description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
BACKGROUND
Electrically powered bicycles, or eBikes, use electric power to assist a user in pedaling a bicycle (a so-called “power-assist” function) or may use allow operation of the eBike solely with an electric motor. In any case, e-bikes generally include batteries that must be charged to operate. Charging typically requires plugging the eBike into an electrical outlet. Some eBikes include generators that allow the eBikes to be recharged, for example, during braking operations. However, such mechanisms do not typically generate significant amounts of power. Accordingly, improved mechanisms for charging eBikes are needed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of an exemplary eBike towing and charging system.
FIG. 2 is a perspective view of an exemplary towing device.
FIG. 3 is another perspective view of the exemplary towing device of FIG. 2 , showing a clamp lever in a relaxed position.
FIG. 4 is another perspective view of the exemplary towing device of FIG. 2 , showing the clamp lever in a tightened position.
FIG. 5 is an exploded view of the exemplary towing device of FIG. 2 .
FIG. 6 is a perspective view of a skewer assembly.
FIG. 7 is a view of the skewer assembly end cap along the cross-section A-A of FIG. 6 .
FIG. 8 is a perspective view of a clamp lever.
DETAILED DESCRIPTION
In the Figures, like numerals indicate like parts throughout the several views. FIG. 1 illustrates a towing system 11 including a towing device 10 attached to a vehicle 12 for towing an electrically powered or power-assisted bicycle, i.e., eBike 14 . The eBike 14 includes a rear wheel 13 and a motor to drive the rear wheel 13 when the eBike 14 is operating in a power-assist mode.
When the eBike 14 is towed behind the vehicle 12 , the motor may be used to generate electrical power based on the rotation of the rear wheel 13 of the eBike 14 when the eBike 14 is being towed. The eBike 14 may be programmed in a charging mode. In the charging mode, the motor may be configured to generate electrical power when driven by rotation of the rear wheel 13 . The rear wheel 13 may rotate due to frictional contact with the road surface during towing. The power generated by the motor may be stored in a battery of the eBike 14 . In this manner, the towing device 10 may facilitate charging of the eBike 14 while the eBike 14 is being towed by the vehicle 12 Moreover, as described below, the towing device 10 allows the eBike 14 to be towed behind the vehicle 12 in a manner that accommodates vertical movement of the vehicle 12 , e.g., caused by bumps and the like in a roadway.
With reference to FIGS. 2-5 , the towing device 10 includes a hitch connector arm 16 that is generally dimensioned, and provided with an opening 17 , for connection to a standard vehicle trailer hitch in a conventional manner, e.g., the opening 17 may receive a lock pin or the like (not shown).
The connector arm 16 has a supporting arm 18 mounted thereon, e.g., via welds, bolts, or some other conventional attachment mechanism. The supporting arm 18 generally extends upward at a right or obtuse angle from the connecting arm 16 . A clamp assembly 20 is mounted on an end of the supporting arm 18 that is distal with respect to the connecting arm 16 . For example, a substantially cylindrical outer sleeve 22 may be welded or the like to the distal end of the supporting arm 18 .
As best seen in FIG. 5 , the clamp assembly 20 includes a skewer assembly 41 including an end cap 46 on a proximal end and a skewer 48 extending from the end cap 46 . The skewer 48 is a cylindrical rod providing a support structure for the clamp assembly 20 and includes a threaded end 49 , at an end distal from the end cap 46 .
A lever 24 is supported on the skewer assembly 41 on the proximal end adjacent to the end cap 46 . An opening 29 of the lever 24 receives the end cap 46 .
A hollow axle 28 forms a substantially cylindrical inner region 34 for receiving the skewer 48 of the skewer assembly 41 . The hollow axle 28 is positioned within a substantially cylindrical interior of a substantially cylindrical inner sleeve 26 , the inner sleeve 26 in turn being inserted in the substantially cylindrical interior of the outer sleeve 22 . The inner sleeve 26 includes reduced diameter portions 30 that are substantially cylindrical. The hollow axle 28 has a generally U-shaped outer surface at fork receiving portions 32 , i.e., the portions or ends 32 are shaped to receive a fork of a bicycle such as the eBike 14 . A portion of the hollow axle 28 within the sleeve 26 may have a generally circular, rectangular, or other cross-section.
Each of a pair of bearings 36 are generally cylindrical, having inner surfaces dimensioned to fit over a central portion 27 of the inner sleeve 26 . Reduced diameter portions of the inner sleeve 26 are provided at respective first and second ends of the central portion 27 . The bearings 36 further have an outer circumference dimensioned to fit within an interior surface of the outer sleeve 22 . The bearings 36 are held in place by lock collars 38 , a position of each of the collars 38 on a reduced diameter portion 30 of the inner sleeve 26 being maintained when a set screw 40 , threadably inserted into an opening of the collar 38 , is tightened. Further mounted on each of the reduced diameter portions 30 is a spacer 42 , the spacer 42 being provided to appropriately dimension a slot 45 configured to receive a bicycle fork piece. The bearings 36 allow the inner sleeve 26 to rotate with respect to the outer sleeve 22 , which as noted above, is fixedly mounted on the arm 18 .
As is best seen in FIGS. 3 and 4 , a first slot 45 is provided between one of the spacers 42 and a side of the lever 24 . A second slot 45 is provided between an adjustor cap 44 and a second one of the spacers 42 at an opposite end of the inner sleeve 26 and hollow axle 28 from the first spacer 42 and the first slot 45 . The adjustor cap 44 is screwed onto the threaded end 49 of the skewer 48 . As described further below, the skewer 48 is slidable along a common longitudinal axis of the skewer 48 , hollow axle 28 and the sleeves 22 , 26 , thereby facilitating narrowing of slots 45 when the lever 24 is moved from an open position to a closed position.
As can be seen by a comparison of FIG. 3 and FIG. 4 , the lever 24 may be moved from an open, or relaxed, position ( FIG. 3 ) to a closed, or tightened, position ( FIG. 4 ). As described further below, the lever 24 when moved to the tightened position, is urged toward an opposing spacer 42 , thereby reducing a width of the slot 45 formed by the spacer 42 and washer 43 . At the same time, the lever 24 is configured, when moved to the tightened position, to urge the skewer 48 in an axial direction toward the proximal end cap 46 such that the slot 45 formed by the adjustor cap 44 and second spacer 42 is made narrower. Further, the adjustor cap 44 may be moved to adjust a width of the slot 45 , typically when the lever 24 is in the relaxed position, by turning the cap 44 on the threaded end 49 of the skewer 48 . Accordingly, when a bicycle fork piece is placed in a fork receiving portion 32 , and the lever 24 is moved from an opened to a closed position, sides of each slot 45 are secured against respective bicycle fork pieces, which are then held in place by friction. As can be seen in FIG. 4 , a gap 47 is formed between a side of the lever 24 and a side of a cap end section of the end cap 46 when the lever is in the closed position.
FIG. 6 provides a perspective view of the skewer assembly 41 . As described above, the skewer assembly 41 includes the end cap 46 and the skewer 48 extending from the end cap 46 . The skewer 48 is generally a cylindrical rod, and has a threaded end 49 opposite the end cap 46 .
The end cap 46 includes various sections 50 , 54 , and 58 all being generally cylindrical but having different diameters. FIG. 7 provides a cross-sectional view of the end cap 46 . A skewer connecting section 48 has a first diameter smaller than a second diameter of a helical threaded section 50 , which in turn has a diameter smaller than a third diameter of a pawl section 54 , the pawl section 54 including a pawl 56 . The third diameter is in turn smaller than a fourth diameter of the end section 58 . A helical outer thread 51 is formed on an outer surface of the helical threaded section 50 . The helical outer thread 51 is configured to threadably engage a helical inner thread 68 on the lever 24 , as described below with reference to FIG. 8 .
As seen in FIG. 6 , the end section 58 may include a cylindrical lock 59 for use with a tubular key (not shown). The lock 59 generally operates in a known manner. For example inserting the tubular key into the lock 59 may cause the pawl 56 to retract into the pawl section 54 , the pawl 56 being spring-mounted or the like on the pawl section 54 . Thus, when the pawl 56 is engaged by a pawl slot 64 in the level 24 (discussed below concerning FIG. 8 ), the tubular key may be used to allow disengagement of the pawl 56 , and movement of the lever 24 from the closed to the open position.
Turning now to FIG. 8 , the lever 24 typically includes a cylindrical portion 25 and a handle portion 27 . The cylindrical portion 25 includes an opening 29 having an interior surface defined by two generally cylindrical sections 62 and 66 having first and second diameters, respectively. A pawl section 62 includes a pawl slot 64 that is dimensioned to receive the pawl 56 of the end cap 46 . An inner surface of a helical thread receiving section 66 has a helical inner thread 68 defined thereon. The helical inner thread 68 is configured to receive the helical outer thread 51 of the end cap 46 . Accordingly, when the skewer assembly 41 is inserted into the opening 29 , the helical outer thread of the end cap 46 can threadably engage the helical inner thread 68 of the lever 24 , and the lever 24 may be screwed onto the end cap 46 . As described above, rotation of the lever 24 with respect to the end cap 46 , as well as the hollow axle 28 and inner sleeve 22 , causes the skewer 48 to slide in an axial direction as mentioned above, thereby narrowing slots 45 and, if fork pieces or the like of the eBike 14 are placed in the slots 45 , securing the fork pieces. Further, as the lever 24 is moved to a closed position, spring action as described above may cause the pawl 56 to engage and lock in the pawl slot 64 .
As used herein, the adverb “substantially” means that a shape, structure, measurement, quantity, time, etc. may deviate from an exact described geometry, distance, measurement, quantity, time, etc., because of imperfections in materials, machining, manufacturing, etc.
In the drawings, the same reference numbers indicate the same elements. Further, some or all of these elements could be changed. With regard to the components, processes, systems, methods, etc. described herein, it should be understood that these are provided for the purpose of illustrating certain embodiments, and should in no way be construed so as to limit the claimed invention.
Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent to those of skill in the art upon reading the above description. The scope of the invention should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the arts discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the invention is capable of modification and variation and is limited only by the following claims.
All terms used in the claims are intended to be given their plain and ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary in made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.
The disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described. | A device comprises an outer sleeve and an inner sleeve that is rotatably supported at least partly in an interior of the outer sleeve. A hollow axle is located in an interior of the inner sleeve, and a skewer is supported within an inner region of the hollow axle. The skewer is slidable along an axis of hollow axle. First and second slots are located on the hollow axle. A lever that is rotatable about the axis of the hollow axle includes a mechanism for causing the rod to slide along the axis to change respective widths of the slots. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 10/186,637 filed Jun. 28, 2002, which is herein incorporated by reference.
FIELD OF THE INVENTION
The invention relates to monitoring user interaction with a computer.
