pressure changes in one brake cylinder. In FIG. 1(B), the solid line indicates the relationship of the present invention between the frequency and the hydraulic pressure change in the two right and left brake cylinder when hydraulic pressure changes in one brake cylinder. These drawings indicate that the phase difference between the two brake cylinders is decreased and therefore the pressure change or the resonant frequency R 1 is increased away from the brake shimmy generation range.
FIG. 6 shows an effect of the present invention, in which the pressure change between the two brake cylinders can be reduced in the present invention at vibration frequency within the brake shimmy generation range in comparison with the prior-art pipe arrangement including no auxiliary pipe 50.
The invention 1 indicates a drop of the hydraulic pressure change obtained when the auxiliary pipe 50 with a length and a diameter susbstantially equal to that of the right or left side pipe 34a or 34b (half of the total length of two pipes 34a and 34b) is connected and the invention 2 indicates a drop of the hydraulic pressure change obtained when the auxiliary pipe 50 with a length substantially equal to the right or left side pipe 34a or 34b and a diameter 1.5 times larger tan that of the right or left side pipe 34a or 34b.
In the prsent invention, the auxiliary pipe 50 can be arranged along a side surface of an engine room or along the suspension member M.
Although the length of the pipe 50 can be determined according to the vehicle width, it is possible to arrange the auxiliary pipe 50 shorter than the main right and left side pipes 34a or 34b. As already expained, the diameter of the auxiliary pipe 50 is determined at least equal to or larger than that of the main right and right side pipes 34a and 34b.
Further, in the brake pipe arrangement according to the present invention, since only the auxiliary pipe 50 is added without modifying the ridigity or dimensions of the brake calipers 28 and 20 or the brake pedal 24, no harmful influence is exerted upon the brake force or brake function of the brake unit.
As described above, in the brake pipe arrangement according to the present invention, since the right and left brake oil pipes are connected by an auxiliary bypass pipe in order to increase the equivalent vibration mass of the brake system, it is possible to shift the resonant hydraulic pressure frequency of the brake system, vibrated when hydraulic pressure varies due to worn-away disk rotors, away from the brake shimmy generation range, it is possible to effectively prevent the brake unit and brake pipe arrangement from normal vibrations. | To shift the resonant (peak) hydraulic pressure vibration frequency, caused when hydraulic pressure varies by brake unit torque fluctuations due to worn-away brake rotor for instance, away from the brake shimmy generation range (e.g. 10 to 17 Hz), an auxiliary pipe is additionally connected between a first pipe connecting the master cylinder to the right side hydraulic cylinder and a second pipe connecting the master cylinder to the left side hydraulic cylinder in the vicinity of the two hydraulic cylinders. | 1 |
This application is a 371 of PCT/EP99/09528 filed Dec. 6, 1999.
FIELD OF THE INVENTION
The present invention relates to novel agrochemical formulations based on certain 2-ethyl-hexanol alkoxylates, to a process for preparing these formulations and to their use for applying the agrochemically active compounds they comprise.
BACKGROUND OF THE INVENTION
Numerous formulations of crop treatment agents comprising the fatty alcohol ethoxylates as wetting agents and/or penetrants have already been disclosed (cf. EP-A 0 579 052). The activity of these preparations is good. However, they have the disadvantage that in some cases a lot of foam is formed on stirring with water.
Furthermore, formulations of agrochemicals comprising fatty alcohol propoxylates as formulation auxiliaries have already been described (cf. U.S. Pat. No. 3,673,087). However, the properties of these preparations are likewise not always satisfactory, since propoxylates having a relatively long alkyl moiety are sparingly soluble in water and thus have a tendency to form deposits.
Moreover, it is known that mixtures of fatty alcohol ethoxylates and propoxylates and their copolymers can be employed as low-foam wetting agents for formulating active compounds in crop protection (cf. EP-A 0 681 865). However, in practice, the properties of such preparations are in some instances unsatisfactory.
SUMMARY OF THE INVENTION
Agrochemical formulation comprise an agrochemically active compound, a 2-ethyl-hexanol alkoxylate of the formula
wherein P represents —CH 2 —CH(CH 3 ), E represent —CH 2 —CH 2 —, and the numbers 8 and 6 are average values, and optionally additives.
DETAILED DESCRIPTION
This invention, accordingly, provides novel agrochemical formulations comprising
a) at least one agrochemically active compound,
b) 2-ethyl-hexanol alkoxylate of the formula
in which
P represents
E represents —CH 2 —CH 2 — and
the numbers 8 and 6 are average values and
c) optionally additives.
Furthermnore, it has been found that the agrochemical formnulations according to the invention can be prepared by mixing
at least one agrochemically active compound
with 2-ethyl-hexanol alkoxylate of the formula (I) and
optionally with additives.
Finally, it has been found that the agrochemical formulations according to the invention are highly suitable for applying the active compounds they comprise to plants and/or their habitat.
It is extremely surprising that the formulations according to the invention are, with respect to their properties, considerably superior to the prior-art preparations of the most similar composition. Besides, based on the teaching of EP-A 0 681 865, it was to be assumed that a mixture of different alkoxylates is required so that the resulting compositions meet all the requirements of practice. However, contrary to expectations, this is not the case. Specifically the presence of 2-ethyl-hexanol alkoxylate of the formula (I) is sufficient to generate formulations having the desired property profile.
The formulations according to the invention have a number of advantages. Thus, on mixing the formulations according to the invention with water, only very little foam is formed. Furthermore, the formulations have a favourable effect on the biological activity of the active components they comprise. Moreover, it is advantageous that sparingly water-soluble active compounds in the formulations according to the invention show a reduced tendency to crystallize on dilution with water.
The formulations according to the invention comprise one or more agrochemically active compounds. Here, agrochemically active compounds are to be understood as meaning all substances which are customary for the treatment of plants. Fungicides, bactericides, insecticides, acaricides, nematicides, herbicides, plant growth regulators, plant nutrients and repellents may be mentioned as being preferred.
Examples of fungicides which may be mentioned are:
2-aminobutane; 2-anilino-4-methyl-6-cyclopropyl-pyrimidine; 2′,6′-dibromo-2-methyl-4′-trifluoromethoxy-4′-trifluoromethyl-1,3-thizole-5-carboxanilide; 2,6-dichloro-N-(4-trifluoromethylbenzyl)-benzamide; (E)-2-methoximino-N-methyl-2-(2-phenoxyphenyl)acetamide; 8-hydroxyquinoline sulphate; methyl (E)-2-{2-[6-(2-cyanophenoxy)-pyrimidin-4-yloxy]-phenyl}-3-methoxyacrylate; methyl (E)-methoximino[alpha-(o-tolyloxy)-o-tolyl]-acetate; 2-phenylphenol (OPP), aldimorph, ampropylfos, anilazine, azaconazole,
benalaxyl, benodanil, benomyl, binapacryl, biphenyl, bitertanol, blasticidin-S, bromuconazole, bupirimate, buthiobate,
calcium polysulphide, captafol, captan, carbendazim, carboxin, quinomethionate, chloroneb, chloropicrin, chlorothalonil, chlozolinate, cufraneb, cymoxanil, cyproconazole, cyprofuram,
dichlorophen, diclobutrazol, diclofluanid, diclomezin, dicloran, diethofencarb, difenoconazole, dimethirimol, dimethomorph, diniconazole, dinocap, diphenylamine, dipyrithion, ditalimfos, dithianon, dodine, drazoxolon,
edifenphos, epoxyconazole, ethirimol, etridiazole,
fenarimol, fenbuconazole, fenfuram, fenitropan, fenpiclonil, fenpropidin, fenpropimorph, fentin acetate, fentin hydroxide, ferbam, ferimzone, fluazinam, fludioxonil, fluoromide, fluquinconazole, flusilazole, flusulfamide, flutolanil, flutriafol, folpet, fosetyl-aluminium, fthalide, fuberidazole, furalaxyl, furmecyclox,
guazatine,
hexachlorobenzene, hexaconazole, hymexazol,
imazalil, imibenconazole, iminoctadine, iprobenfos (IBP), iprodione, isoprothiolane,
kasugamycin, mancozeb, maneb, mepanipyrim, mepronil, metalaxyl, metconazole, methasulfocarb, methfuroxam, metiram, metsulfovax, myclobutanil,
nickel dimethyldithiocarbamate, nitrothal-isopropyl, nuarimol,
ofurace, oxadixyl, oxamocarb, oxycarboxin,
pefurazoate, penconazole, pencycuron, phosdiphen, pimaricin, piperalin, polyoxin, probenazole, prochloraz, procymidone, propamocarb, propiconazole, propineb, pyrazophos, pyrifenox, pyrimethanil, pyroquilon,
quintozene (PCNB), quinoxyfen,
tebuconazole, tecloftalam, tecnazene, tetraconazole, thiabendazole, thicyofen, thiophanate-methyl, thiram, toiclophos-methyl, tolylfluanid, triadimefon, triadimenol, triazoxide, trichlamide, tricyclazole, tridemorph, triflumizole, triforine, triticonazole,
validamycin A, vinclozolin,
zineb, ziram,
8-tert-butyl-2-(N-ethyl-N-n-propyl-amino)-methyl-1,4-dioxa-spiro-[4,5]decane,
N-(R)-[1-(4-chlorophenyl)-ethyl]-2,2-dichloro-1-ethyl-3t-methyl-1r-cyclopropanecarboxamide (diastereomer mixture or individual isomers),
1-methylethyl [2-methyl-1-[[[1-(4-methylphenyl)-ethyl]-amino]-carbonyl]-propyl]-carbamate,
N-(2,3-dichloro-4-hydroxy)-1-methyl-cyclohexyl-1-carboxanilide,
2-[2-(1-chloro-cyclopropyl)-3-(2-chlorophenyl)-2-hydroxypropyl]-2,4-dihydro-[1,2,4]-triazole-3-thione,
1-(3,5-dimethyl-isoxazole-4-sulphonyl)-2-chloro-6,6-difluoro-[1,3]-dioxolo-[4,5-f]-benzimidazole and
(5,6-dihydro-1,4,2-dioxazin-3-yl)-{2-[[6-(2-chloro-phenoxy)-5-fluoro-4-pyrimidinyl]-oxy]phenyl}-methanone-O-methyloxime.
Examples of Bactericides Which may be Mentioned are:
bronopol, dichlorophen, nitrapyrin, nickel dimethyldithiocarbamate, kasugamycin, octhilinone, furanecarboxylic acid, oxytetracyclin, probenazole, streptomycin, tecloftalam, copper sulphate and other copper preparations.