BACKGROUND OF THE INVENTION
A problem that often arises in an Internet environment is that of unauthorized or improper access to web sites by robots, commonly referred to as “bots”. Bots are programs that are run on computers that automatically access a web site without the need for user interaction. Although some bots may access a web site for proper purposes, e.g., search engine spiders that are authorized to scrape information from web pages, other bots perform improper functions. For example, certain bots access web sites and register multiple fictitious users for improper purposes, access web site to mine confidential user information, guess user passwords, list items without authorization on sale or auction web sites, and so on. It will be appreciated that, due to the high processing power of computers running bots, a large number of unauthorized accesses may take place in an extremely short period of time. However, although unauthorized access by a user or human may still occur, it is a substantially slower process.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not limitation, in the figures of the accompanying drawings, in which like references indicate similar features.
In the drawings,
FIG. 1 shows a schematic block diagram of an exemplary system, in accordance with one aspect of the invention, for monitoring interaction between a user and a computer;
FIG. 2 shows a schematic flow diagram of an exemplary method, in accordance with another aspect of the invention, of generating reference data including a random reference string;
FIG. 3 shows a schematic flow diagram of an exemplary method, also in accordance with an aspect of the invention, of generating an image, readable by the user, including the random reference string;
FIG. 4 shows a more detailed schematic flow diagram of the method of FIG. 3 showing inclusion of the random reference string in the image;
FIG. 5 shows a schematic flow diagram of an exemplary method, also in accordance with an aspect of the invention, of monitoring user interaction with the computer;
FIG. 6 shows a schematic representation of an exemplary user interface presented to the user on the computer;
FIG. 7 shows an exemplary user interface for a visually impaired user;
FIG. 8 shows an exemplary table for monitoring repetitive use of a token; and
FIG. 9 shows schematic hardware architecture of an exemplary computer.
DETAILED DESCRIPTION
A method of, and system for, monitoring user interaction with a computer are described. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.
Referring in particular to FIG. 1 , reference numeral 10 generally indicates a system, in accordance with an aspect of the invention, for monitoring user interaction with a computer 12 . In one embodiment of the invention, the system 10 is used in an Internet environment where a user accesses a web site of an Internet service facility. Accordingly, the invention is described with reference to a user registration process via the Internet 11 . However, it should be appreciated that the invention may be applied in any computer environment in which user interaction with the computer is to be monitored.
The computer 12 includes a web browser application 14 , which generates a user interface such as an exemplary registration form 16 . The registration form 16 includes a display zone 18 for displaying an image 20 including a random reference number and, in order to effect registration, a user is required to read the random reference number from the image 20 and enter it into a user data input field 22 . In order to complete registration, the user activates a “GO” button 24 which then communicates the registration information to a registration server 26 . As described in more detail below, the image 20 is distorted and modified to inhibit the acquisition of the reference number by an automated process such as a software robot using optical character recognition (OCR). However, the image 20 is sufficiently clear so that the user may read the reference number for entry into the input data field 22 . Thus, in order to effect registration, human interaction with the computer 12 is required.
In one embodiment, the reference number is generated by an Internet application server 28 , which passes the random number in reference data, e.g., in the form of a token, via the Internet 11 to the browser application 14 as shown by arrow 30 . The browser application 14 then passes the token to an image server 32 , as shown by arrow 34 , during a HyperText Markup Language (HTML) image call. The image server 32 then decrypts the token and includes the reference number in the image 20 in a random fashion whereafter it is communicated, as shown by line 36 , to the browser application 14 for inclusion in the display zone 18 . After the user has entered the number into the user data input field 22 , and completed other details in the registration form, e.g. completed details in the fields 38 , 40 , the token and the user input data in the field 22 are then communicated to the registration server 26 . The registration server 26 then decrypts the token to obtain the reference number, and then compares the number entered by the user with the reference number and, if the numbers match, the registration server 26 may authenticate the user. However, in addition to comparing the two numbers, the registration server 26 also performs a checksum validation and time stamp analysis of the token, as described in more detail below.
Referring in particular to FIG. 2 , reference numeral 50 generally indicates an exemplary method, in accordance with an aspect of the invention, for generating random reference data including a reference string in the exemplary form of a random reference number, for inclusion in the image 20 . In one embodiment, the method 50 is carried out in the application server 28 . It is to be appreciated that, although the random reference string is in the form of a random reference number, in other embodiments, the random reference string may be numeric, alphanumeric characters and/or any graphical data. However, when the random reference string is in the form of a random number with numerical digits, the system 10 may be language independent.
In an exemplary registration process, the method 50 is initiated when the web browser application 14 requests a registration form from the application server 28 (see block 52 ). Thereafter, as shown at block 54 , the particular token size, to convey the reference data, in the system 10 is determined and is time stamped in milliseconds (see block 56 ). The random reference number is generated as shown at block 58 and further randomized as shown at block 60 . Thereafter, the reference number is limited in size (see block 62 ) to conform to the token size selected at block 54 . A checksum of the time stamp and the reference number is then performed (see block 64 ) to produce reference data including time data, the reference number, and the checksum (see block 66 ) which is then encrypted, e.g. using BLOWFISH algorithm, as shown in block 68 . The encrypted reference data is then Base64 encoded (see block 70 ) to produce an encrypted and encoded token (see block 72 ) which is then included in an HTML web page (see block 74 ) and sent to the user (see block 76 in FIG. 2 and arrow 30 in FIG. 1 ).
An example of the token including the reference data generated by the application server 28 is as follows:
(64 bit)
(32 bit)
(32 bit)
1595139460
069587
59991
Time Stamp
Random #
Checksum
The time stamp of the token (see block 56 in FIG. 2 ) indicates when the token was generated and, as described in more detail below, is used by the server 26 to determine whether or not the token has been used before in a valid registration process. The time stamp is typically the time on the application server 28 when the token was created.
Although in the embodiment described above, the token is communicated to the browser application 14 in an HTML web page, it is to be appreciated that it may also, in other embodiments, be passed in a cookie, in other forms, URLs, or the like. Further, the encryption of the token is typically by means of a private key and the random number is generated on-the-fly or dynamically when a request for the registration form 16 is received from the browser application 14 . Accordingly, in one embodiment, no library of numbers or images is provided, and different reference data including the random number, is generated each time a request from the computer 12 is processed.
When the browser application 14 performs an image call to the image server 32 to retrieve the image 20 for display in the web page received from the application server 28 , it passes the encrypted and encoded token received from the application server 28 , to the image server 32 as shown by the arrow 34 in FIG. 1 . Referring in particular to FIG. 3 of the drawings, reference numeral 80 generally indicates an exemplary method, in accordance with a further aspect of the invention, for generating the image 20 . As shown at block 82 , the image server 32 receives the user call from the browser application 14 and identifies the token with the reference data and decodes the reference data using Base64 decoding (see block 84 ). Thereafter, the reference data is decrypted using BLOWFISH algorithm (see block 86 ) to obtain decoded and decrypted reference data including the time data, the reference number, and the checksum as shown at block 88 . The integrity of the reference data is then checked based on the checksum as shown at block 90 whereafter the image 20 is generated.
Referring in particular to FIG. 4 , reference numeral 100 generally indicates an exemplary method, in accordance with an aspect of the invention, for generating the random image 20 including the random reference number. As shown at block 102 , an image modification random number is generated at the image server 32 and, based on the image modification random number, the image is then created and modified. For example, the image modification random number may be used randomly to select one of a plurality of different fonts (see block 104 ) for each digit in the reference number thereby to inhibit the acquisition of the number by a robot. In one embodiment, a plurality of image modification random numbers may be iteratively generated, as shown by block 106 and line 108 , and, in response to each random number, the position in the image 20 in which each digit is displayed may be randomly off-centered, various colors in which the digit is to be displayed may be randomly generated, a grid may be added to the image 20 , random distortion or noise may be added to the image 20 , and so on (see block 104 ). Once the image 20 has been sufficiently distorted, it is then converted to a jpeg format (see block 108 ) whereafter it is sent to the computer 12 as shown at block 110 in FIG. 4 and by the arrow 36 in FIG. 1 .
In one embodiment, it is to be appreciated that as the image modification number is a random number, the image not only includes the random reference number, but also includes the number within the image in a random fashion. In one embodiment, the image is distorted or modified so that a modicum of human interpretation is required to assimilate or identify the reference number.
As mentioned above, the browser application 14 displays the image 20 in the display zone 18 so that the user may read the numbers provided therein and manually enter the digits, into the entry form or field 22 via a keyboard of the computer 12 . Once the user has completed the entire registration form, the user typically activates the “GO” button 24 in response to which the browser application 14 communicates the user entered data, data entered into the form 16 , and the token including the reference data to the server 26 as shown by arrow 41 in FIG. 1 .
Referring in particular to FIG. 5 , reference numeral 120 generally indicates an exemplary method, in accordance with an aspect of the invention, for monitoring user interaction with the computer 12 . As shown at block 122 , in one embodiment the server 26 receives the token including the reference data, as part of the form 16 , as well as the user entered number. The reference data of the token is then Base64 decoded and decrypted using BLOWFISH algorithm to obtain the reference data including the random reference number (see block 124 ). As in the case of the server 32 , the integrity of the reference data is then checked using the checksum (see block 126 ) and, as shown at decision block 128 , if the integrity of the reference data of the token is rejected (see block 130 ), the user is then given a further opportunity of a limited number of opportunities (see block 132 ) to re-enter the number which is shown in the image 20 .
However, returning to decision block 128 , if the integrity of the reference data is accepted, then the time stamp of the token is checked to ensure that it is within a particular predetermined time range or window period as shown at block 131 . In particular, and depending upon the amount of detail a user is required to enter into the registration form 16 , a window period of about 3 to 20 minutes is allowed during which the reference data of the token is valid. If the time stamp indicates a time period of less than about 3 minutes or a time period of more than about 20 minutes, it is assumed that the registration attempt is either by a robot, or a replay attack in which multiple registration attempts using the same token are attempted. Accordingly, as shown at decision block 132 , if the time stamp of the token is not within the window period, the registration attempt is rejected (see block 130 ).
However, if the time stamp is within the acceptable window period, the user entered number is compared with the reference number to see if they match, as shown at block 134 . If the user entered number and the reference number do not match (see block 136 ) then the registration attempt is rejected (see block 130 ). In the embodiment depicted in the drawings in which the application server 28 performs the time stamping and the registration server 26 checks the time stamping, time on the servers 26 , 28 is synchronized.
In certain circumstances, a user may inadvertently activate the “GO” button 24 more than once, for example, due to a slow refresh rate on a display screen. Thus, in certain embodiments, the reference data may be valid for more than one perceived registration attempt. In these circumstances, if the user entered number and the reference number match, a further check is conducted to determine if the same token has already been used as a basis for a registration validation (see block 138 ). In particular, the method 120 accesses a table 140 (see FIG. 8 ) to obtain usage information on the token and its reference data. As shown at decision block 142 in FIG. 5 , if the number of the token is not included in the table 140 , it is then inserted into the table 140 (see block 144 ) and its reference count is set at “1 ” (see column 148 in FIG. 8 ). Thereafter, the registration process is authenticated or effected, as shown at block 146 .