Examples of Insecticides, Acaricides and Nematicides Which may be Mentioned are:
abamectin, acephate, acrinathrin, alanycarb, aldicarb, alphamethrin, amitraz, avermectin, AZ 60541, azadirachtin, azinphos A, azinphos M, azocyclotin,
Bacillus thuringiensis , 4-bromo-2-(4-chlorophenyl)-1-(ethoxymethyl)-5-(trifluoromethyl)-1H-pyrrole-3-carbonitrile, bendiocarb, benfuracarb, bensultap, betacyfluthrin, bifenthrin, BPMC, brofenprox, bromophos A, bufencarb, buprofezin, butocarboxin, butylpyridaben,
cadusafos, carbaryl, carbofuran, carbophenothion, carbosulfan, cartap, chloethocarb, chloroethoxyfos, chlorofenvinphos, chlorofluazuron, chloromephos, N-[(6-chloro-3-pyridinyl)-methyl]-N′-cyano-N-methyl-ethanimidamide, chloropyrifos, chloropyrifos M, cis-resmethrin, clocythrin, clofentezine, cyanophos, cycloprothrin, cyfluthrin, cyhalothrin, cyhexatin, cypermethrin, cyromazine,
deltamethrin, demeton-M, demeton-S, demeton-S-methyl, diafenthiuron, diazinon, dichlofenthion, dichlorvos, dicliphos, dicrotophos, diethion, diflubenzuron, dimethoate, dimethylvinphos, dioxathion, disulfoton,
edifenphos, emamectin, esfenvalerate, ethiofencarb, ethion, ethofenprox, ethoprophos, etrimphos,
fenamiphos, fenazaquin, fenbutatin oxide, fenitrothion, fenobucarb, fenothiocarb, fenoxycarb, fenpropathrin, fenpyrad, fenpyroximate, fenthion, fenvalerate, fipronil, fluazinam, fluazuron, flucycloxuron, flucythrinate, flufenoxuron, flufenprox, fluvalinate, fonophos, formothion, fosthiazate, fubfenprox, furathiocarb,
HCH, heptenophos, hexaflumuron, hexythiazox,
imidacloprid, iprobenfos, isazophos, isofenphos, isoprocarb, isoxathion, ivermectin,
lambda-cyhalothrin, lufenuron,
malathion, mecarbam, mevinphos, mesulfenphos, metaldehyde, methacrifos, methamidophos, methidathion, methiocarb, methomyl, metolcarb, milbemectin, monocrotophos, moxidectin,
naled, NC 184, nitenpyram,
omethoate, oxamyl, oxydemethon M, oxydeprofos,
parathion A, parathion M, permethrin, phenthoate, phorate, phosalone, phosmet, phosphamidon, phoxim, pirimicarb, pirimiphos M, pirimiphos A, profenofos, promecarb, propaphos, propoxur, prothiofos, prothoate, pymetrozin, pyrachlophos, pyridaphenthion, pyresmethrin, pyrethrum, pyridaben, pyrimidifen, pyriproxifen,
quinalphos,
salithion, sebufos, silafluofen, sulfotep, sulprofos,
tebufenozide, tebufenpyrad, tebupirimiphos, teflubenzuron, tefluthrin, temephos, terbam, terbufos, tetrachlorvinphos, thiafenox, thiodicarb, thiofanox, thiomethon, thionazin, thuringiensin, tralomethrin, transfluthrin, triarathen, triazophos, triazuron, trichlorfon, triflumuron, trimethacarb,
vamidothion, XMC, xylylcarb, zetamethrin.
Examples of herbicides which may be mentioned are: anilides such as, for example, diflufenican and propanil; arylcarboxylic acids such as, for example, dichloropicolinic acid, dicamba and picloram; aryloxyalkanoic acids such as, for example, 2,4-D, 2,4-DB, 2,4-DP, fluroxypyr, MCPA, MCPP and triclopyr; aryloxy-phenoxy-alkanoic esters such as, for example, diclofop-methyl, fenoxaprop-ethyl, fluazifop-butyl, haloxyfop-methyl and quizalofop-ethyl; azinones such as, for example, chloridazon and norflurazon; carbamates such as, for example, chlorpropham, desmedipham, phenmedipham and propham; chloroacetanilides such as, for example, alachlor, acetochlor, butachlor, metazachlor, metolachlor, pretilachlor and propachlor; dinitroanilines such as, for example, oryzalin, pendimethalin and trifluralin; diphenyl ethers such as, for example, acifluorfen, bifenox, fluoroglycofen, fomesafen, halosafen, lactofen and oxyfluorfen; ureas such as, for example, chlortoluron, diuron, fluometuron, isoproturon, linuron and methabenzthiazuron; hydroxylamines such as, for example, alloxydim, clethodim, cycloxydim, sethoxydim and tralkoxydim; imidazolinones such as, for example, imazethapyr, imazamethabenz, imazapyr and imazaquin; nitriles such as, for example, bromoxynil, dichlobenil and ioxynil; oxyacetamides such as, for example, mefenacet; sulphonylureas such as, for example, amidosulfuron, bensulfuron-methyl, chlorimuron-ethyl, chlorsulfuiron, cinosulfuron, metsulfuron-methyl, nicosulfuron, primisulfuron, pyrazosulfuron-ethyl, thifensulfuron-methyl, triasulfuron and tri-benuron-methyl; thiolcarbamates such as, for example, butylates, cycloates, diallates, EPTC, esprocarb, molinates, prosulfocarb, thiobencarb and triallates; triazines such as, for example, atrazine, cyanazine, simazine, simetryne, terbutryne and terbutylazine; triazinones such as, for example, hexazinone, metamitron and metribuzin; others such as, for example, aminotriazole, 4-amino-N-(1,1-dimethylethyl)-4,5-dihydro-3-(1-methylethyl)-5-oxo-1H-1,2,4-triazole-1-carboxamide, benfuresate, bentazone, cinmethylin, clomazone, clopyralid, difenzoquat, dithiopyr, ethofumesate, fluorochloridone, glufosinate, glyphosate, isoxaben, pyridate, quinchlorac, quinmerac, sulphosate and tridiphane.
Plant growth regulators which may be mentioned are chlorocholine chloride and ethephon.
Examples of plant nutrients which may be mentioned are customary inorganic or organic fertilizers for providing plants with macro- and/or micronutrients.
Examples of repellents which may be mentioned are diethyltolylamide, ethylhexanediol and butopyronoxyl.
Particularly preferred examples of fuingicides which may be mentioned are the active compounds of the formulae
The formulations according to the invention furthermore comprise 2-ethyl-hexanol alkoxylate of the formula (I). In this formula, the numbers 8 and 6 are average values. Thus, the 2-ethyl-hexanol alkoxylate of the formula (I) is a substance mixture having preferably 8 propylene oxide and 6 ethylene oxide units.
The 2-ethyl-hexanol alkoxylate of the formula (I) is already known (cf. EP-A 0 681 865).
Suitable additives which may be present in the formulations according to the invention are all customary formulation auxiliaries such as, for example, organic solvents, emulsifiers, dispersants, preservatives, colourants, fillers and also water.
Suitable organic solvents are all customary organic solvents which dissolve the agrochemically active compounds used well. These are preferably aliphatic and aromatic, optionally halogenated hydrocarbons, such as toluene, xylene, Solvesso®, mineral oils, such as white spirit, petroleum, alkylbenzenes and spindle oil, furthermore carbon tetrachloride, chloroform, methylene chloride and dichloromethane, moreover esters, such as ethyl acetate, furthermore lactones, such as butyrolactone, moreover lactams, such as N-methylpyrrolidone, N-octylpyrrolidone and N-methylcaprolactam, and also alkanecarboxamides, such as N,N-dimethyl-decanecarboxamide and N,N-dimethyl-octanecarboxamide, and also dimethylformamide.
Suitable emulsifiers are customary surfactants which are present in formulations of agrochemically active compounds. Examples which may be mentioned are ethoxylated nonylphenols, polyethylene glycol ethers of linear alcohols, reaction products of alkylphenols with ethylene oxide and/or propylene oxide, furthermore fatty esters, alkylsulfonates, alkyl sulfates, aryl sulfates, ethoxylated arylalkylphenols, such as, for example, tristyryl-phenol ethoxylate having on average 16 ethylene oxide units per molecule, furthermore ethoxylated and propoxylated arylalkylphenols and sulfated or phosphated arylalkylphenol ethoxylates or ethoxy- and propoxylates.
Suitable dispersants are all substances which are customarily used for this purpose in crop protection compositions. These are preferably natural and synthetic water-soluble polymers, such as gelatin, starch and cellulose derivatives, in particular cellulose esters and cellulose ethers, further polyvinyl alcohol, polyvinylpyrrolidone, polyacrylic acid, polymethacrylic acid and copolymers of (meth)acrylic acid and (meth)acrylic esters, and furthermore also copolymers of methacrylic acid and methacrylic ester which are neutralized with alkali metal hydroxide.
Suitable preservatives are all substances which are customarily present for this purpose in crop treatment compositions. Examples which may be mentioned are Preventol® and Proxel®.
Suitable colourants are all inorganic or organic colourants which are customarily used for preparing crop protection compositions. Examples which may be mentioned are titanium dioxide, colour black, zinc oxide and blue pigments.
Suitable fillers are all substances which are customarily used for this purpose in crop protection compositions. These are preferably inorganic particles, such as carbonates, silicates and oxides having an average particle size of from 0.005 to 5 μm, particularly preferably from 0.02 to 2 μm. Examples which may be mentioned are silicon dioxide, so-called finely divided silicic acid, silica gels, and natural and synthetic silicates and alumosilicates.
The content of the individual components in the formulations according to the invention can be varied within a relatively wide range. Thus, the concentrations
of agrochemically active compounds are generally between 1 and 90% by weight, preferably between 5 and 30% by weight
of 2-ethyl-hexanol alkoxylate of the formula (I) are generally between 1 and 90% by weight, preferably between 10 and 50% by weight and
of additives are generally between 0 and 98% by weight, preferably between 20 and 85% by weight.
The agrochemical formulations according to the invention are prepared by mixing the components in the particular ratios desired. If the agrochemically active compound is a solid, it is generally employed in finely ground form or in the form of a solution or suspension in an organic solvent. If the agrochemically active compound is liquid, it is frequently not necessary to use an organic solvent. It is furthermore possible to employ a solid agrochemically active compound in the form of a melt.
When carrying out the process according to the invention, the temperatures can be varied within a certain range. In general, the process is carried out at temperatures between 0° C. and 80° C., preferably between 10° C. and 60° C.
The process according to the invention is generally carried out by mixing 2-ethylhexanol alkoxyate of the formula (I) with one or more agrochemically active compounds and, if appropriate, with additives, by stirring intensively. The components can be mixed with one another in any order. In a preferred variant of the process according to the invention, however, 2-ethyl-hexanol alkoxylate of the formula (I) is mixed with one or more agrochemically active compounds and with other additives, and the resulting premix is dispersed in water, giving emulsions, suspensions or solutions.
Suitable for carrying out the process according to the invention is customary apparatus which are employed for preparing agrochemical formulations.