However, returning to decision block 142 , if the reference number associated with the token is included in the table 140 , its reference count included in column 148 is incremented (see block 150 ) and the method 120 then checks to see if the count associated with the token exceeds a predetermined maximum number. For example, if the predetermined maximum number is three, then once the count in the table 140 has reached three, any registration attempt after that using the same reference number is rejected (see blocks 152 and 130 in FIG. 5 ). If, however, the account is less than three, then the registration process may be completed (see block 146 ).
In certain embodiments, the table 140 includes an age column 154 , which is used to check whether or not the time stamp is within the predetermined window period (see block 131 ). A registration attempt may be selectively rejected dependent upon the count in column 148 and the age of the token as shown in column 154 . Comments 156 in FIG. 8 show an exemplary application of the methodology described above in which the time window is 120 minutes and the maximum number of retry attempts using the same reference data is three.
An exemplary screen shot of an embodiment of a user interface served by the application server 28 to the browser application 14 is shown in FIG. 6 . The user interface of FIG. 6 is typically generated using HTML and, as mentioned above, although the invention is described with reference to a registration process, it may be used to monitor user interaction with the computer 12 in any other circumstances. As the image 20 is modified in such a fashion that it inhibits identification of the reference number by a robot or any other automated process, the resultant image 20 may be difficult for a visually impaired person to read. Accordingly, as shown in FIG. 7 , an alternative sign up or registration procedure may be provided in which a toll free number 158 is provided for a visually impaired person to call and thereby to effect registration.
In the embodiments described above, the servers 26 , 28 , and 32 are shown as separate servers, which may be located at different facilities. Thus, in one embodiment, the token communicated between the different servers may be the only interaction between the servers 26 , 28 , 32 . In this embodiment, a single centralized table 140 may be provided on the server 26 and it need not be replicated on the servers 28 and 32 . However, it will be appreciated that in other embodiments, any two or more of the servers may be combined into a single server.
FIG. 9 shows a diagrammatic representation of machine in the exemplary form of a computer system 200 within which a set of instructions, for causing the machine to perform any one of the methodologies discussed above, may be executed. The computer 12 and servers 26 , 28 , and 32 may resemble the computer system 200 .
In alternative embodiments, the machine may comprise a network router, a network switch, a network bridge, Personal Digital Assistant (PDA), a cellular telephone, a web appliance, Set-Top Box (STB) or any machine capable of executing a sequence of instructions that specify actions to be taken by that machine.
The computer system 200 includes a processor 202 , a main memory 204 and a static memory 206 , which communicate with each other via a bus 208 . The computer system 200 may further include a video display unit 210 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)). The computer system 200 also includes an alphanumeric input device 212 (e.g., a keyboard), a cursor control device 214 (e.g., a mouse), a disk drive unit 216 , a signal generation device 218 (e.g., a speaker) and a network interface device 220 .
The disk drive unit 216 includes a machine-readable medium 222 on which is stored a set of instructions (software) 224 embodying any one, or all, of the methodologies described above. The software 224 is also shown to reside, completely or at least partially, within the main memory 204 and/or within the processor 202 . The software 224 may further be transmitted or received via the network interface device 220 . For the purposes of this specification, the term “machine-readable medium” shall be taken to include any medium that is capable of storing or encoding a sequence of instructions for execution by the machine and that cause the machine to perform any one of the methodologies of the present invention. The term “machine-readable medium” shall accordingly be taken to included, but not be limited to, solid-state memories, optical and magnetic disks, and carrier wave signals. While the machine-readable medium may reside on a single machine, it is also to be appreciated that it may reside on more than one machine in a distributed fashion.
Thus, a method and system for monitoring user interaction with a computer have been described. Although the present invention has been described with reference to specific exemplary embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the invention. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | A system is provided to monitor a user's interaction with a computer. The system may comprise a reference string generator to generate a random reference string, an image generator to generate an image including the random reference string, a communications module to communicate the image to a client computer for display to a user and to receive user input data and a comparator to compare the random reference string and the user input data to detect human interaction with the computer. The image including the random reference string may be generated such that each character in the random reference string is off-centered. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM TO PRIORITY
[0001] The present application claims the benefit of U.S. provisional patent application serial No. 60/290,342, filed May 14, 2001, the disclosure of which is incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention is directed to a method and apparatus for packaging a product, and, more specifically, toward a method and apparatus for transferring a plurality of stacks of discrete objects supported by a platform from the platform to a box while maintaining the integrity and arrangement of the stacks.
BACKGROUND OF THE INVENTION
[0003] Various packing or packaging machines are known for placing a product into a box, carton, or other container. However, special problems are encountered when the product to be packaged comprises stacks of discrete objects. These stacks, for example, may have previously been formed by a stacking machine and set on a support surface for further processing. Such stacks can be lifted manually and placed into a box, but if multiple stacks have to be placed in the same box, it can be difficult to maintain the integrity of the stacks as they are moved; this leads to the occasional need for a manual restacking step. Furthermore, it is difficult to lift multiple adjacent stacks of objects at the same time by hand, and therefore a person would normally be limited to lifting the stacks one at a time when placing them in a box. However, if the stacks are to be packed tightly in the box, that is, if they are to be packed with a minimal amount of space between the stacks themselves and between the stacks and the inner walls of the box, it may be difficult to manually position the stacks that are adjacent a sidewall, and especially difficult to place the last stack into a box, which stack will be bounded on four sides by box sidewalls or other stacks of products.
[0004] Stacks of products such as those discussed above can be moved by gripping the top and bottom of the stack and applying pressure to hold the stack together while it is moved. An apparatus for gripping and moving stacks in this manner is disclosed in a co-pending application entitled “Stack Transfer Device” filed concurrently herewith and assigned to the assignee of this application, the disclosure of which is hereby incorporated by reference. However, gripping a stack from the top and bottom makes it difficult to insert the stack into a previously formed box having an open top. To package a stack that is gripped in this manner, either a box must be formed around the stacks of objects while they are being gripped, or the objects must be deposited on a surface and moved again from the surface to a box.
[0005] When using a stack transfer device, such as the one disclosed in the above application, the stacks are often placed on a device called a matrix former before they are packaged. A matrix former comprises a horizontal platform and two or three upstanding, movable sidewalls forming a structure that resembles a cube with an open top and no front wall. The purpose of the matrix former is to consolidate several stacks by sliding them toward one another and removing the spaces therebetween, to make them easier to fit into a box. The upstanding walls of the matrix former, however, make it even more difficult to transfer the stacks from the matrix former to a preformed box or case. It would therefore be desirable to provide a method and apparatus for automatically, simultaneously, transferring a plurality of stacks of discrete objects from a support platform, such as a matrix former, to a box in a manner that preserves the integrity and arrangement of the stacks.
SUMMARY OF THE INVENTION
[0006] These problems and others are addressed by the present invention which comprises a method and apparatus for transferring objects, and especially multiple stacks of discrete objects, from a support surface to an open-topped box. While the present invention could be used in a number of environments, it finds particular use in transferring stacks of frozen hamburger patties from a support surface having upstanding walls to an open-topped cardboard box and will be described in terms of such as system, it being understood that the invention is by no means limited to use in such environments.
[0007] The preferred embodiment of the invention comprises a first generally horizontal platform, which forms a part of a matrix former, on which a plurality of stacks of discrete objects are to placed, and a second platform for supporting a box into which the stacks are to be packed. The second platform is movable vertically and can also be pivoted about an axis parallel to its box-contacting surface. The second platform includes at least one gripper for holding the bottom of the box securely against the box-contacting surface and, preferably, also includes a plurality of fingers for engaging the top edges of the box to control the movement of the box and to hold down flaps extending from the top edge of the box. The box-contacting surface of the second platform also preferably includes a plurality of rollers that allow an empty box to roll on and off the platform when the platform is inclined.
[0008] In operation, the second platform is aligned with a conveyor that feeds empty boxes one at a time. A box rolls onto the second platform and is gripped by at least one gripper on the second platform to hold it in place, with its bottom on rollers and its open top facing away from the rollers. The second platform is then pivoted 180 degrees to an inverted position, with the open box top positioned over and facing down towards the first platform above the stacks of objects on the first platform. The second platform is next lowered over the stacked objects, until the first platform is about even with or slightly inside the top opening of the box so that the stacks of objects are disposed completely within the box. The orientation of the stacked objects is maintained by the walls of the box and the platform. The first and second platforms are pivoted together, until the top opening of the box is again facing upwardly and the objects are supported on the closed bottom of the box rather than by the first platform. The second platform and box are moved away from the first support, so the first support may return to its original orientation. The second support is then moved to a discharge location where it tilts to slide the fully loaded box onto a conveyor for further processing, and finally the second support returns to its original position to receive another empty box from the feeding conveyor to start the process again.
[0009] It is therefore a principal object of the present invention to provide an apparatus for packing a plurality of stacks of discrete objects in a container.
[0010] It is another object of the invention to provide an apparatus for transferring a plurality of stacks of discrete objects from a platform to a box while maintaining the integrity and mutual relationship of the stacks.
[0011] It is a further object of the invention to provide a method for packing a plurality of stacks of discrete objects in a box.
[0012] It is still another object of the invention to provide a method of packing stacks of discrete objects supported by a platform having at least one upstanding sidewall taller than the stacks of objects.
[0013] It is yet another object of the invention to provide an apparatus for simultaneously boxing a matrix of discrete objects.
[0014] In furtherance of these objects, a packing apparatus is provided that includes a first platform having a product contact surface. The first platform is pivotable about an axis parallel to and spaced from the product contact surface between a first position, wherein the product contact surface faces in a first direction, and a second position, wherein the product contact surface faces in a second direction. The apparatus also includes a second platform comprising a box support having a box contact side and a box holder for holding a box on the box support. The second platform is movable between a first position and a second position, and the box support is pivotable between a first angular orientation and a second angular orientation.
[0015] Another aspect of the invention comprises a method of packing a product that involves providing a first platform having a product support surface facing in a first direction and placing a product to be packaged on the product support surface. A second platform including a box support having a box contact surface is aligned with a first conveyor and receives a box having a closed bottom and an open top. The box is secured to the box support with the closed bottom in contact with the box contact surface. The box support is pivoted so that the box contact surface faces the first platform product support surface and the box open top faces the product. The second platform is moved towards the first platform until the product passes through the box top opening, and the first platform and the box support platform are pivoted until the box open top faces in the first direction. The second platform is moved away from the first platform, and the first platform is pivoted until the product support surface faces in the first direction. The second platform is aligned with a second conveyor, and the box is released onto the second conveyor.
[0016] Another aspect of the invention comprises a packing apparatus that includes a first platform having a product contact surface that is pivotable, via an actuator, about an axis parallel to and spaced from the product contact surface between a first position, wherein the product contact surface faces in a first direction, and a second position, wherein the product contact surface faces in a second direction. The apparatus also includes a second platform that includes a box support having a first wall and a box contact side and a positioning device for positioning and holding a box on the box support. The positioning device includes a second, movable, wall and an actuator for moving the movable wall with respect to the first wall. At least one gripper is also provided for gripping an edge of a box having a closed bottom and open top on the box support. The second platform is movable between a first position and a second position, and the box support is pivotable between a first angular orientation and a second angular orientation with respect to said first platform. The apparatus also includes at least one guide track for guiding the movement of the second platform between the first position and the second position, a drive belt extending between a first wheel and a second wheel, and a drive operably coupled to the drive belt. The second platform is coupled to the drive belt.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other objects and other objects and advantages of the invention will be better understood after a reading of the following detailed description of the invention together with the following drawings.
[0018] [0018]FIG. 1 is a perspective view of the packing system of the present invention which system includes a feeding conveyor, a discharge conveyor, a lift apparatus and a matrix former.
[0019] [0019]FIG. 2 is an assembly diagram of the lift apparatus of the packing system shown in FIG. 1.
[0020] [0020]FIG. 3 is an exploded perspective view of matrix former of FIG. 1.
[0021] [0021]FIG. 4 is a rear elevational view of the motor of the matrix former of FIG. 1.
[0022] [0022]FIG. 5 is a fragmentary perspective view of the box holding portion of the lift apparatus in an inverted position.
[0023] [0023]FIG. 6 is an elevational view of the matrix former of FIG. 1.
[0024] [0024]FIG. 7 is a side elevational view of the packing system of FIG. 1 in a first configuration with the lift positioned to receive an empty box from the feeding conveyor.
[0025] [0025]FIG. 8 is a side elevational view of the packing system of FIG. 1 in a second configuration with an empty box gripped on a platform of the lift apparatus.
[0026] [0026]FIG. 9 is a side elevational view of the packing system of FIG. 1 in a third configuration with the platform and box positioned over the matrix former.
[0027] [0027]FIG. 10 is a side elevational view of the packing system of FIG. 1 in a fourth configuration with the platform held near the matrix former so that the matrix former is substantially covered by the box.
[0028] [0028]FIG. 11 is a side elevational view of the packing system of FIG. 1 in a fifth configuration with the platform and matrix former rotated 180 degrees from the position shown in FIG. 8.
[0029] [0029]FIG. 12 is a side elevational view of the packing system of FIG. 1 in a sixth configuration with the platform moved away from the matrix former.
[0030] [0030]FIG. 13 is a side elevational view of the packing system of FIG. 1 in a seventh configuration showing the matrix former pivoted 180 degrees from the position shown in FIG. 10.
[0031] [0031]FIG. 14 is a side elevational view of the packing system of FIG. 1 in an eighth configuration with the platform and box raised to the level of the discharge conveyor.
[0032] [0032]FIG. 15 is a side elevational view of the packing system of FIG. 1 in a ninth configuration showing a full box that has been released from the platform to the discharge conveyor and a new empty box in position on the feeding conveyor.
[0033] [0033]FIG. 16 is a side elevational view, partly in section, of the lift apparatus and the matrix former in a position similar to that shown in FIG. 8.
[0034] [0034]FIG. 17 is a side elevational view, partly in section, of the lift apparatus and the matrix former in a position similar to that shown in FIG. 9.
[0035] [0035]FIG. 18 is a side elevational view, partly in section, of the lift apparatus and the matrix former in a position similar to that shown in FIG. 10.
[0036] [0036]FIG. 19 is a side elevational view, partly in section, of the lift apparatus and the matrix former in a position similar to that shown in FIG. 11.
DETAILED DESCRIPTION OF THE INVENTION
[0037] Referring now to the drawings, wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting same, FIG. 1 shows a packing apparatus designated generally by the numeral 110 which includes an empty-box feeding conveyor 12 , a packed-box discharge conveyor 14 , a lift mechanism 16 , and a matrix former 18 .
[0038] Lift mechanism 16 , as best shown in FIG. 2, includes a reversible motor 20 for turning a drive shaft 22 which is supported on one end by motor 20 and on the other by a bearing 24 mounted on a support (not shown). First and second flanged wheels 26 are mounted on shaft 22 for rotation therewith, and a second shaft 28 is rotatably supported by first and second bearing plates 30 mounted to supports (not shown) parallel to the drive shaft 22 . First and second flanged wheels 32 are mounted on second shaft 28 and aligned with the flanged wheels 26 on the drive shaft 22 . First and second belts 34 extend between aligned pairs of flanged wheels 26 and 32 on the shafts 22 and 28 such that shafts 22 and 28 are rotated simultaneously when motor 20 turns drive shaft 22 . Parallel guide tracks 36 are mounted adjacent the belts 34 , each track 36 defining a channel facing toward the channel of the other track 36 .
[0039] Lift platform 40 includes a first sidewall 42 , a second sidewall 43 , a top support 44 , and a bottom support 46 supported for rolling movement along the guide tracks 36 by wheels 48 , as best shown in FIG. 7, and is clamped to belts 34 by clamps 50 . Thus, motor 20 moves lift platform 40 between raised and lowered positions on guide tracks 36 by rotating shaft 22 . Motor controller 51 controls the operation of motor 20 , and thus the position of lift platform 40 with respect to the guide tracks 36 and the matrix former 18 .
[0040] Lift platform 40 , as best shown in FIG. 2, further includes a pivoting platform 52 mounted on lift platform 40 for pivoting movement with respect to platform 40 . Platform 52 includes a base frame 54 , including a projecting arm 56 and a sidewall 58 . A first axle 60 extends from first sidewall 42 and connects to sidewall 58 , while a second axle 62 extends from second sidewall 43 and connects to projecting arm 56 . The axles 60 and 62 are coaxial. Under the influence of appropriate actuators, pivoting platform 52 may be pivoted between first and second positions with respect to lift platform 40 .
[0041] Pivot platform 52 further includes a guide track 64 , as best shown in FIG. 5, connected between sidewall 58 and sidewall 43 , a first fixed wall 65 adjacent track 64 and a second wall 66 slidingly connected to track 64 . An actuator 68 , shown in FIG. 5, is mounted adjacent track 64 , for moving sliding wall 66 toward and away from fixed wall 65 to grip a box placed therebetween. A roller support 70 , comprising a plurality of free-spinning rollers, is mounted on base frame 54 between sidewalls 43 and 58 . Four posts 72 extend from walls 65 and 66 which posts are mutually parallel and arranged generally in a square. The top of each post 72 includes a finger 74 pivotally attached thereto, and an actuator 76 connects each finger 74 to the top of sidewall 65 or sliding wall 66 , so that the fingers 74 can be pivoted between first and second positions with respect to the sliding walls by the actuators 76 and function as grippers for gripping the top edge of a box.
[0042] A crank arm 80 , as best shown in FIG. 1, is attached to the end of axle 60 , and a first cylinder and piston assembly 82 extends between crank arm 80 and sidewall 42 of lift platform 40 . A second cylinder and piston assembly 84 extends between pivot platform 52 and sidewall 42 . Operation of the first and second cylinder and piston assemblies 82 and 84 moves pivot platform 52 between first and second positions.
[0043] Referring now to FIGS. 3, 4 and 6 , matrix former 18 can be seen to comprise a reversible motor 90 for rotating a drive shaft 92 approximately 180 degrees between first and second positions. Plate 94 , having first and second ends 96 , is supported on shaft 92 , and first and second arms 98 are attached to the ends 96 of plate 94 . Arms 98 are connected to a shaft 100 by a triangular plate member 102 . One end of shaft 100 is connected to a first vertex of plate member 102 , while arms 98 are connected to the other two vertices of the triangular plate member 102 . Shaft 100 is securely supported by two bearing plates 104 fixedly mounted to a support structure 106 , as best shown in FIG. 1. An L-shaped support 108 depends from shaft 100 and includes a projection 110 for supporting an actuating assembly 112 . Actuating assembly 112 comprises side plates 114 connected by telescoping cylinders 116 and an actuator 118 . The matrix former 18 , as best shown in FIG. 3, further includes a patty-receiving platform 120 having three slots 122 therein, a first sidewall 124 connected to one of the side plate 114 , and a second sidewall 126 connected to the other of the side plates 114 . (The slots 122 are narrower than the width of the patties to be placed thereover.) The sidewalls 124 and 126 are movable toward and away from each other by operation of the actuating assembly 112 which is attached to the two side plates 114 . FIG. 6 illustrates three stacks 128 of hamburger patties between the sidewalls 124 , 126 of the matrix former 18 in a closely spaced relationship.
[0044] In operation, a first set of three stacks of hamburger patties is placed onto receiving platform 120 , one stack over each of slots 122 , by a stack placing device (not shown). A second set of three stacks is then placed on receiving platform 120 next to the first set of stacks by the stack placing device. The stacks are formed with a spacing between them, and are thus transferred to the receiving platform 120 with a spacing. To remove or substantially decrease this spacing, controller 51 operates actuator 118 to move side plates 114 , and thus first and second sidewalls 124 and 126 which are connected to side plates 114 , toward each other to slide the patties toward one another and form a tighter matrix of patties.
[0045] [0045]FIGS. 7 through 15 illustrate the interaction of the lift mechanism 16 and the matrix former 18 during one patty boxing operation. In FIG. 7, system 10 can be seen with an empty box 130 , having an opening 132 , that has been released to slide down box feed roller conveyor 12 toward and onto roller support 70 of lift platform 40 . At this stage, matrix former 18 already holds six stacks (two rows of three stacks each) of hamburger patties. Once box 130 is received on roller platform 70 , sliding side walls 66 are moved toward each other and toward box 130 by actuator 68 , until they engage the sidewalls of the box and hold box 130 securely on platform 70 . Actuators 76 pivot fingers 74 and move them into the opening 132 of box 130 , where they further secure the box to the roller platform 70 and help hold down any flaps that the box might have. Platform 70 is then pivoted to the position shown in FIG. 8, with its surface generally normal to guide tracks 36 . First cylinder and piston assembly 82 , with a first end connected to first sidewall 42 , presses against crank arm 80 on first axle 60 , which causes pivoting platform 52 to pivot about the axes of first axle 60 and second axle 62 from the position shown in FIG. 8 to the position shown in FIG. 9 so that roller platform 70 is positioned over matrix former 18 and with the opening 132 of box 130 facing the stacks of patties on the matrix former. Sliding sidewalls 66 and fingers 74 , held in place by actuators 76 , keep box 130 secured with its bottom wall against roller platform 70 .
[0046] Controller 51 next causes motor 20 to rotate shaft 22 , in order to move belts 34 and thus platform 70 toward matrix former 18 until the sidewalls 124 , 126 of the matrix former 18 and the patties on the matrix former surface 120 are inside box 130 , as best shown in FIG. 10. In this position, shaft 100 of the matrix former is coaxially aligned with axles 60 and 62 of the lift platform.