The agrochemical formulations according to the invention can be applied in the forms of preparation which are customary for liquid preparations, either as such or after prior dilution with water, i.e., for example, as emulsions, suspensions or solutions. The application is carried out by customary methods, i.e., for example, by spraying, watering or injecting.
The application rate of the agrochemical formulations according to the invention can be varied within a relatively wide range. It depends on the respective agrochemically active compounds and their content in the formulations.
Using the formulations according to the invention, it is possible to apply agrochemically active compounds in a particularly advantageous manner to plants and/or their habitat. Undesired formation of foam both during dilution of the concentrates with water and during spraying is substantially avoided. Moreover, the tendency towards crystallization of solid active compounds is reduced and the biological activity of the active components is increased in comparison to customary formulations.
The invention is illustrated by the examples below.
PREPARATION EXAMPLES
Example 1
To prepare a formulation according to the invention, 10 g of active compound of the formula
are initially mixed with
40 g of butyrolactone and then with
50 g of 2-ethyl-hexanol alkoxylate of the formula (I)
with stirring at room temperature. After the addition has ended, the mixture is stirred at room temperature for another 30 minutes. This gives a homogeneous solution.
Example 2
To prepare a formulation according to the invention, 10 g of active compound of the formula
are initially mixed with
35 g of butyrolactone and then with
35 g of 2-ethyl-hexanol alkoxylate of the formula (I) and
20 g of tristyryl-phenol ethoxylate having an average of 16 ethylene oxide units per molecule
with stirring at room temperature. After the addition has ended, the mixture is stirred at room temperature for another 30 minutes. This gives a homogeneous solution.
Comparative Example I
To prepare a conventional formulation, 10 g of active compound of the formula
are initially mixed with
70 g of butyrolactone and then with
20 g of tristyryl-phenol ethoxylate having an average of 16 ethylene oxide units per molecule
with stirring at room temperature. After the addition has ended, the mixture is stirred at room temperature for another 30 minutes. This gives a homogeneous solution.
USE EXAMPLES
Example A
Erysiphe Test (Barley)/protective
To prepare a ready-to-use preparation of active compound, the concentrate is in each case diluted with water to the desired concentration.
To test for protective activity, young plants are sprayed with the preparation of active compound at the stated application rate.
1 day after spraying, the plants are dusted with spores of Erysiphe graminis f.sp. hordei.
The plants are placed in a greenhouse at a temperature of approximately 18° C. and a relative atmospheric humidity of approximately 80% to promote the development of mildew pustules.
Evaluation is carried out 7 days after the inoculation. 0% means an efficacy which corresponds to that of the control, whereas an efficacy of 100% means that no infection is observed.
Formulations, active compound application rates and test results are shown in the tables below.
TABLE A-1
Erysiphe test (barley)/protective
Active compound
Formulation according
application rate in
Efficacy
to Example
g/ha
in %
Known:
(I)
62.5
76
According to the invention:
(1)
62.5
90
TABLE A-2
Erysiphe test (barley)/protective
Active compound
Formulation according
application rate in
Efficacy
to Example
g/ha
in %
Known:
(I)
62.5
72
According to the invention:
(2)
62.5
89
Example B
Erysiphe Test (Wheat)/curative
To prepare a ready-to-use preparation of active compound, the concentrate is in each case diluted with water to the desired concentration.
To test for curative activity, young plants are dusted with spores of Erysiphe graminis f.sp. tritici . 48 hours after the inoculation, the plants are sprayed with the preparation of active compound at the stated application rate.
The plants are placed in a greenhouse at a temperature of approximately 18° C. and a relative atmospheric humidity of approximately 80% to promote the development of mildew pustules.
Evaluation is carried out 7 days after the inoculation. 0% means an efficacy which corresponds to that of the control, whereas an efficacy of 100% means that no infection is observed.
Formulations, active compound application rates and test results are shown in the tables below.
TABLE B-1
Erysiphe test (wheat)/curative
Active compound
Formulation according
application rate in
Efficacy
to Example
g/ha
in %
Known:
(I)
62.5
38
According to the invention:
(1)
62.5
86
TABLE B-2
Erysiphe test (wheat)/curative
Active compound
Formulation according
application rate in
Efficacy
to Example
g/ha
in %
Known:
(I)
62.5
60
According to the invention:
(2)
62.5
77
250 ppm
Example C
Leptosphaeria nodorum Test (Wheat)/curative
To prepare a ready-to-use preparation of active compound, the concentrate is in each case diluted with water to the desired concentration.
To test for curative activity, young plants are sprayed with a conidia suspension of Leptosphaeria nodorum . The plants remain in an incubation cabin at 20° C. and 100% relative atmospheric humidity for 48 hours and are then sprayed with the preparation of active compound at the stated application rate.
The plants are placed in a greenhouse at a temeprature of approximately 22° C. and a relative atmospheric humidity of approximately 80%.
Evaluation is carried out 10 days after the inoculation. 0% means an efficacy which corresponds to that of the control, whereas an efficacy of 100% means that no infection is observed.
Formulations, active compound application rates and test results are shown in the table below.
TABLE C
Leptosphaeria nodorum test (wheat)/curative
Active compound
Formulation according
application rate in
Efficacy
to Example
g/ha
in %
Known:
(I)
62.5
87
According to the invention:
(1)
62.5
100
Example D
Pyrenophora teres Test (Barley)/curative
To prepare a ready-to-use preparation of active compound, the concentrate is in each case diluted with water to the desired concentration.
To test for curative activity, young plants are sprayed with a conidia suspension of Pyrenophora teres . The plants remain in an incubation cabin at 20° C. and 100% relative atmospheric humidity for 48 hours. The plants are then sprayed with the preparation of active compound at the stated application rate.
The plants are placed in a greenhouse at a temperature of approximately 20° C. and a relative atmospheric humidity of approximately 80%.
Evaluation is carried out 7 days after the inoculation. 0% means an efficacy which corresponds to that of the control, whereas an efficacy of 100% means that no infection is observed.
Formulations, active compound application rates and test results are shown in the table below.
TABLE D
Pyrenophora teres test (barley)/curative
Active compound
Formulation according
application rate in
Efficacy
to Example
g/ha
in %
Known:
(I)
62.5
54
According to the invention:
(1)
62.5
73 | Agrochemical formulations comprising
a) at least one agrochemically active compound,
b) 2-ethyl-hexanol alkoxylate of the formula
in which
P represents
E represents —CH 2 —CH 2 — and
the numbers 8 and 6 are average values and
c) optionally additives,
a process for preparing these formulations and their use for applying the active compounds they comprise are described. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of application Ser. No. 13/109,953, filed May 17, 2011, now U.S. Pat. No. 8,739,375, which claims the priority benefit of U.S. Provisional Application 61/345,470, filed May 17, 2010, which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention relates to a corrugated fiberboard container and corrugated fiberboard container kits with multiple corrugated fiberboard containers for holding and moving a body in preparation for cremation and methods of manufacture and assembly for the corrugated fiberboard container and kit.
SUMMARY OF THE INVENTION
With a larger percentage of adults choosing cremation over burial for a variety of economic, environmental and personal preferences, a greater emphasis is placed on the methods and materials involved in the process. The present design offers both an answer to finding the most desirable method and material to the cremation process.
Corrugated fiberboard was selected as the material to be used for the cremation box. Corrugated fiberboard others a distinct advantage over other materials. With its inherent strength, incendiary nature and low cost, corrugated fiberboard is the logical choice to accomplish the environmental and economic goals of the deceased.
The present design was created to improve the method and needs of the crematory technicians. The crematory technicians must have the cremation box be flexible enough to load the deceased, strong enough to carry the deceased, and flammable enough to leave little waste behind after the cremation. The corrugated fiberboard design present below achieves all of these prerequisites.
According to the present invention, the corrugated cremation box offers a unique design and ability to be fabricated from single, double or triple thickness corrugated fiberboard, depending on the preference of the technician. The four sides and bottom of the cremation box are one piece. During shipment two boxes are shipped together, each utilizes a piece of the outside shipment container for the top of their respective box.
There is no need for dowels, pins or outside materials. The present design offers the technician the ability to interlock each panel with one another. The body may be placed on top of the box prior to assembly or placed into the box from the bottom panel, which is subsequently connected to the side panels. The technician then takes either the top or bottom of the aforementioned shipping package and places this piece on top of the box. The design specifications allow for this to fit tight enough to avoid the need for straps, locks, hinges or tape.
BRIEF DESCRIPTION OF THE DRAWINGS
The utility, objects, features, and advantages of the present invention will be readily appreciated and understood from consideration of the following detailed description of the embodiments of this invention, when taken with the accompanying drawings, in which:
FIG. 1 is a plan view of a main unit portion of a cremation box showing specific design features and measurements of the main unit, in accordance with an embodiment of the present invention;
FIG. 2 is a plan view of the main unit portion of the cremation box of FIG. 1 , in accordance with an embodiment of the present invention;
FIG. 3 is a plan view of a top of a container box showing specific design features and measurements of the top, in accordance with an embodiment of the present invention;
FIG. 4 is a plan view of the top of the container box of FIG. 3 , in accordance with an embodiment of the present invention;
FIG. 5 is a plan view of a bottom of a container box showing specific design features and measurements of the bottom, in accordance with an embodiment of the present invention;
FIG. 6 is a plan view of the bottom of the container box of FIG. 5 , in accordance with an embodiment of the present invention;
FIG. 7 is a plan view of a liner for a cremation box, in accordance with an embodiment of the present invention;
FIG. 8 is a plan view of the liner of the cremation box of FIG. 5 showing specific design features and measurements of the liner, in accordance with an embodiment of the present invention;
FIG. 9 is a bottom perspective view of one half of a container in which a cremation box is shipped, in accordance with an embodiment of the present invention;
FIG. 10 is a top perspective view of a bound first portion and a liner of a cremation box, in accordance with an embodiment of the present invention;
FIG. 11 is a side perspective view of the unbound first portion and liner of the cremation box of FIG. 10 , in accordance with an embodiment of the present invention;
FIG. 12 is a side perspective view of an open liner of the cremation box of FIGS. 10 and 11 , in accordance with an embodiment of the present invention;
FIG. 13 is a side perspective view of a partially open first portion of the cremation box of FIGS. 10 and 11 , in accordance with an embodiment of the present invention;
FIG. 14 is a side perspective view of the first portion of the cremation box of FIG. 13 in a more open position, in accordance with an embodiment of the present invention;
FIG. 15 is a side perspective view of the first portion of the cremation box of FIG. 14 in a fully open position, in accordance with an embodiment of the present invention;
FIG. 16 is a side perspective view of a top right end of the first portion of the cremation box of FIG. 15 in a partially assembled position, in accordance with an embodiment of the present invention;
FIG. 17 is an inside view of the top right end of the first portion of the cremation box of FIG. 15 in a fully assembled position, in accordance with an embodiment of the present invention;
FIG. 18 is an outside view of the top right end of the first portion of the cremation box of FIG. 15 in a fully assembled position, in accordance with an embodiment of the present invention;
FIG. 19 is a side perspective view of a top left end of the first portion of the cremation box of FIG. 15 in a partially assembled position, in accordance with an embodiment of the present invention;
FIG. 20 is an outside view of the top left end of the first portion of the cremation box of FIG. 15 in a fully assembled position, in accordance with an embodiment of the present invention;
FIG. 21 is an inside view of the top left end of the first portion of the cremation box of FIG. 15 in a fully assembled position, in accordance with an embodiment of the present invention;
FIG. 22 is top perspective view of the partially assembled first portion of the cremation box with a liner being positioned inside, in accordance with an embodiment of the present invention;
FIG. 23 is top perspective view of the top end of the partially assembled first portion of the cremation box of FIG. 22 with the liner positioned inside, in accordance with an embodiment of the present invention;
FIG. 24 is top perspective view of the partially assembled first portion of the cremation box without the liner positioned inside, in accordance with another embodiment of the present invention;
FIG. 25 is a top perspective view of the bottom end of the partially assembled first portion of the cremation box without the liner positioned inside, in accordance with another embodiment of the present invention;
FIG. 26 is a top perspective view of the bottom end of the partially assembled first portion of the cremation box of FIG. 25 with the bottom end partially positioned inside the side walls, in accordance with another embodiment of the present invention;
FIG. 27 is a top perspective view of the bottom end of the partially assembled first portion of the cremation box of FIG. 26 with the bottom end partially positioned inside the side walls, in accordance with another embodiment of the present invention;
FIG. 28 is a top perspective view of the bottom end of the fully assembled first portion of the cremation box, in accordance with another embodiment of the present invention;
FIG. 29 is a top perspective view of the left bottom end of the fully assembled first portion of the cremation box, in accordance with another embodiment of the present invention;
FIG. 30 is a top perspective view of the right bottom end of the fully assembled first portion of the cremation box, in accordance with another embodiment of the present invention;
FIG. 31 is a top perspective view of the fully assembled first portion of the cremation box without a liner, in accordance with another embodiment of the present invention;
FIG. 32 is a top perspective view of the fully assembled first portion of the cremation box with a liner, in accordance with another embodiment of the present invention;
FIG. 33 is a top perspective view of one half of a container in which a cremation box is shipped, in accordance with an embodiment of the present invention;
FIG. 34 is a top perspective view of the bottom end of the fully assembled cremation box, in accordance with another embodiment of the present invention; and
FIG. 35 is a top perspective view of the top end of the fully assembled cremation box, in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION
As times change, so do traditions. The age-old practice of a casket burial has seen a decline as cremation becomes a viable option for many in today's economically-frugal, environmentally-conservative and philosophically-diverse society. The demand for more efficient and effective cremation materials and procedures has never been higher.
In response to this ideological shift and its corresponding needs, a cremation box, in accordance with embodiments of the present invention, provides an ideal structure to facilitate the cremation process for both the deceased and the practitioner.
A cremation box is produced by cutting and creasing corrugated fiberboard to form the four (4) components of the cremation box, specifically, a main unit, a top, a bottom, and a liner as shown and described in FIGS. 1 to 40 , in accordance with an embodiment of the present invention. The construction of the cremation box of the present invention can be further understood and the actual assembly of the cremation box can occur in accordance with the detailed description and assembly instructions provided below.
FIG. 1 is a plan view of a main unit portion of a cremation box showing specific design features and measurements of the main unit, in accordance with an embodiment of the present invention. In FIG. 1 , a cremation box 100 includes a bottom portion 110 , a left side panel 120 connected to a left edge of the bottom portion 110 by a left side crease portion 112 extending the length of the bottom portion 110 and the left side panel 120 , a right side panel 130 connected to a right edge of the bottom portion 110 by a right side crease portion 114 extending the length of the bottom portion 110 and the right side panel 130 , a top end panel 140 connected to a top edge of the bottom portion 110 by a top end crease portion 116 extending the width of the bottom portion 110 and the top end panel 140 , and a bottom end panel 150 connected to a bottom edge of the bottom portion 110 by a bottom end crease portion 118 extending the width of the bottom portion 110 and the bottom end panel 150 . In FIG. 1 , a top left hand hole 121 is formed in the left side panel 120 adjacent the top end of the left side panel 120 and a bottom left hand hole 122 is formed in the left side panel 120 adjacent the bottom end of the left side panel 120 . However, unlike the top left hand hole 121 , which is completely cut out and open, the bottom left hand hole 122 is partially cut out around about three-quarters of the bottom left hand hole 122 closest to the left side crease portion 112 , so the portion of the portion of the left side panel 120 inside the bottom left hand hole 122 remains connected to the left side panel 120 by a crease 125 on the side of the bottom left hand hole 122 closest to the outer edge of the left side panel 120 . Similarly, a top left slot 123 is formed in the left side panel 120 adjacent the top left hand hole 121 in the left side panel 120 and a bottom left slot 124 is formed in the left side panel 120 adjacent the bottom left hand hole 122 in the left side panel 120 .
In FIG. 1 , a top right hand hole 131 is formed in the right side panel 130 adjacent the top end of the right side panel 130 and a bottom right hand hole 132 is formed in the right side panel 130 adjacent the bottom end of the right side panel 130 . However, unlike the top right hand hole 131 , which is completely cut out and open, the bottom right hand hole 132 is partially cut out around about three-quarters of the bottom right hand hole 132 closest to the right side crease portion 114 , so the portion of the portion of the right side panel 130 inside the bottom right hand hole 132 remains connected to the right side panel 130 by a crease 135 on the side of the bottom right hand hole 132 closest to the outer edge of the right side panel 130 . Similarly, a top right slot 133 is formed in the right side panel 130 adjacent the top right hand hole 131 in the right side panel 130 and a bottom right slot 134 is formed in the right side panel 130 adjacent the bottom right hand hole 132 in the right side panel 130 .
In FIG. 1 , the top end panel 140 includes a top end center section 141 connected to a top left inside side flap 142 by a crease 143 on one side, the top left inside side flap 142 is in turn connected to a top left outside flap 145 by another crease 146 on another side. A top left slot 144 is formed in a left edge of the top end center section 141 with one side along crease 143 . A top left outside flap 145 has a hand hole 147 formed therein and a tab 151 extending outwardly away from and along a portion of an outer left edge of the top left outside flap 145 . A left inside side flap hand hole 148 is formed in about the center of the top left inside side flap 142 . However, unlike the top left outside flap hand hole 147 , which is completely cut out and open, the left inside side flap hand hole 148 is partially cut out around about three-quarters of the left inside side flap hand hole 148 closest to an inside edge of the top left inside side flap 142 , so a portion 150 of the top left inside side flap 142 remains connected to the top left inside side flap 142 by a crease 149 on the side of the top left inside side flap 142 closest to the outer edge of the top left inside side flap 142 .
In FIG. 1 , a right side of the top end center section 141 is connected to a top right inside side flap 152 by a crease 153 on one side, the top right inside side flap 152 is in turn connected to a top right outside flap 155 by another crease 156 on another side. A top right slot 154 is formed in a right edge of the top end center section 141 with one side along crease 153 . A top right outside flap 155 has a hand hole 157 formed therein and a tab 161 extending outwardly away from and along a portion of an outer left edge of the top right outside flap 155 . A right inside side flap hand hole 158 is formed in about the center of the top right inside side flap 152 . However, unlike the top right outside flap hand hole 157 , which is completely cut out and open, the right inside side flap hand hole 158 is partially cut out around about three-quarters of the right inside side flap hand hole 158 closest to an inside edge of the top right inside side flap 152 , so a portion 160 of the top right inside side flap 152 remains connected to the top right inside side flap 152 by a crease 159 on the side of the top right inside side flap 152 closest to the outer edge of the top right inside side flap 152 .
In FIG. 1 , the bottom end panel 170 includes a bottom end center section 171 is connected to a bottom left side flap 172 by a crease 173 on a left side, the bottom left side flap 172 is in turn connected to a tab 174 extending outwardly away from and along a portion of an outer left edge of the bottom left flap 172 . A bottom left side flap hand hole 175 is formed in about the center of the bottom left side flap 172 . The bottom end center section 171 is also connected to a bottom right side flap 176 by a crease 177 on a right side, the bottom right side flap 176 is in turn connected to a tab 179 extending outwardly away from and along a portion of an outer right edge of the bottom right flap 176 . A bottom right side flap hand hole 178 is formed in about the center of the bottom right side flap 176 .
In FIG. 1 , the length of the unassembled cremation box 100 is 97⅞ inches and the width is 63 inches. When the cremation box is assembled, the inner dimensions are 75⅜ inches long by 23 Yz inches wide by 10⅝ inches high. The corrugated fiberboard used for the cremation box 100 can include 1-200 BC Kraft, 1-275 BC Kraft and 1-350 BC Kraft weight and, generally, the cremation box 100 portion is made using 1-350 BC Kraft weight corrugated fiberboard.
FIG. 2 is a plan view of the main unit portion of the cremation box 100 of FIG. 1 highlighting the main sections of the cremation box 100 , in accordance with an embodiment of the present invention.
FIG. 3 is a plan view of a top of a container box showing specific design features and measurements of the top, in accordance with an embodiment of the present invention. In FIG. 3 , a top 300 includes a top body portion 310 connected to a left side panel 320 by a left side crease portion 322 extending the length of a left side of the top body portion 310 and the left side panel 320 , a right side panel 330 connected to a right edge of the top body portion 310 by a right side crease portion 332 extending the length of the top body portion 310 and the right side panel 330 , a top end top panel 340 connected to a top edge of the top body portion 310 by a top end crease portion 342 extending the width of the top portion 310 and the top end top panel 340 , and a top end bottom panel 350 connected to a bottom edge of the bottom portion 310 by a bottom end crease portion 352 extending the width of the bottom portion 310 and the bottom end panel 350 . The top end top panel 340 includes a top center section 341 , which is connected to the top body portion 310 by the top end crease portion 342 . The top center section 341 is connected on a left side to a left side flap 343 by a crease 345 and is connected on a right side to a right side flap 344 by a crease 346 . The bottom end top panel 350 includes a center section 351 , which is connected to the top body portion 310 by the bottom end crease portion 352 . The center section 351 is connected on a left side to a left side flap 353 by a crease 355 and is connected on a right side to a right side flap 354 by a crease 356 . When assembled, the top 300 fits over the top of the cremation box 100 of FIG. 1 . The corrugated fiberboard used for the top 300 can include 1-200 BC Kraft, 1-275 BC Kraft and 1-350 BC Kraft weight and, generally, the top 300 is made using 1-200 BC Kraft weight corrugated fiberboard.