[0047] Next, matrix former motor 90 actuates to rotate plate 94 and move one of the arms 98 toward shaft 100 and the other of arms 98 away from the shaft 100 , thus rotating triangular plate 102 and shaft 100 connected thereto. This causes the receiving platform 120 to pivot about the axis of shaft 100 . Simultaneously, first cylinder and piston assembly 82 and second cylinder and piston assembly 84 contract to pivot roller support platform 70 about axles 60 and 62 , so that the box 130 on the roller support platform 70 and the patty support platform 120 of the matrix former remain essentially parallel as they rotate through 180 degrees to the position shown in FIG. 11. The patties, which had been supported by receiving platform 120 and covered by box 130 , are in this new orientation supported by box 130 with the receiving platform 120 positioned thereover.
[0048] Motor 20 next rotates shaft 22 to move roller support platform 70 and box 130 thereon away from patty support platform 120 and away from shaft 22 until the patty support platform 120 is clear of the box 130 , as best shown in FIG. 12. Motor 90 rotates shaft 100 to return the patty support platform 120 to its starting orientation as best shown in FIG. 13. Roller support platform 70 is next raised to the position shown in FIG. 14, generally parallel to the surface of discharge conveyor 14 . Actuators 76 pivot fingers 74 out of top opening 132 of the box 130 and sliding sidewall 66 moves away from box 130 . The box 130 may then slide under the force of gravity off roller platform 70 and onto the adjacent discharge conveyor 14 as best shown in FIG. 15. The lift platform 40 is then raised back toward the feed conveyor 12 to receive another box and start the cycle again.
[0049] FIGS. 16 - 19 show in more detail the transfer of the stacks of patties 128 from the matrix former 18 to the box 130 . FIG. 16 is a sectional view showing the inside of the box 130 and the matrix former 18 when the box 130 is held over the matrix former 18 as shown in FIG. 9. As can be seen in FIG. 17, the support platform 120 of the matrix former fits within the inside of box 130 , with a small amount of clearance, and at about the level of opening 132 . FIG. 18 shows the inside of box 130 when the matrix former 18 and lift platform 40 are positioned as in FIG. 11, so that the stacks 128 of patties are now resting on the bottom of box 130 . FIG. 19 corresponds to the position of the matrix former 18 and lift platform 40 shown in FIG. 12.
[0050] The present invention has been described herein in terms of a preferred embodiment. However, numerous changes and additions to this embodiment will become apparent to those skilled in the relevant arts upon a reading and understanding of the foregoing description. For example, while the matrix former of the present invention has been described as accommodating two rows of three stacks each, it can readily be adapted, by the use of larger or smaller components, have more or fewer slots in the bottom wall, to accommodate rows having a greater or lesser number of stacks and to accommodate a greater or lesser number of rows as well. It is intended that all such changes and additions be included within this invention to the extent that they are covered by scope of the several claims appended hereto. | A packing method and system are disclosed which system includes a first platform having a product support surface for supporting a product and a second platform for supporting a box into which the product is to be packed. After a box is received on and secured to the second platform, the second platform is rotated so that the open top of the box faces the first platform and moved toward the first platform until the box substantially surrounds the product on the product support surface. The first and second platforms are then rotated simultaneously so that the product is transferred from the product support to the box, and the full box is discharged to a discharge conveyor. | 1 |
FIELD OF THE INVENTION
The present invention relates to a method for communication in a wireless control network. More particularly, the present invention relates to a method for ensuring maintenance of correct communication between a communication device and a destination device in a wireless network.
This invention is, for example, relevant for wireless networks comprising resource-restricted devices having low power resources. In a specific application, the present invention is relevant for wireless networks using communication protocols compliant with the IEEE802.15.4 and also IEEE802.15.4-based protocols, e.g. ZigBee protocol, especially the ZigBee Green Power protocol.
BACKGROUND OF THE INVENTION
Wireless control networks have recently become a ubiquitous trend in the field of communication and connectivity/automation, especially for building management systems. Wireless technologies present major advantages in terms of freedom of device placement, device portability, and installation cost reduction, since there is no need for drawing cables and drilling. Thus, such technologies are particularly attractive for interconnecting, sensing, automation, control or monitoring systems using sensor devices such as light switches, light dimmers, wireless remote controllers, movement or light detectors, window or door openers, that have to be set up in distant places one from the other and from the devices they control, e.g. lights.
One of the drawbacks appearing in networks of the like relates to device powering. Indeed, since the devices are not wired, they can not receive power necessary for performing all the operations required in the network from the mains or via the connection with the controller. Thus, it has been envisaged to equip such devices with built-in batteries. However, since the devices are quite size-restricted, batteries may not be of a large size, which results either in a reduced device lifetime, or in labour intensive battery replacement.
It has been suggested to remedy this issue by equipping sensor devices with self-sustained energy sources that harvest energy from its environment or from the interaction with the user. Still, the amount of energy achievable by off-the-shelf energy harvesters is very limited, which means that the features and functions of the resource-restricted devices are heavily restricted.
Among the functions that are mandatory for good operation in a wireless network is the maintenance of correct communication, which makes it possible to ensure at any time that a resource-restricted device is linked to a router, also called proxy, which forwards messages on its behalf. In existing implementations therefore, a parent-child relationship is established between a device, generally resource-restricted, and its parent router. The child end device addresses all its communication to the parent for being forwarded to its final destination. However, especially in case of energy-harvesting device, this relationship creates a single point of failure in the network, because if the parent link is broken, communication from the end device can not be successfully performed anymore.
Several solutions have been suggested to remedy this problem, using proxy redundancy. A first type of solution aims at ensuring that, at any given time, one and only one proxy is forwarding frames on behalf of the resource-restricted device to the destination. However, the existing procedures of the like involve, for guaranteeing proxy redundancy, a large amount of additional communication, a large amount of additional proxy code, and considerable delay when a device moves in the network. Moreover, in these procedures, some prior master proxies may remain undiscovered, thus leading to many master conflicts.
SUMMARY OF THE INVENTION
It is an object of the invention to propose a method for wireless communication in a network allowing the use of proxy redundancy while overcoming at least some of the above-mentioned drawbacks.
More precisely, it is an object of the invention to propose a method for wireless communication wherein the amount of communication between different proxy devices in the network is reduced.
Yet another object of the invention is to provide a method allowing master proxy election.
To this end, the invention relates to a method for wireless communication in a network comprising a resource-restricted device, at least two proxy devices and at least one destination device, wherein the method comprises the following steps:
the resource-restriced device transmitting a frame to be forwarded to a destination device in the network, said frame containing a unique source identifier of the resource-restricted device, at least one proxy device receiving the frame and identifying the frame as originating from a resource-restricted device, the proxy device determining the unique source identifier and deriving a group identifier as a known function of the unique source identifier, the group identifier designating a group of devices in the network, if the proxy was not yet a member of the group identified by the derived group identifier: the proxy becoming a member of the group with the derived group identifier; the proxy constructing, from the frame, an appropriate packet to be forwarded, the proxy forwarding the packet by taking into account the group identifier.
Within the meaning of the invention a resource-restricted device relates to a communicating device that is restricted at least in terms of energy-resource, acting as a reduced functionality device in the network. This formulation includes, but is not limited to, battery-powered devices with limited energy storage and energy-harvesting devices.
A resource-restricted device is, for example, a light switch, a light sensor, a presence detector, or any device of the like used in control networks requiring high link reliability, such as lighting control networks, building or home automation network. The energy harvesting may be performed using electro-mechanical element, e.g. operated by the user; solar cells, or harvesting vibration, thermal, flow or other types of energy.
A proxy device, also called a router in the present specification, is a device having proxy capabilities, corresponding to capacities of routing messages received from an originating device to a destination device. Furthermore, proxy device has the capabilities of receiving the frames sent by the resource-restricted device and acting upon them.
A destination device within the meaning of the present invention is a device for which a frame is intended in the network. Such a device can be a resource-restricted device, a proxy device, or any other type of device, with or without proxy capabilities.
A method according to the invention allows all proxies to independently derive the same multicast identifier from the unique source identifier of the resource-restricted device, using a known function.
In a first embodiment, the group identified by the identifier is a proxy maintenance group. The proxy maintenance group identifier (PGroupID) is used for proxy maintenance communication, thus allowing for reaching all interested parties and providing the keepalive feature between the proxies for free. The group comprises proxy devices involved in forwarding the frames on behalf of a resource-restricted device and the packet constructed from the frame is a notification packet for the master proxy device. In such an embodiment, in case the proxy receiving the frame is not a member of the group identified by the group identifier, then the proxy becomes a member of the group and starts a master proxy resolution procedure for determining a master proxy. Such a procedure is performed by sending a master request message to the group identified by the group identifier.
Then, as soon as the master proxy resolution procedure has been performed, the determined master proxy receives information on the destination devices, derives a packet from the frame sent by the resource-restricted device, determines a destination addressing mode, and forwards the packet by using the determined destination addressing mode.
The destination addressing mode is, for example, unicast or multicast. The information regarding the destination devices is received by the elected master proxy via a configuration procedure, or from an older master proxy.
In a second embodiment, the group designated by the identifier is a control group, comprising target devices, i.e. destination devices for which the frame sent by the resource-restricted device is intended. The Control group identifier (CGroupID) is used for multicast-based application control, allowing the proxies not to care about holding, maintaining and exchanging binding information, i.e. information about the destination devices, thus guaranteeing that resource-restricted device can immediately be operated at any location, without any delay, and thus supporting portability and mobility of resource-restricted device. In such an embodiment, the step of constructing the packet to be forwarded further comprises using a sequence number supplied by the resource-restricted device. The packet constructed from the frame is a data or command packet for the destination device(s), and is forwarded to the identified group.
In a preferred configuration of a method according to the invention, the resource-restricted device has a unique source identifier (SrcID), and the proxies are provided with predetermined functions f1 and f2. Thus, the proxies have the capability to derive the control group identifier as CGroupID=f1(SrcID) and the proxy maintenance group identifier as PGroupID=f2(SrcID). In addition, the proxies have the capability, when located in the range of a resource-restricted device, to recognize frames as being sent by the resource-restricted device. For example, this recognition can be performed thanks to a special frame format used by the resource-restricted device, and identified by the proxy devices.
In one embodiment, the method comprises the step for the proxy device of scheduling the packet forwarding after a predetermined delay, wherein the delay is determined based on one or several of the following criteria: a link quality indicator of the reception of the resource-restricted device's frame, a reception success rate of the resource-restricted device's frame, a memory availability, the fact of being early to forward in the past, the knowledge of the destination device(s), the knowledge of the route to the destination device(s), and the path cost to the destination(s).
In another embodiment, the method comprises the step for the proxy device of listening, during the countdown, if a message corresponding to the same frame is being transmitted by other devices of the network, and if so, of forwarding this message and cancelling its own scheduled transmission or re-transmission.