In FIG. 3 , in accordance with one or more embodiments of the present invention, the outer dimensions of the unassembled top can include a length of 87 13/32 and a width of 35 9/32, the dimensions of the top body portion 310 can include a length of 76% and a width of 24% inches, the side panels 320 , 330 can include a length of 76% and a width of 5 inches, and the end panels can include a length of 35 9/32 and a width of 5 inches, where the center of the end panels is connected to the respective top and bottom ends of the top body portion 310 .
FIG. 4 is a plan view of the top of the container box of FIG. 3 highlighting the main sections of the top body portion 310 , in accordance with an embodiment of the present invention.
FIG. 5 is a plan view of a bottom of a container box showing specific design features and measurements of the bottom, in accordance with an embodiment of the present invention. In FIG. 5 , a bottom portion 500 includes a bottom body portion 510 connected to a left side panel 520 by a left side crease portion 522 extending the length of a left side of the bottom body portion 510 and the left side panel 520 , a right side panel 530 connected to a right edge of the bottom body portion 510 by a right side crease portion 532 extending the length of the bottom body portion 510 and the right side panel 530 , a bottom end top panel 540 connected to a top edge of the bottom body portion 510 by a top end crease portion 542 extending the width of the bottom body portion 510 and the top end top panel 540 , and a top end bottom panel 550 connected to a bottom edge of the bottom body portion 510 by a bottom end crease portion 552 extending the width of the bottom portion 510 and the bottom end panel 550 . The top end top panel 540 includes a top center section 541 , which is connected to the bottom body portion 510 by the top end crease portion 542 . The top center section 541 is connected on a left side to a left side flap 543 by a crease 545 and is connected on a right side to a right side flap 544 by a crease 546 . The bottom end top panel 550 includes a center section 551 , which is connected to the bottom body portion 510 by the bottom end crease portion 552 . The center section 551 is connected on a left side to a left side flap 553 by a crease 555 and is connected on a right side to a right side flap 554 by a crease 556 . When assembled, like the top portion 510 of FIG. 3 , the bottom body portion 510 fits over the top of the cremation box 100 of FIG. 1 . Although in this embodiment the dimensions of the bottom body portion 510 are smaller than the top body portion 310 of FIG. 3 , the opposite may also be true.
In FIG. 5 , in accordance with one or more embodiments of the present invention, the outer dimensions of the unassembled bottom 300 can include a length of 86 25/32 and a width of 34 25/32 inches, the dimensions of the bottom body portion 510 can include a length of 76 V4 and a width of 24 V4 inches, the side panels 520 , 530 can include a length of 76 V4 and a width of 5 inches, and the end panels can include a length of 34 25/32 and a width of 5 inches, where the center of the end panels is connected to the respective top and bottom ends of the bottom body portion 510 . While the dimensions of the bottom 500 in the embodiment described above is slightly larger than the dimensions of the top 300 , in other embodiments the bottom and top dimensions may be reversed. The corrugated fiberboard used for the bottom 500 can include 1-200 BC Kraft, 1-275 BC Kraft and 1-350 BC Kraft weight and, generally, the bottom 500 is made using 1-200 BC Kraft weight corrugated fiberboard.
FIG. 6 is a plan view of the bottom of the container box of FIG. 5 highlighting the main sections of the top body portion 510 , in accordance with an embodiment of the present invention.
FIG. 7 is a plan view of a liner for a cremation box, in accordance with an embodiment of the present invention. In FIG. 7 , a liner 700 includes a liner body portion 710 connected to a left side liner panel 720 by a left crease 721 extending the length of the liner body portion 710 and the left side liner panel 720 and the liner body portion 710 is also connected to a right side liner panel 730 by a right crease 731 extending the length of the liner body portion 710 and the right side liner panel 730 . The left side liner panel 720 further includes a top left hand hole 722 formed in the left side liner panel 720 adjacent a top end of the left side liner panel 720 and a bottom left hand hole 724 formed in the left side liner panel 720 adjacent the bottom end of the left side liner panel 720 . The right side liner panel 730 further includes a top right hand hole 732 formed in the right side liner panel 730 adjacent a top end of the right side liner panel 730 and a bottom right hand hole 734 formed in the right side liner panel 730 adjacent the bottom end of the right side liner panel 730 . The corrugated fiberboard used for the liner 700 can include 1-200 BC Kraft, 1-275 BC Kraft and 1-350 BC Kraft weight and, generally, the liner 700 is made using either 1-275 BC Kraft weight or 1-350 BC Kraft corrugated fiberboard.
FIG. 8 is a plan view of the liner of the cremation box of FIG. 5 showing specific design features and measurements of the liner, in accordance with an embodiment of the present invention. In FIG. 8 , in accordance with one or more embodiments of the invention, a length of the liner body portion 710 and each of the side liner panels 720 , 730 is 74 13/16 inches and a width of the liner body portion 710 is 22% inches. The width of the side liner panels 720 , 730 is 10 15/16 inches. Notwithstanding the dimensions given above, the dimensions of the liner will be adjusted to fit closely within the inner dimensions of the cremation box 100 .
Assembly Instructions
The following is a step-by-step guide for constructing the cremation box.
Step 1:
FIG. 9 is a bottom perspective view of one half of a container in which a cremation box is shipped, in accordance with an embodiment of the present invention. In FIG. 9 , a top 105 for the cremation box 100 also acts as half of a shipping container for the cremation box 100 . In the shipment configuration, the other half of the shipping container is a bottom (see FIGS. 5 and 6 ) that can either fit within or over the top 105 and that is configured substantially identically to the top 105 . Since they are used as part of the cremation box 100 , the top 105 and bottom of the shipping container should not be damaged during opening and not discarded. This reduction of waste is environmentally friendly and fiscally responsible.
Step 2:
FIG. 10 is a top perspective view of a bound first portion and a liner of a cremation box, in accordance with an embodiment of the present invention. FIG. 10 shows a cremation box 100 bound to a liner 700 .
FIG. 11 is a side perspective view of the unbound first portion and liner of the cremation box of FIG. 10 after removal of the binding strap and separation of the cremation box 100 and the liner 700 , in accordance with an embodiment of the present invention.
FIG. 12 is a side perspective view of an open liner of the cremation box of FIGS. 10 and 11 , in accordance with an embodiment of the present invention. The liner 700 is generally used for larger-sized, heavier individuals needing extra support. If the deceased does indeed require the extra support, the can be used with the cremation box 100 . No additional materials, dowels, hinges, nails of any kind are needed to construct the cremation box.
Step 3:
FIG. 13 is a side perspective view of a partially open first portion of the cremation box of FIGS. 10 and 11 , in accordance with an embodiment of the present invention. In FIG. 13 , the cremation box 100 is shown after the side panels 120 and 130 are opened away from the cremation box body portion 110 .
FIG. 14 is a side perspective view of the first portion of the cremation box of FIG. 13 in a more open position, in accordance with an embodiment of the present invention. In FIG. 14 , the cremation box 100 is shown after the side panels 120 and 130 are fully opened away from the cremation box body portion 110 .
FIG. 15 is a side perspective view of the first portion of the cremation box of FIG. 14 in a fully open position, in accordance with an embodiment of the present invention. In FIG. 13 , the cremation box 100 is shown after the end panels 141 and 171 are opened away from the cremation box body portion 110 .
At this point, the cremation box 100 is open and ready for assembly.
Step 4:
FIG. 16 is a side perspective view of a top right end of the first portion of the cremation box of FIG. 15 in a partially assembled position, in accordance with an embodiment of the present invention.
In FIG. 16 , one side panel, for example, the right side panel 130 is folded upwardly to be positioned in a substantially perpendicular relationship to the cremation box body portion 110 . The top end panel 140 is next raised to be positioned in a substantially perpendicular relationship to the cremation box body portion 110 and the right side panel 130 and the top right inside side flap 152 is folded down against the outside of the right side panel 130 along crease 153 and the top right outside side flap 155 is folded toward and pushed through top right slot 133 .
Step 5:
FIG. 17 is an inside view of the top right end of the first portion of the cremation box of FIG. 15 in a fully assembled position, in accordance with an embodiment of the present invention. In FIG. 17 , the top right outside side flap 155 is fully pushed through top right slot 133 and folded back toward the top end panel 140 and tab 161 is inserted into slot 153 in top end panel 140 to lock the assembly into place and should now stand on their own and be joined into place without requiring any outside force or material. At this stage of the assembly, the right inside side flap hand hole 158 should not be pushed through the other hand holes, if the liner 700 will be used with the cremation box 100 .
FIG. 18 is an outside view of the top right end of the first portion of the cremation box of FIG. 15 in a fully assembled position, in accordance with an embodiment of the present invention.
Step 6:
FIG. 19 is a side perspective view of a top left end of the first portion of the cremation box of FIG. 15 in a partially assembled position, in accordance with an embodiment of the present invention. In FIG. 19 , the other side panel, for example, the left side panel 120 is folded upwardly to be positioned in a substantially perpendicular relationship to the cremation box body portion 110 . The top end panel 140 is already positioned in a substantially perpendicular relationship to the cremation box body portion 110 and the left side panel 120 , and the top left inside side flap 142 is folded down against the outside of the left side panel 120 along crease 143 and the top left outside side flap 145 is folded toward and pushed through top left slot 123 .
FIG. 20 is an outside view of the top left end of the first portion of the cremation box of FIG. 15 in a fully assembled position, in accordance with an embodiment of the present invention.
FIG. 21 is an inside view of the top left end of the first portion of the cremation box of FIG. 15 in a fully assembled position, in accordance with an embodiment of the present invention. In FIG. 21 , the top left outside side flap 145 is fully pushed through top left slot 123 and folded back toward the top end panel 140 and tab 151 is inserted into slot 144 in top end panel 140 to lock the assembly into place and should now stand on their own and be joined into place without requiring any outside force or material. At this stage of the assembly, the left inside side flap hand hole 148 should not be pushed through the other hand holes, if the liner 700 will be used with the cremation box 100 . Upon locking the left side panel into place, the cremation box 100 should stand on its own and, in some embodiments, should require no additional means in order to serve its ultimate purpose.
Step 7:
If applicable, the liner 700 is placed inside the cremation box 100 and locked into place by pushing the left inside side flap hand hole 148 and the right inside side flap hand hole 158 through the hand holes and toward the inside of the cremation box 100 . FIG. 22 is top perspective view of the partially assembled first portion of the cremation box 100 with the liner 700 being positioned inside the cremation box 100 , in accordance with an embodiment of the present invention.
FIG. 23 is top perspective view of the top end of the partially assembled first portion of the cremation box of FIG. 22 with the liner positioned inside and locked inside the cremation box 100 , in accordance with an embodiment of the present invention.
If no liner is required, the top end of box is locked into place by pushing the left inside side flap hand hole 148 and the right inside side flap hand hole 158 through the slots designated for hand holes. This provides an extra level of support for the cremation box.
Step 8:
FIG. 24 is top perspective view of the partially assembled first portion of the cremation box without the liner positioned inside and ready for body placement, in accordance with another embodiment of the present invention.
Step 9:
In order to close the bottom of the box, for example, after the body of the deceased is placed in the unit, the bottom right and left flaps 172 , 176 are folded back toward the bottom center panel 171 and the bottom end panel 170 is raised up toward the bottom edges of the side panels and the flaps are placed on the inside of cremation box 100 side panels 120 , 130 . FIG. 25 is a top perspective view of the bottom end of the partially assembled first portion of the cremation box without the liner positioned inside, in accordance with another embodiment of the present invention. The smaller left and right bottom tabs 174 , 179 should align directly with the bottom left and bottom right slots, respectively, on the side panels. FIG. 26 is a top perspective view of the bottom end of the partially assembled first portion of the cremation box of FIG. 25 with the bottom end partially positioned inside the side walls, in accordance with another embodiment of the present invention. FIG. 27 is a top perspective view of the bottom end of the partially assembled first portion of the cremation box of FIG. 26 with the bottom end partially positioned inside the side walls, in accordance with another embodiment of the present invention.
Step 10:
FIG. 28 is a top perspective view of the bottom end of the fully assembled first portion of the cremation box, in accordance with another embodiment of the present invention.
FIG. 29 is a top perspective view of the left bottom end of the fully assembled first portion of the cremation box, in accordance with another embodiment of the present invention. FIG. 30 is a top perspective view of the right bottom end of the fully assembled first portion of the cremation box, in accordance with another embodiment of the present invention. To fasten the bottom panel into place, after extending the bottom panel up, slide the bottom flaps 174 , 179 through the slots located on the side panels. Extend each flap completely through the associated side panel in order for the bottom panel to be flush with the side panels. Once again, the hand hole flaps 122 , 132 are pushed into the inside of the cremation box 100 to secure the bottom panel to the sides 120 , 130 . The tabs 174 , 179 may be folded back toward the bottom end of the creation box 100 to further secure them in place. As a result, the walls are locked into place with no need for additional materials.
The cremation box 100 assembly is now complete ready for the top 300 and final destination.
Step 11:
FIG. 31 is a top perspective view of the fully assembled first portion of the cremation box without a liner, in accordance with another embodiment of the present invention. FIG. 32 is a top perspective view of the fully assembled first portion of the cremation box with a liner, in accordance with another embodiment of the present invention. FIG. 33 is a top perspective view of one half of a container in which a cremation box is shipped, in accordance with an embodiment of the present invention. FIG. 34 is a top perspective view of the bottom end of the fully assembled cremation box, in accordance with another embodiment of the present invention. Utilizing the top piece of the original shipping container, which was set aside as required by Step 1, place this piece on top of the newly constructed unit. The snug fit will ease any logistical questions and answer any needs for straps, tape or other adhesive materials. FIG. 35 is a top perspective view of the top end of the fully assembled cremation box, in accordance with another embodiment of the present invention.
The cremation box is now complete and ready for combustion.
While the invention has been described in conjunction with a number of embodiments, it is evident that many alternatives, modifications and variations would be or are apparent to those of ordinary skill in the applicable arts. Accordingly, Applicants intend to embrace all such alternatives, modifications, equivalents and variations that are within the spirit and scope of the appended claims. | A corrugated fiberboard box assembly including a first portion including a bottom section having a pair of opposite long edges and a pair of opposite short edges with all edges being bounded by a plurality of creases, a pair of opposing side panels running along and connected to the pair of opposite long edges by two of the plurality of creases, and a pair of opposing end panels running along and connected to the pair of opposite short edges by another two of the plurality creases. The first portion being foldable to form a rectangular box with the bottom section on the bottom and the side panels and end panels both extending substantially perpendicularly upwardly away from the bottom to form side walls of the box. The box further includes a separate inner liner configured to fit within an inside of the side walls and a top configured to fit over the tops of the side walls. | 0 |
[0001] This application is a Continuation application of Ser. No. 10/679,849, filed on Oct. 6, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to building construction. Particularly, the present invention relates to a modular building assembly. More particularly, the present invention relates to a monolithic post and beam reinforced concrete structure using a system of permanent forms.
[0004] 2. Description of the Prior Art
[0005] A common form of modern building construction is steel frame construction. Steel frame construction is relatively expensive due to the expense of the structural steel and the skilled labor involved. A less expensive method of construction is that of reinforced concrete construction. All reinforced building construction requires forms to mold the concrete into the different structural shapes required to carry the building loads. The forms create the voids where steel reinforcing rods are placed followed by filling with concrete in its fluid state, which is poured creating the structural components such as columns, walls, beams, floors, and roof slabs.
[0006] There are two distinct ways of building reinforced concrete structures with numerous combinations of both. There is conventional form making at the job site. In such construction, concrete forms are erected at the site, steel reinforcement rods placed in the forms, and concrete poured into the forms to create walls, load bearing columns, and floors of reinforced concrete. Upon curing of the concrete, interior and exterior facing panels are then secured to the outside surfaces, especially walls and floors, resulting in a reinforced concrete structure. This method still requires extensive amounts of on-site labor, which can be quite expensive when compared to factory labor.
[0007] A second way to build reinforced concrete structures is to prefabricate the components in a factory. Fabrication of construction components can be carried out at lower cost in a factory setting. This type of construction method is known as precast concrete structural components. This is accomplished by the manufacture of all or part of a structure at an off-site factory and then transporting the components to the site for assembly. The following prior art addresses various systems and methods for building structures utilizing pre-cast concrete structures.
[0008] U.S. Pat. No. 1,469,955 (1923, Reilly) discloses using a plurality of wall blocks having recesses in their ends designed to form spaces when the blocks are set together for receiving concrete to form a plurality of columns. Some of the wall blocks have outer walls projected above the inner walls to form a seat on the inner wall for receiving a floor comprised of a plurality of tiles, slabs and a concrete floor interlocked with the slabs.
[0009] U.S. Pat. No. 1,757,077 (1930, Eiserloh) discloses building construction that includes a series of duplicate wall sections fashioned with staggered vertically extending openings. End edges of the tiles abut and middle portions therebetween are recessed. The opposed recesses define a duct or well and corner sections are L-shaped. A trough is permanently set along the tops of the wall sections. The troughs are provided with a series of definitely spaced apertures. Preformed beams are shaped to fit in the apertures. The beams support flooring and extend across parallel walls with their ends occupying a pair of aligned apertures.
[0010] U.S. Pat. No. 3,712,008 (1973, Georgiev et al.) discloses a modular building construction system in which prefabricated modules are supported on a separate framework, the individual members of the framework also being modular and prefabricated. The framework also defines vertical and horizontal passages required for utilities, corridors, elevators, etc. The prefabricated modules are generally constructed off the site and assembled together on the job during erection of the building.
[0011] U.S. Pat. No. 3,300,943 (1967, Owens) discloses a tilt-up building system for producing a monolithic construction. Prefabricated reinforced wall panels are tilted-up or raised to vertical positions of support upon vertical spacer members positioned upon a continuous footing at longitudinally spaced intervals. There are gaps between the panels and footings where reinforcing rods are positioned and secured. The gaps are then formed in to define voids and concrete is poured in to fill the void forming a reinforced concrete belt between the panels and footings. The forms are then removed from the panels and footings.
[0012] U.S. Pat. No. 4,081,935 (1978, Wise) discloses a building structure in which precast columns and beam and deck members are used. Upper columns are supported in spaced apart relationship to lower columns by pairs of rods extending from each column and clamped together. Topping concrete is poured to lock the members together into a unitary structure.
[0013] U.S. Pat. No. 4,127,971 (1978 Rojo, Jr.) discloses a building constructed of precast L-shaped concrete units. The precast L-shaped concrete units are obtained by utilizing reusable mold forms and casting the units vertically on a wheeled base between separable vertical mold forms. The concrete unit is transported on the wheeled base from between the separated molds to complete the curing. The building is erected on a concrete slab foundation using a plurality of precast concrete units in the form of L-shaped walls. H-beams are placed across the tops of the walls and filled with concrete to serve as a support and anchoring means for precast concrete roof slabs.
[0014] U.S. Pat. No. 4,343,125 (1982 Shubow) discloses a building block module and method of construction. Reinforced concrete building block modules are assembled into load bearing walls. The modules are configured as hollow rectangles having beveled corners with reinforcing rods extending through the side of the rectangle into the beveled spaces. The spaces are filled with concrete to form solid columns of reinforced concrete construction through which continuous reinforcing extends. The floors can be either poured or precast floor sections. The modules are erected into vertical walls that are integrated into a wall-floor system, whereby the walls support the building floors.
[0015] A disadvantage of the prior art regarding precast concrete structural components is that the structural systems depend on field point connections (e.g., welded steel plates, anchor bolts, post-tensioned cables, etc.). Building stresses concentrate at these field point connections, requiring redundancy in their design to avoid failure of the whole system in the event one connection fails. The design redundancy increases the use of materials and requires highly skilled labor, supervision and costly quality controls at the building site. The increased weight and size of these components requires costly transportation and expensive hoisting equipment. Another problem with these systems is sealing and waterproofing their joints, which is very costly and has to be replaced and maintained every 5 to 10 years increasing greatly the cost of the building.
[0016] A disadvantage of the prior art regarding conventional form making at the job site is that the construction methods are time consuming, require intensive skilled labor, exposure to weather conditions that affect scheduling and quality control of the forms, limited dimensional accuracy and wasteful in material consumption. Also, once the forms are stripped, the unfinished reinforced concrete surfaces require plastering or the use of other finishes like brick, tiles, stone, etc., unless expensive liners are used.
[0017] Therefore, what is needed is a reinforced concrete structure that provides for reductions in both the volume of concrete used and in the overall weight of the building. What is further needed is a reinforced concrete structure that provides for reductions in both steel reinforcement materials and in the labor for steel reinforcement. What is also needed is a reinforced concrete structure that provides reductions in both shoring and footing sizes. What is yet further needed is a reinforced concrete structure that provides reductions in forming (creating concrete forms), form removal and overall construction time. What is still further needed is a system that incurs a reduced transportation cost due to a reduction in weight of the precast concrete components. What is also needed is a reinforced concrete structure that provides for a reduction in capital costs, which are tied up in temporary forms, their installation, removal, care and storage. Finally, what is needed is a building of increased quality.