Another aspect of the invention relates to a method for wireless communication in a network comprising a resource-restricted device, at least two proxy devices, and at least one destination device, wherein the method comprises the following steps:
the resource-restricted device transmitting a frame to be forwarded to a destination device in the network, said frame containing a unique source identifier of the resource-restricted device, at least one proxy device receiving the frame and identifying the frame as originating from a resource-restricted device, the proxy device determining the unique source identifier and deriving a group identifier as a known function of the unique source identifier, the group identifier designating a source address to be used by a group of proxy devices in the network, the proxy constructing, from the frame, an appropriate packet to be forwarded to the destination device(s), using the derived group identifier as a group source address and using a sequence number supplied by the resource-restricted device, the proxy scheduling forwarding the frame to destination device(s) after a predetermined delay, wherein the delay is determined based on one or several criteria comprised in the group comprising a link quality indicator of the resource-restricted device's frame, a reception success rate of the resource-restricted device's frame, a memory availability, the knowledge of the destination device(s), the knowledge of the route to the destination device(s). the fact of being early to forward in the past, the proxy device listening, during the countdown of the delay, if a message corresponding to the same frame is being forwarded by other devices of the network, and if so, of forwarding this message and cancelling its own scheduled transmission.
In one embodiment, this method comprises the step of the destination device receiving the packet and sending an acknowledgement frame to the group identifier contained in the source address field of the received packet, using non-member multicast mode.
In another embodiment, this method comprises the step of a first proxy device being member of the source proxy group, receiving an acknowledgement in non-member mode, forwarding it in member-mode to the source proxy group, and second proxy device receiving the acknowledgement in the member-mode multicast and dropping the scheduled transmission or forwarding of the packet corresponding to this acknowledgement.
These and other aspects of the invention will be apparent from and will be elucidated with reference to the embodiments described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
The sole FIGURE depicts a ZigBee network.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a method for wireless communication in a network comprising a resource-restricted device, at least two proxy devices and at least one destination device. This invention will now be described in detail, without limiting the scope of the invention as defined in the claims.
The resource-restricted device is, for example, an energy-harvesting device, or a ZigBee Green Power device (ZGPD), using a dedicated frame format for sending frames (ZGP frame). The proxy devices (ZP 1 , ZP 2 , ZP 3 , ZP 4 and ZP 5 ) are, for example, devices having the capability of understanding such dedicated frame format, and of generating frames compliant with the ZigBee standard (ZB frames) from a ZGP frame. The destination device (DD) is controlled by the resource-restricted device, and has the capability to support the ZB format. For example, a destination device might be a device fully compliant with the ZigBee specification. In another embodiment, a destination device has, in addition, proxy capability, i.e. it can receive ZGP frames and/or ZGP proxy messages.
The resource-restricted device has a unique identifier, which is, for example, distinct from an IEEE address and from a ZigBee network address. The size of the identifier is preferably comprised between 1 and 4 bytes.
Moreover, the resource-restricted frame, i.e. the frame sent by the resource-restricted device contains a sequence number in the MAC header. In an example, this sequence number is not incremental, which means that there is no need for the resource-restricted device to reserve energy to store it in a non-volatile way. Moreover, the packet derived from the resource-restricted frame contains a sequence number, either in the network or application layer, allowing the receiving device to check message freshness and/or to filter duplicate messages.
In the simple embodiment described above, where solely the CGroupID is being used, it can happen that proxies still keep forwarding the resource-restricted frame to the master proxy, although the master proxy already received and forwarded the resource-restricted frame. This adds to unnecessary medium occupation. It can also happen that several proxies forward the resource-restricted packet to the destination at approximately the same time, i.e. before the other simultaneously forwarding proxies can notice.
These drawbacks can be avoided by advantageously combining both embodiments previously described, i.e. the one using the PGroupID and the one using the CGroupID. The selected proxy master uses the CGroupID to forward the data to the destinations using the CGroupID, and all redundancy proxies drop scheduled resource-restricted packet transmission, as soon as they see the master forwarding the resource-restricted packet as a ZigBee packet to the destination(s), and drop the scheduled master notification as soon as they see some other proxy forwarding the resource-restricted packet to the master or as soon as they see the master forwarding the resource-restricted packet as a ZigBee packet to the destination. In this case, it is possible that f1=f2, i.e. PGroupID=CGroupID. It may be beneficial, to keep them separate, as it may allow for different handling already on NWK layer.
A first procedure will now be described in detail, in the case where a proxy sees a packet from a yet unknown resource-restricted device, and wherein it derives a proxy maintenance group identifier from the frame and uses it to forward the resource-restricted device's frame to a master proxy, and wherein the mater proxy then uses a control group identifier for communicating the packet to the destination device. The destination does not necessarily have proxy capabilities. This first procedure comprises, in an exemplary embodiment, the following steps:
Step 1: the resource-restricted device is triggered by external means, such as a user interaction or a sensor, or by internal means such as an internal timer. The device thus sends a ZGPD frame, containing data or command. This frame is sent with the MAC layer using a generic Personal Area Network Identifier (PANId), such as broadcast PANId or a special PANId dedicated for ZGP communication, and MAC broadcast Destination Address. In this case, the MAC layer header contains a random number within the sequence number field. The frame further contains unique a 4 bytes source identifier of the resource-restricted device and a sequence number. Step 2: All devices with proxy capabilities situated in the network in the radio range of the resource-restricted device identify the frame as being sent by a resource-restricted device and each of them checks whether the resource-restricted device is already known to it. This checking is performed by first deriving a proxy maintenance group identifier by applying a known function to the source identifier, and then by searching for the group identifier in a table, either the nwkGroupIDTable or the apsGroupTable. Step 3: each proxy that does not find the group ID dervied from the source identifier of the resource-restricted device in an appropriate table adds itself to the group by including the PGroupID in the table. Inclusion into nwkGroupIDTable enables usage of NWK layer member-mode multicast; inclusion into apsGroupTable enables usage of application layer multicast a.k.a. groupcast. Step 4: each proxy device which just became member of this PGroupID, i.e. which does not yet have the information about the master proxy for this particular resource-restricted device, starts a master election procedure, by sending a Master_request packet comprising at least the source identifier of the resource-restricted device, to the PGroupID. Step 5: the newly elected master chooses a network-wide unique control GroupID, CGroupID to be controlled by ZigBee cluster derived from the ZGPD, and waits for commissioning to be performed locally on the master proxy or else for the binding information to be distributed in the PGroupID/network-wide broadcast Step 6: in the case where the resource-restricted device was known, it means that the master proxy having to forward the packet is known as well; thus, each proxy except the master proxy constructs a Master_notification packet to notify the master proxy of the ZGPD frame, the packet comprising as payload the relevant contents of the ZGPD frame (such as source identifier of the resource-restricted device, sequence number from the ZGPD frame, the application layer payload from the ZGOD frame), the packet being addressed to this PGroupID, and the packet being sent using the individual source address and sequence number of the forwarding proxy device, to allow the master proxy to treat each notification sent as separate packet. Each proxy schedules the Master_notification packet forwarding, with a delay as a function of one or several parameters among: a link quality indicator for reception of the ZGPD frame, the success rate of the reception of the ZGPD frames, and the fact of being early to forward in the past. Step 7: During the timeout, i.e. the time before forwarding the packet, the proxy listens to incoming frames: if the proxy receives a Master_notification packet in member mode on PGroup ID, it forwards it according to member mode multicast rules to the PGroupID, and and drops the scheduled transmissions of Master_notification, as well as any packet to any binding destination resulting from the same SrcID and sequence number. Step 8: After the timeout, the proxy sends the packet constructed as described above to the PGroupID and starts a timer. If no Master_Notification_response is received until timeout, master re-election has to be started. Step 9: The master proxy receives the ZGPD frame or the Master_notification packet and constructs ZigBee frame to be sent to the controlled destination device(s). The frame is built by using the control group identifier as non-member mode multicast or groupcast destination, the own source address of the master proxy, and the own sequence number of the master proxy, and it contains the command or data derived from the application layer payload of the ZGPD frame. Step 10: The master proxy forwards the packet to the CGroupID and constructs a Master_Notification_response packet, to be sent to the PGroupID with the source address of the master, and ignores subsequent notifications related to the same ZGPD packet and ZGPD packet repetitions (to be identified by the ZGPD SrcID and ZGPD sequence number). Step 11: The destination receives the ZGPD frame via the master only, so no duplicate detection should be required.