SUMMARY OF THE INVENTION
[0018] It is an object of the present invention to provide a modular system of permanent forms for constructing reinforced concrete buildings where the volume of concrete used and the overall weight of the building are reduced. It is another object of the present invention to provide for a reduction in steel reinforcement materials and in the labor required to assemble the steel reinforcement. It is a further object of the present invention to provide for a reduction in shoring and in footing sizes. It is still another object of the present invention to provide for a reduction of time required in forming (making concrete forms), form removal and overall construction. It is yet another object of the present invention to reduce transportation costs by reducing the weight of the precast concrete components. It is another object is to provide for a reduction in capital costs, which are tied up in temporary forms, their installation, removal, care and storage. Finally, it is an object of the present invention to increase the quality of the building.
[0019] The present invention achieves these and other objectives (1) by providing a relatively lightweight, prefabricated building component that is erected on site and reinforced with poured concrete and (2) by providing a prefabricated construction system for reinforced concrete buildings. The system employs a variety of precast glass-fiber reinforced concrete (GRC) components such as walls, flooring, roofs, columns, beams, etc. The system is amenable for use in a variety of construction projects, including but not limited to retaining walls, above grade walls, and reinforced concrete buildings. The system is assembled over footings and/or a foundation. For reinforced concrete buildings, a foundation is made up of a concrete floor slab with the periphery depressed or stepped to receive precast GRC wall panels. The depressed or stepped periphery minimizes mechanically the infiltration of water into the structure.
[0020] The GRC components are made of a concrete material that is made up of a slurry of cement and sand with AR fibers, which give this matrix a high flexural strength. The high flexural strength of the material allows it to be used for secondary structural loads with a typical thickness of about ⅜ inches and weighing typically 4 to 5 pounds per square foot. Because of the material's high density, forms made with the typical thickness disclosed previously are impervious. Further the material's high density also allows for a reduction in the thickness of the concrete required for the protection of steel rods of the primary structural components cast on site. The relative thinness of the GRC coupled with its strength allows for the formation of very strong and lightweight precast forms that reduce the amount of the temporary shoring compared to conventional precast concrete forming techniques. In addition, the forms are fireproof. With respect to GRC components used for retaining walls, above grade walls, support beams, support columns, and the like, the lightweight components are assembled on site and serve as the permanent forms for receiving poured concrete.
[0021] For use in constructing buildings, the present invention includes pre-cast GRC wall components or panels having a top and bottom perimeter, a first and second vertical perimeter, and includes either a single skin wall or a double skin wall. The wall panel top perimeter is typically U-shaped for receiving steel reinforcement and poured concrete. The wall panel top perimeter can be configured in different shapes other than U-shaped and still be suitable for its intended purpose so long as the top perimeter is open. The top perimeter may optionally have a top perimeter portion that mates with a bottom perimeter mating portion of the bottom perimeter.
[0022] The first and second vertical perimeters typically have flanges that project out of the plane of the inside face of the wall panel such that, when assembled with other wall panels, form a space or void between adjacent wall panels that is in communication with the U-shaped top perimeter of the wall panel. The wall panels have in their exterior vertical perimeters a wall panel mating connection that mates adjacent wall panels together. The wall panel bottom perimeter optionally has a lip on the outside face to overlap the exterior face of the top perimeter of another wall panel or the foundation floor slab to minimize, mechanically, water penetration into the building. Column steel reinforcements are placed into the voids and a GRC enclosing panel is installed between flanges of adjacent wall components enclosing the voids, which are to receive the concrete to form the building support columns. The wall components/panels come in a variety of shapes and sizes, have numerous configurations involving the location of precast openings for doors, windows, air conditioning/heating components, etc., or may be devoid of precast openings.
[0023] After the concrete has been poured into the column voids to stabilize the walls, steel reinforcements for the beams are placed into the U-shaped top perimeter of the pre-cast GRC wall panels. Pre-cast GRC floor or roof panels are then placed on top of the interior side of the top perimeter of the wall panels, spanning the interior sides of the wall panels, forming an enclosed room space. Pre-cast GRC floor panels of the present invention typically have a width of 8 feet with two U-shaped ribs between typically three hollow core regions. The U-shaped ribs may be of varying width and height depending on the loads and spans and are spaced 2 feet 8 inches on center. The floor panel preferably includes L-shaped edges to accommodate easier fitting and assembly. The pre-cast GRC floor panels can vary in length up to 50 feet. The hollow core regions are about 7 inches high by 26 inches wide allowing for the installation of electrical wiring, piping, ducts, etc. By using GRC components, the present invention's floor panel typically weighs an average of 12 pounds. The prior art has a hollow core of about 4 inches and weighs about 52 pounds.
[0024] Steel reinforcements are placed in the U-shaped ribs. Concrete is then poured over the U-shaped ribs and beam voids to create a monolithic structure bounding integrally the walls with the floor. The pre-cast GRC floor panels of the present invention are used as permanent formwork for floor slabs and roofs on top of which a concrete toping is poured in place especially when the concrete is poured over the U-shaped ribs and beam voids. Depending on the building configuration, additional floors can be constructed in the same manner as the ground floor. In multistory buildings, finishing work to the interior of the building can be accomplished while additional floors are constructed. Interior wall panels, if required, are attached to the precast panel. Doors and windows as well as the wiring for electrical service can also be installed.
[0025] The present invention, which uses pre-cast GRC components as permanent forms for casting reinforced concrete buildings, retaining walls, etc., on site, has several distinct advantages over the prior art. Use of the present invention system particularly for building construction provides (1) a reduction in the volume of concrete by about 20 to about 30%, (2) a reduction in the use of steel reinforcement materials by about 10% to about 15%, (3) a reduction in labor for installation of the steel reinforcement by about 30% to about 45%, (4) a reduction in shoring by about 20% to about 30%, (5) a reduction in the overall weight of the building by about 20%, (6) a reduction in footing sizes and steel reinforcement by about 10% to about 20% (depending on building height and weight), (7) a reduction in labor time of about 20% to about 40% for formwork and form removal, and (8) a reduction in the amount of working capital tied up in temporary forms, their installation, remove, care, and storage.
[0026] All of the present invention's advantages, which are only traditionally attributed to steel structures, become part of the present invention and is better than steel because the components of the present invention do not require fireproofing and do not corrode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a perspective view of one embodiment of a foundation of the present invention.
[0028] FIG. 2 is a perspective view of the present invention showing erection of the ground floor walls.
[0029] FIG. 3 is a perspective view of the present invention showing the formation of the support columns for the building.
[0030] FIG. 4 is a perspective view of the present invention showing placement of the steel reinforcements for the beams and installation of the pre-cast floor or roof GRC panels.
[0031] FIG. 5 is a perspective view of the present invention showing placement of steel reinforcements on the pre-cast GRC floor panels and the pouring of concrete to create a monolithic structure.
[0032] FIG. 6 is a perspective view of the present invention showing construction of an additional floor in the same manner as the ground floor.
[0033] FIG. 7 is a perspective view of the present invention showing installation of a GRC roof panel.
[0034] FIG. 8 is a cross-sectional, perspective view of the present invention showing finishing work being done to the interior of the structure.
[0035] FIG. 9 is a cross-sectional view of a side of the present invention showing the foundation, floor slab, ground floor and additional floor GRC wall panels, and a GRC roof panel.
[0036] FIG. 10 is a perspective view of a pre-cast GRC wall panel showing the mating ends of a pre-cast GRC wall panel forming a void where the support columns are formed.
[0037] FIGS. 11A and 11B are cross-sectional side and top views, respectively, of another embodiment of a GRC wall panel of the present invention.
[0038] FIGS. 12A and 12B are cross-sectional end and side views of another embodiment of a floor/roof GRC panel.
[0039] FIG. 13 is a top cutaway view of a permanent formwork column.
[0040] FIG. 14 are plan views of the “U” shaped beam form.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] The preferred embodiment(s) of the present invention is illustrated in FIGS. 1-14 . FIG. 1 illustrates a foundation 10 made up of a concrete floor slab 12 supported by a plurality of building footings below ground and represented by reference 15 . The periphery 14 of concrete floor slab 12 is depressed or stepped to receive one or more pre-cast GRC wall panels (not shown). The depressed/stepped periphery 14 is designed to minimize mechanically the infiltration of water into the structure. Steel dowels 16 are installed at locations where building support columns will be formed. Steel dowels 16 are installed using a template to insure their precise location and arrangement.
[0042] FIG. 2 illustrates assembly of the ground floor of a building using the construction system of the present invention. A plurality of pre-cast GRC wall panel 18 is assembled over foundation 10 . Pre-cast GRC wall panel 18 includes a top perimeter 36 , a first and second vertical perimeter 28 and 30 , a bottom perimeter 26 , and an exterior and interior side. The wall panel top perimeter 36 is preferably U-shaped creating a void or channel 37 . The U-shaped channel is typically 6 inches deep by 12 inches wide. A person of ordinary skill in the art will realize that the wall panel top perimeter 36 may be shaped other than U-shaped and still be suitable for its intended purpose within the system of the present invention.
[0043] First and second vertical perimeters 28 , 30 have flanges 48 that project out of the plane of the inside surface 22 of wall panel 18 . When two wall panels 18 are assembled adjacent each other, flanges 48 form a column void 49 where the building support columns are formed. The voids are typically 6 inches by 24 inches. The wall panel bottom perimeter 26 has preferably a bottom surface 27 and a lip 27 ′ on the outside face to overlap exterior vertical edge of floor slab 12 to mechanically prevent water filtration into the building. Pre-cast GRC wall panel 18 may have a variety of shapes and sizes, have numerous different configurations involving the location of precast openings for doors, windows, etc. or may be devoid of precast openings. As illustrated, a plurality of pre-cast GRC wall panels 18 are moved to the building site and then erected in place. Column steel reinforcement 50 , which is an assembly of concrete reinforcing rods and/or screens, is positioned in the voids created by flanges 48 of adjacent wall panels 18 .
[0044] FIG. 3 illustrates finishing of the erection of the precast GRC wall panels 18 on the ground floor. A GRC form 47 is installed to enclose column void 49 between two precast GRC wall panels 18 . Fluid concrete for the columns is then poured into column void 49 , which contains column reinforcement 50 , forming reinforced support columns and temporarily stabilizing all of the walls.
[0045] Turning now to FIG. 4 , continued construction of a building according to the teachings of the present invention is illustrated. Steel reinforcement 52 is placed into top perimeter channel 37 of each wall panel 18 once all the columns have been filled with the fluid concrete. Pre-cast floor or roof GRC panels 58 are positioned on top of the interior side 36 ′ of the top perimeter 36 of wall panels 18 , spanning the interior sides of the wall panels forming an enclosed room area.
[0046] FIG. 5 shows all of the pre-cast floor or roof GRC panels 58 installed over wall panels 18 . Steel reinforcement 61 is placed into the floor voids 59 of the permanent GRC floor or roof panels 58 . Fluid concrete 60 is then poured over the GRC floor/roof panels 58 and the top perimeter channel 37 to create a monolithic structure bounding and supporting integrally the walls with the floor/roof, thereby forming floor slab 59 ′.
[0047] Tuning now to FIG. 6 , continued construction of a second story/level of a building according to the teachings of the present invention is illustrated. A plurality of wall panels 18 is assembled over the perimeter of the floor slab 59 ′ to add an additional floor to the building. The assembly of wall panels 18 is performed in the same manner as previously explained by forming the support columns, placing steel reinforcement within the column voids and pouring the liquid concrete into the column voids. If a shaped roof panel is intended to be used to cover the second floor, then typically steel reinforcement is place into the top perimeter channels 37 and fluid concrete is poured into top perimeter channels 37 before the roof panels are attached.
[0048] FIG. 7 illustrates the assembly of a shaped GRC roof to the structure. After the top perimeter channels 37 have received the fluid concrete, one or more shaped GRC panels 62 are installed on top of the pre-cast GRC wall panel 18 . Although an arched or vault roof is illustrated, roof panels may have any shape.
[0049] FIG. 8 illustrates a building construction where the wall panels 18 are single skin wall panels. In such a construction, interior wall panels 70 may be attached to wall panel 18 forming a wall space 71 . Doors 72 and windows 74 can now be installed. Preferably, the door frames and window frames are installed at the plant where the pre-cast GRC wall panels 18 are manufactured and the doors and windows are installed on-site. The windows may be installed in the wall panels 18 while at ground level before the wall panels 18 are assembled to the foundation 10 or floor slab 59 ′. Wiring 76 for electrical service can also be installed within wall space 71 as well as plumbing where kitchens, bathrooms, laundry rooms and the like are intended. Preferably, electrical conduits and boxes are factory installed for cost savings and ease of use at the building site. The roof panel connection 78 with the top perimeter 36 of wall 18 can also be adjusted at this time.
[0050] FIG. 9 illustrates a cross-sectional side view of the construction system. The floor slab 12 is shown with a depressed/stepped perimeter 14 upon which is positioned a wall panel 18 . The depressed/stepped perimeter 14 in conjunction with wall bottom surface 27 prevents water infiltration. Temporary connection 34 is optionally used to temporarily stabilize wall panel 18 until concrete beam and floor slab topping 60 is cast on site. Wall panel 18 has an exterior and interior side 20 , 22 , respectively, a lip 27 ′ on the exterior bottom of wall panel 18 to mechanically prevent water infiltration, and the U-shaped structure 24 which forms the top perimeter channel 37 where the steel reinforcement is installed and the concrete is poured forming a reinforced beam. The GRC vault roof panel 62 is shown as a two skin panel with factory installed rigid insulation. Roof panel 62 may also include factory installed electrical boxes and solar panels.
[0051] FIG. 10 illustrates an enlarged perspective view of the wall panel of the present invention. In this view, the top half of wall panel 18 is separated from the bottom half in order to illustrate one useful embodiment of the flanges and GRC form panel. The GRC pre-cast wall panel 18 has an exterior side 20 and an interior side 22 . In this embodiment, the wall panels 18 have an overlapping connection 46 that mates adjacent wall panels together. The top perimeter 36 of wall panel 18 has a U-shaped top structure 24 that creates a void, channel or beam form 37 . Also shown is the interior side of the flanges 48 with rough finish for adherence with poured on site concrete. The wall panels have vertical perimeter flanges 48 with vertical flange edges 42 and 44 that mate with the vertical edges of GRC form 47 creating column void 49 where column steel reinforcements are positioned before fluid concrete is poured to form a support column.
[0052] FIGS. 11A and 11B illustrate cross-sectional views of another embodiment of a wall panel. In this configuration, wall panel 18 has a double skin of GRC material with an air space 19 that serves as air insulation. To create an active air insulation, an opening (not shown) in the bottom and top of the wall panel 18 provides for a thermo siphon, which causes air in panel air space 19 to flow up to cool the inner surface of the wall in summer. In winter, the openings are closed to minimize cooling of the inner surface. Conventional insulation may optionally be installed in wall panel 18 . In addition, top wall perimeter 36 has mating joint 39 that mates with bottom wall surface 27 .
[0053] FIGS. 12A and 12B illustrate end and side plan views of a pre-cast GRC floor panel 58 . Pre-cast GRC floor panel 58 typically has a width of 8 feet with two U-shaped ribs 58 a between typically three hollow core regions 58 b . U-shaped ribs 58 a may be of varying width and height depending on the loads and spans and are spaced 2 feet 8 inches on center. Floor panel 58 preferably includes L-shaped edges 58 c to accommodate easier fitting and assembly. Pre-cast GRC floor panel 58 can vary in length up to 50 feet. Hollow core regions 58 b are about 7 inches high by 26 inches wide allowing for the installation of electrical wiring, piping, ducts, etc. By using GRC components of the present invention, floor panel 58 typically weighs an average of 12 pounds. The prior art has a hollow core of about 4 inches and weighs about 52 pounds. As previously disclosed, the pre-cast GRC floor panels of the present invention are used as permanent formwork for floor slabs and roofs on top of which a concrete toping is poured in place.
[0054] FIG. 13 illustrates a cross-sectional view of a pre-cast GRC column 90 using the permanent formwork of the present invention. Pre-cast GRC column 90 includes a first column form 92 , a second column form 94 , a connecting plate 96 , and reinforcing framework 98 . Preferably, the components of pre-cast GRC column 90 are shipped to the job site for assembly. First column form 92 and second column form 94 surrounds reinforcing framework 98 and are held in position by connecting plate 96 . Once assembled and positioned into place, pre-cast GRC column 90 is filled with fluid concrete.
[0055] FIG. 14 illustrates a cross-sectional view of a pre-cast GRC beam 110 using the permanent formwork of the present invention. Beam 110 is typically U-shaped with an open top 112 . Steel reinforcement rods 114 are positioned within beam cavity 111 of beam 110 and the fluid concrete is then poured into beam cavity 111 . GRC beam 110 may be straight, curved, arched, or irregular shaped as long as top 112 is open.
[0056] It is important to note that that the permanent GRC form system of the present invention provides for a strong, yet lightweight, prefabricated form that reduces the amount of temporary shoring required compared with conventional forming techniques. The permanent GRC form system of the present invention provides for an unlimited use where concrete forming is required. For example, a retaining wall permanent form may be made with varying wall thickness, depending on the wall height and structural soil conditions. The retaining wall permanent form would include rectangular voids of varying dimensions that are space on 2 feet eight inch centers with U-shaped vertical edges and a U-shaped top edge. Reinforcing steel similar to that previously described is placed within the voids and fluid concrete is poured into the voids creating a continuous post and beam reinforced concrete retaining wall.
[0057] With regard to the wall panels, once the concrete is poured on site, the structural connection between the wall panels also becomes the structural connection between panels without requiring any connectors. In addition, this method provides a waterproof joint without the need for sealants.
[0058] Although a basic flat floor and/or flat roof slabs were described, it should be noted that these GRC components may be constructed as a sandwich panel having a bottom (i.e., ceiling) finished surface and a top surface the two U-shaped ribs previous disclosed. The floor/roof panels may include electrical and mechanical components factory installed.
[0059] The use and installation of the present invention reduces labor by about 40% to about 60%. This is achieved because skilled labor is not required for installation since only the forms need to be properly positioned, unlike conventional techniques that require point connections to weld or bolt, or cable post tensioning, etc. Only a minimal amount of bracing (about 70% less than is used with standard pre-cast reinforced concrete panel installation) is required to hold the wall panels or column forms in place temporarily while the steel reinforcement is placed in the voids and the concrete poured. Further, the next day floor or roof panels are positioned and minimal shoring is required (about 70% less than conventional shoring). Because no forms need to be removed, these operations can be repeated the next day while the concrete of the previous day cures. Under ideal conditions, the present invention enables a full building floor to be cast/erected in two days. This system makes it competitive with steel structures with regard to time, especially since steel structures later require fireproofing and the enclosing of the exterior walls with other panels.
[0060] Due to the lightness of GRC material, a single skin, one-half inch thick wall panel with 5 inch by 12 inch top horizontal and vertical channels in its perimeter averages 6 pounds per square foot against 50 pounds per square foot for a 4-inch pre-cast reinforced concrete panel. For a 6-inch thick hollow double skin panel, with the same channels as the single skin panel, its average weight is 12 pounds per square foot against 75 pounds per square foot for a 6-inch thick pre-cast reinforced concrete panel. The GRC panel weighs about 6 times less than the conventional pre-cast panel. Translating this into transportation costs, a typical 8 foot wide×45 foot long trailer platform with a net maximum load of 60,000 pounds is cable of transporting 5,000 square feet of 6-inch thick GRC panels while it is only capable of transporting 800 square feet of 6-inch thick conventional pre-cast concrete panels, 6.25 times less.
[0061] This weight difference is also reflected in the hoisting capacity requirements, fuel consumption, ease of handling and installation and the total weight of the building which in turn reduces the size of all the structural members including foundations. This is a very relevant safety fact in earthquake zones, where the lighter the building the better its performance.
[0062] In terms of construction time, this is reduced as much as 40% depending on the building type, size and site conditions and design. In high rise construction, computer simulations have shown that a 55% time reduction may be achieved by enclosing simultaneously the exterior walls of the building with the construction of its supporting structure since interior work may be performed two or three floors below the one being installed. Following this construction protocol reduces dramatically the time required by the typical linear sequence of conventional construction, both in reinforced concrete and steel structures. This reduction in time reduces the builders overhead, which reduces the interim financing costs and the capital required for a given project.
[0063] The buildings built with the prefab permanent form system of the present invention achieves a better building by transferring the most difficult activities within the controlled environment of a manufacturing plant. All the subsystems are installed in the prefab permanent forms increasing the quality of the finishes and avoiding much of the typically uncontrolled environment of a building site. For example, the installation of the windows in a high rise building, if installed in the factory or in the ground floor of the site prior to hoisting the panel accomplishes in one operation the hoisting of the panel and the window which regularly is done separately. It is more efficient since all the window installers are in one place, which eliminates the time spent going up and down the building. Further, working in the factory or in the ground floor of the building site is safer than installing and caulking the windows from the outside of the building, which is done up in the air and requiring the use of expensive scaffolding or motorized equipment. The quality control of the window assembly is made in the factory or the ground floor of the site prior to erecting the panel, thus avoiding costly repairs of the windows once up on the building.
[0064] Although the preferred embodiments of the present invention have been described herein, the above description is merely illustrative. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims. | A lightweight, permanent form system includes a plurality of GRC forms having a one or more open cavities that form a continuous interconnecting void within and throughout the plurality of GRC forms when assembled on-site to form a permanent form assembly. The continuous interconnecting void is configured to receive pourable concrete which creates a support structure for the plurality of GRC forms when the concrete hardens and to permanently join the plurality of GRC forms together. | 4 |
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