A second procedure will now be described, where no master proxy is elected, in order to avoid proxy communication overhead and the point of failure introduced by the special role of the proxy. Further, in the case it is assumed, that applications of the network require reliable unicast communication, as well as duplicate filtering at the destination(s). The destination is not required to have proxy capabilities. In this case, when a proxy receives a packet from yet unknown resource-restricted device, it derives the proxy maintenance GroupID (PGroupID), forwards the resource-restricted device's frame to the destination(s), using aliasing, and the destination sends back an acknowledgment message to the alias, which is then distributed in the PGroupID. This second procedure comprises the following steps, wherein steps 1 to 3 are similar to those of the procedure previously described:
Step 1: the resource-restricted device is triggered by external means, such as a user interaction or a sensor, or by internal means such as an internal timer. The device thus sends a ZGPD frame, containing data or command. This frame is sent with the MAC layer using a generic Personal Area Network Identifier (PANId), such as broadcast PANId or a special PANId dedicated for ZGP communication, and MAC broadcast Destination Address. In this case, the MAC layer header contains a random number within the sequence number field. The frame further contains unique 4 bytes source identifier of the resource-restricted device and a sequence number. Step 2: All devices with proxy capabilities situated in the network in the radio range of the resource-restricted device identify the frame as being sent by a resource-restricted device and each of them checks whether the resource-restricted device is already known to it. This checking is performed by first deriving a proxy maintenance group identifier by applying a known function to the source identifier, and then by searching for the group identifier in a table, either the nwkGroupIDTable or the apsGroupTable. Step 3: each proxy that can not find the groupID derived from the source identifer of the resource-restricted device in an appropriate table, each proxy adds itself to the group by including the PGroupID in a table. Inclusion into nwkGroupIDTable enables usage of NWK layer member-mode multicast; inclusion into apsGroupTable enables usage of application layer multicast a.k.a. groupcast. Step 4: each proxy which just became member of this PGroupID, i.e. which does not yet have the information about the destination(s), waits for commissioning to be performed locally on the proxy or else for the binding information to be distributed in the PGroupID (or alternatively via network-wide broadcast) by the proxy with which the binding was performed. Step 5: each proxy knowing the destination(s) for the resource-restricted device constructs a ZigBee packet to be forwarded to the controlled device(s). The packet is constructed by using the bound device(s) as a unicast destination, network and/or application layer sequence numbers derived from the number supplied by the resource-restricted device in the ZGPD frame, and the alias source address derived from the source identifier of the resource-restricted device, and contains as payload the data or command derived from the application layer payload of the ZGPD frame. Then, each proxy schedules packet forwarding, with a delay as a function of the reception link quality indicator from the ZGPD, knowledge of the route to the destination(s), total path cost to each of the destination(s), and fact of being early to forward in the past. Step 6: During the timeout, i.e. the time before forwarding the packet, the proxy listens to incoming frames :if the proxy receives an acknowledgment message (either APS ACK or APPL response message) in unicast from the destination, it creates a ZGPD confirmation packet containing SrcID and sequence number corresponding to the received acknowledgment, as well as the short address of the destination which has sent the acknowledgment. Then the proxy forwards it to other proxies in the PGroupID using member mode multicast and using PGroupID as destination address and alias as source address, stops the timer and drops all scheduled transmissions for any packet to any binding destination resulting from the same ZGPD packet (the same ZGPD packet means a packet containing the same source identifier and the same sequence number). Step 6bis: If the proxy receives the ZGPD confirmation packet in member mode multicast to PGroupID, the proxy forwards it according to member mode multicast rules to the PGroupID, stops the timer and drops all scheduled transmissions for any packet to any binding destination resulting from the same ZGPD packet. Step 6ter: if the proxy receives the same ZigBee packet (i.e. derived from the same ZGPD frame and using the same destination and source aliasing information), which is unlikely, because it requires special receiving methods, such as promiscuous mode, the proxy stops the timer and drops all scheduled transmissions for any packet to any binding destination resulting from the same ZGPD packet. Step 7: After the timeout, the proxy sends the packet constructed as described above to the bound destination(s) and schedules retransmissions after the acknowledgment timeout. Step 8: One or several destination device(s) receive the ZigBee packet. If the alias source address is new, the destination devices discover the reoute to the alias. Otherwise, and following the route discovery, the destination devices construct an acknowledgment packet and unicast it to the alias. Step 9: During the acknowledgment timeout, if the proxy receives an acknowledgment packet in unicast from a destination device, then the proxy creates a ZGPD confirmation packet containing the source identifier and a sequence number corresponding to the received acknowledgment, as well as the short address of the destination that forwarded the APS ACK; then it forwards it to other destinations in the PGroupID, using multicast member mode and using PGroupID as destination address and alias as source address; and drops the scheduled re-transmissions of this packet, resulting from the same ZGPD frame to this binding destination Step 9bis : If the proxy receives the a ZGPD confirmation packet in member mode on PGroupID, the proxy forwards it according to member mode multicast rules to the PGroupID and drops the scheduled re-transmissions for this packet to this binding destination resulting from the same SrcID and sequence number. Step 10: If any proxy keeps seeing ZGPD packets, but does not receive acknowledgements from the destination(s), neither direct APS ACKs or APPL response commands, or indirectly via confirmation packets forwarded to the PGroupID, it should re-discover the route to the destination, so that the reverse route is also re-established—or the destination is discovered to be non-existent.
A third procedure will now be described, wherein the destination devices are assumed to have proxy capabilities. In such a case, the ZGPD frame, or a special notification frame derived from it can be forwarded all the way to the destinations. This allows the destination(s) to perform level duplicate filtering at proxy-endpoint level, without the need for the forwarding proxies to use special aliasing procedures, special multicast source address modes, or without the need for the complicated and bandwidth-consuming master proxy election procedure. The mentioned means may still be used, if minimizing the traffic to the destination(s) is desirable. Furthermore, binding information handling can still be simplified on the proxies. Broadcast communication can be used, because the proxy-capable destination is able to filter on the endpoint level, based on the packet content. Analogously, non-unique CGroupIDs, e.g. resulting from deriving a 2-bytes GroupID from a 4-bytes SrcID, can be used, because the destinations will be able to filter the packets, based on their content.
Thus, an exemplary procedure according to this third method can contain the following steps:
When receiving a packet from a previously unknown resource-restricted device, the proxies derive the CGroupID from the resource-restricted device's SrcID, and add themselves as group members. Each proxy constructs a notification packet, being ZigBee packet and containing the relevant fields of the ZGPD frame as a payload. When forwarding a packet to the destination on behalf of this resource-restricted device, the proxies use the derived CGroupID as NWK layer or APS layer destination address and use their individual source address and source sequence number.
If acknowledgements are required, upon receipt of such a notification packet, the proxy endpoint unicasts a notification response message back to the proxy having forwarded the notification. The proxy can then distribute the notification response among other proxies, by sending to PGroupID, so that other proxies can drop all scheduled transmissions and re-transmissions of the resource-restricted packet with the corresponding sequence number.
A fourth procedure will now be described, where source multicast group is used. As mentioned previously, in some cases it is required to receive an acknowledgment to the message derived from the ZGPD frame. However, in the case of multicast destination addressing, sending acknowledgment messages is not trivial, especially when multiple proxies forward independently to the destination(s). If address aliasing is used for source address determination by the proxies, the proxies are required to implement special procedures to respond to communication addressed both to their individual short address and to the alias. Still, many proxy devices may act on behalf of the same resource-restricted device, thus leading to multiple potential destinations for the APS ACK, resulting in
potential address conflict perception by the destination, when it tries to map the alias to an IEEE address or discover the route to any of the proxies using the alias; unless aliasing is used also for IEEE address, and/or in need for route re-discovery when the proxy that previously had shortest reverse path to the destination(s) or the master proxy disappears, e.g. is removed from the network or switched off), and/or in unnecessary transmissions by the proxies, due to the inability to observe or filter the same packet forwarded by different proxies.
If no aliasing is used by the proxies for source addressing, the destination that does not have proxy capabilities is unable to filter out duplicates. Furthermore, sending APS ACKs to multicast-addressed frames is strictly speaking not supported in the current ZigBee protocol.
Thus, it is herein proposed to extend ZigBee addressing modes to include GroupIDs as source addresses. This source GroupID (SGroupID) could be generated using a function of resource-restricted device's address: SGroupID=f3(SrcID), identical to or different than f1 and f2 described above.
One possibility to accommodate that in ZigBee is to include the SGroupID in the Source Address field of the network layer header, indicate that it is a group address by using one of the now reserved values in the Multicast Mode sub-field of the Multicast Control Field of the network layer header of a data frame (all frame/field formats below as defined by ZigBee specification release r17), no allow for network-layer multicast source addressing.
Another possibility is to accommodate that in the APS layer, using the APS header Group Address field in combination with the reserved value of the Delivery Mode subfield of the Frame Control field of the APS header, so that the destination can respond with APS level multicast, rather than NWK level multicast.
It will allow the controlled devices to respond with an acknowledgment (APS ACK or APPL response frame) even to multicast-destined packets, without address conflicts, without the proxies having to support the special aliasing, without the need of keeping data on changing master proxies, or frequent route re-discovery, or the problem of guaranteeing to address all of the potentially multiple forwarding devices.
Thus, and exemplary procedure according to this third method contains the following steps. When receiving a packet from a previously unknown resource-restricted device, the proxies add themselves as group members for the SGroupID derived from the resource-restricted device's SrcID; then, when forwarding a packet to the destination on behalf of this resource-restricted device, the proxies use this SGroupID as NWK layer source address and a source sequence number derived from the sequence number included in the resource-restricted frame, and further using CGroupID as the destination address on either network or APS level. Note that the proxies here are not members of the group CGroupID themselves. The CGroupID is preferably derived from the source identifier of the resource-restricted device, as described before, or can be configured and distributed among the proxies.
Upon receipt of such a packet with group source address, in non-member mode multicast, the destination forwards it to other destinations in the CGroupID, changing multicast mode to member mode and using CGroupID as destination address and SGroupID as source address and sends an acknowledgement to that SGroupID using non-member-mode multicast, with the CGroupID in the source address field. Upon receipt of such a packet with group source address, in member mode multicast, the destination forwards it according to member mode multicast rules.
Upon receipt of the multicast-targeted acknowledgement packet, in non-member mode multicast, the proxy forwards it to other destinations in the SGroupID, changing multicast mode to member mode and using SGroupID as destination address and CGroupID as source address. Upon receipt of the multicast-targeted acknowledgement packet, in member mode, the proxy forwards it according to member-mode multicast rules and drop all scheduled transmissions and re-transmissions of the resource-restricted packet with the corresponding sequence number.
It can happen that the proxies in the group SGroupID keep seeing and forwarding the ZGPD packets, but do not receive the acknowledgement from the destination anymore, neither directly or via the SGroupID-addressed multicast. This can indicate, that either the destination disappeared from the network (or moved), or that the reverse path to the SGroupID is broken, or that the previous entry point into the group SGroupID, i.e. the proxy with the best reverse cost to the destination disappeared. Then, the remaining proxies should force the destination to re-discover the reverse path to the group. This can be achieved by a proxy starting route discovery for the destination, with the SGroupID as the source, if the nwkSymLink parameter of the NIB is set to TRUE, as is the case for ZigBee PRO stack profile, or e.g. sending a maintenance command, such as Network Status Command, to the destination.
As can be seen from the above-description of several procedures, different combination of destination addressing schemes, source addressing schemes, and PGroupID and CGroup ID membership, as well as proxy capability at the destination(s) can be used. These combinations and the resulting solution properties and features are summarized in the table below:
(M) (O) Duplicate Proxy: Proxy EP: NWK Proxy- Duplicate (M) APS ACK multicast NWK layer APS (EP) layer capabilities filtering or APPL layer forwarding membership membership source at the at the response by filtering the (O) Proxy Reaching in CGroupID in CGroupID addr mode destination destination destination proxy keepalive all ZDs Yes Yes individual not required no no limited on Ep Yes; EP-level; One local ZD and not level all proxies cloud (Member- utilized mode) Yes No individual no no No No One local ZD cloud (Member- mode) No yes individual no no limited, Ep YES; EP-level ALL (depending leve, all all proxies on bcast range) proxies No No individual no no no No One dense ZD cloud, local or distant (Non- member mode) Yes yes Alias yes no EP level, NWK level; One local ZD potentially neighbour cloud, (member NWK/APS proxies only mode) layer Yes No Alias yes -″- Maybe NWK level; One local ZD NWK/APS neighbour could (Member- layer proxies only mode) No yes Alias yes -″- EP level, No All (depending Maybe NWK on bcast radius) level/APS level No No Alias yes -″- No No One distant ZD cloud (Non- member mode) Yes yes Multicast yes yes NWK layer NWK level; One local ZD SGroupID neighbour cloud (Member- proxies only mode) Yes No Multicast yes Yes NWK layer NWK level; One local ZD SGroupID neighbour cloud (Member- proxies only mode) No yes Multicast yes Yes APS layer No All (depending SGroupID on bcast radius) No No Multicast yes yes No (EP level No One distant ZD SGroupID in promiscouos cloud (Non- mode) member mode) Unicast individual No Yes No No All (requires storing bindings) Unicast Alias yes No No No All (requires storing bindings) Unicast Multicast yes Yes no no yes SGroupID Broadcast any Not possible at all Yes yes Individual Required, and Yes Yes (can be Yes Yes One local ZD utilized (proxyEP- distributed (ProxyEP- cloud (Member- level; to other level; lower- mode) lower-level proxies, level filtering filtering using possible possible PGroupID with aliasing/ with aliasing/ SGroupID source SGroupID addressing) source addressing) Yes No Individual Yes Yes (can be Yes Yes One local ZD (proxyEP- distributed (ProxyEP- cloud (Member- level; to other level; lower- mode) lower-level proxies, level filtering filtering using possible possible PGroupID with aliasing/ with aliasing/ SGroupID source SGroupID addressing) source addressing) No yes Individual Yes Yes (can be Yes Yes ALL (depending (proxyEP- distributed (ProxyEP- on bcast range) level; to other level; lower- lower-level proxies, level filtering filtering using possible possible PGroupID with aliasing/ with aliasing/ SGroupID source SGroupID addressing) source addressing) No No Individual Yes Yes (can be Yes Yes One danse ZD (proxyEP- distributed (ProxyEP- cloud, local or level; to other level; lower- distant (Non- lower-level proxies, level filtering member mode) filtering using possible possible PGroupID with aliasing/ with aliasing/ SGroupID source SGroupID addressing) source addressing) Unicast Individual Yes Yes (can be NO No yes (proxyEP- distributed level; to other lower-level proxies, filtering using possible PGroupID with aliasing/ SGroupID source addressing) Broadcast Individual Yes Yes (can be Yes yes Yes (proxyEP- distributed (proxyEP- level; to other level; lower- lower-level proxies, level filtering filtering using possible with possible PGroupID aliasing/SGroupID with aliasing/ source addressing) SGroupID source addressing)
The proper choice of the multicast communication flavour and thus also group membership in the proxies is the key, depending on the options.
A method according to the invention can be implemented into different procedures, some of them being above-described for illustrating purpose.
The present invention is more especially dedicated to be used in any wireless network using resource-restricted devices, such as lighting control networks, building automation and home automation networks.
In the present specification and claims the word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. Further, the word “comprising” does not exclude the presence of other elements or steps than those listed.
The inclusion of reference signs in parentheses in the claims is intended to aid understanding and is not intended to be limiting.
From reading the present disclosure, other modifications will be apparent to persons skilled in the art. Such modifications may involve other features which are already known in the art of wireless communications and which may be used instead of or in addition to features already described herein. | A method for wireless communication in a network comprising a resource-restricted device (ZGPD), at least two proxy devices (ZP 1 , ZP 2 ) and at least one destination device (DD), wherein the method comprises the following steps: the resource-restriced device transmitting a frame to be forwarded to a destination device in the network, said frame containing a unique source identifier of the resource-restricted device, at least one proxy device receiving the frame and identifying the frame as originating from a resource-restricted device, —the proxy device determining the unique source identifier and deriving a group identifier as a known function of the unique source identifier, the group identifier designating a group of devices in the network or a source address, the proxy constructing, from the frame, an appropriate packet to be forwarded, the proxy forwarding the packet by taking into account the group identifier. | 7 |
This application is a continuation-in-part of application Ser. No. 08/602,195 filed on Feb. 16, 1996, now U.S. Pat. No. 5,784,682.
TECHNICAL FIELD
This invention relates generally to systems for separating material and more particularly relates to systems which use electromagnetic radiation to separate constituents from a base material.
BACKGROUND OF THE INVENTION
Innovative technologies are needed to effectively (and efficiently) separate specific components from a variety of composite materials. For example, there is a need for toxic and/or inherently dangerous materials to be converted into commercially useful products. Also, there exists a large number of sites which are contaminated with toxic and/or radioactive waste materials. Although certain processes are known for cleaning up contaminated sites, many of them employ solvents or other chemicals which often increase the disposal problem in an attempt to reduce it.
More recently, the use of radio frequency has been employed for heating liquid wastes for both volume reduction and stabilization in solid form. This process involves the slow application of moderate levels of radio frequency (RF) power which permits melting and stimulates out gassing from liquids and solids. Another application of the use of energy for separating constituents from a base material is currently being pursued with respect to refining mineral ores.
Although the broad concept of using RF energy for separating constituents from a base material is known (e.g. mineral refinement, see U.S. Pat. Nos. 4,894,134 and 5,024,740), many problems exist which impede the cost effectiveness and general ability of RF techniques to be used in a way which makes the RF approach commercially feasible.
For example, fundamental limitations in the application of gyrotron technology has presented an impediment to implementing the power levels necessary to make the RF approach commercially feasible. The fundamental limitations in the RF approach which heretofore have impeded its application on a widespread commercial bases will now be explained.
In order for the RF approach to be commercially feasible, the process of separating constituents from a base material must be cost effective. Very often, a major determination of whether a process is cost effective involves flow rate at which the base material can be processed. It is a fundamental principal of radio frequency heating that the power absorbed by a base material is directly proportional to the volume of the material. By increasing the volume flow per unit time through a separating apparatus, the power applied must also be increased to effect the same constituent separation. Thus, the ability to deliver power to a base material has become the central focus, and critical limiting factor, regarding the rate at which constituents could be separated from base material.
In the vast majority of applications, for which constituents must be separated from a base material, a gyrotron or a gyro-frequency device is the only practical source for generating the necessary power levels. Beyond 30 GHz, the power available from classical tubes declines sharply. The gyrotron offers the possibility of high power at millimeter wave frequencies. Because of the smooth shape of the gyrotron circular wave guide, and other features of the gyrotron, it is more efficient than other microwave tubes. The power available with a gyrotron is many times greater than that available from classical tubes at the same frequency. Additionally, recent advancements in microwave tube technology have made it possible to generate power levels in the range of 200K Watt continuous wave (CW). Moreover, at least one gyrotron manufacturer is currently experimenting with a gyrotron capable of generating power in the range of one megawatt CW at 110 GH Z .
Although the generation of radio frequency power at the levels mentioned above, has potentially solved one of the primary impediments to making RF techniques for separating constituents commercially feasible, it has given rise to other problems. These will be explained in conjunction with FIG. 1.
Now referring to FIG. 1, the traditional approach when using RF energy for separating constituent materials from a base material is shown in FIG. 1. Traditionally, an RF source 10 is used (e.g. gyrotron, klystron, magnetron, etc.) for generating RF energy. This energy is conveyed through transmission line 12, window 14, transmission line 16 and into reaction chamber 18. Within reaction chamber 18 the base material 20 is metered through feed apparatus 22 and is acted upon by the RF energy within reaction chamber 18. This reaction typically involves sublimation whereby gas escapes from base material 20 and is removed from reaction chamber 18 by way of off gas pump 24.
Transmission line 12 and 16 form a conventional wave guide which functions to couple the transfer of energy from RF source 10 to reaction chamber 18. In many wave guide applications, a window is not necessary. However, in applications such as the one depicted in FIG. 1, it is critical to isolate the environment of RF energy source 10 from the environment of reaction chamber. The primary purpose for this isolation is to prevent any gases or particles released during the sublimation process to migrate into RF energy source 10. If gases or particles were permitted to enter the RF energy source, electrical arcing would occur damaging or potentially destroying the gyrotron. The traditional approach for preventing the migration of undesirable gases and particles into RF energy source 10 has been to use a window 14. Ideally, the window should be transparent (i.e. lossless) to the propagation of the electromagnetic waves while hermetically sealing reaction chamber 18 from RF energy source 10. As RF energy sources have increased in their ability to generate higher and higher power levels, various window designs have been implemented in order to withstand the heat which is generated within the window by virtue of its exposure to the electromagnetic energy. For example, U.S. Pat. No. 5,450,047 sets forth an improved wave guide window for use in high power wave guide applications. Also, an article entitled A VACUUM WINDOW OR A ONE MW CW 110 GHz GYROTRON, C. P. Moeller, J. P. Doane and M. DiMartino, General Atomics Report GA-821741 discloses a vacuum window which uses a water cooled sapphire as the dielectric.
Notwithstanding the advancements made in improving the ability of the window to be used in conjunction with higher and higher RF energy sources, the technology in generating RF energy has advanced to the point where the windows are the factor which limits the maximum power which can be developed in reaction chamber 18.
The present invention eliminates the limitations associated with the state of the art window technology (and its inability to transmit high power levels) by eliminating the requirement for a window while still hermetically sealing the RF energy source from the reaction chamber. Thus, by implementing the system of the present invention, the only factor which will limit the maximum amount of energy deliverable to a base material is the ability of the RF energy source to develop the energy and the ability of the reaction chamber to receive and focus the energy.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides an apparatus for separating constituents from a base material comprising a source for generating electromagnetic radiation, a resonator, and a reactor. The resonator forms a resonating cavity wherein the resonating cavity is coupled to the electromagnetic radiation source. The reactor defines a reaction chamber which is at least partially disposed within the resonating cavity. The reactor is sealed to the resonator in a way that the reaction chamber is hermetically sealed from the resonating cavity. By disposing the reactor within the resonator in this way, the power density experience per unit volume of the reactor wall is much less (orders of magnitude) than that which would be experienced by a traditional window arrangement. Thus, the apparatus of the present invention completely eliminates the maximum power level limitations imposed by traditional windows.
In a second aspect, the present invention provides a system for separating constituents from a base material including a first and second source for respectively generating first and second electromagnetic waves. First and second resonators are provided for respectively forming first and second resonating cavities and the first and second resonating cavities are respectively coupled to the first and second magnetic wave sources. A reactor which defines a reaction chamber is partially disposed within the first and second resonating cavities wherein the first and second resonators are sealed to the reactor such that a first and second resonating cavities are hermetically sealed from the reaction chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 discloses a typical prior art system for separating constituents from a base material.
FIG. 2 shows the first embodiment of the system of the present invention.
FIG. 3 shows the preferred embodiment for the reaction chamber of the present invention.
FIG. 4 shows a top view of the reaction chamber of FIG. 3.
FIG. 5 shows a second embodiment of the system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring to FIG. 2, the system of the present invention includes RF energy source 10 which is coupled to resonator 30 by way of transmission line 12. Although the preferred RF energy source includes a gyrotron, a magnetron, klystron, traveling-wave tube, or any other high power RF source may be equally suitable depending on the power requirements of the task at hand. Consistent with techniques well known in the art, RF energy source 10 is used to generate RF energy and that energy is coupled into resonator 30 by way of transmission line 12. Preferably, resonator 30 is comprised of copper, stainless steel, or any other material which is highly reflective of RF energy. Base material 20 is stored within upper bin 25 and is metered from upper bin 25 (through material feed gate 22) into reactor 21. Reactor 21 is defined by reactor walls 19 which form reaction chamber 18. Reactor walls 19 can be constructed from any material transparent to RF waves including suitable pyrolytic material such as boron nitride, silicon nitride, quartz, sapphire, or diamond material.
In some applications, the power levels present within resonating cavity 34 may be sufficiently high to necessitate reinforcement of reactor walls 19. If such support is needed, one preferred way of adding this support is shown in FIGS. 3 and 4. In this preferred embodiment, reaction chamber 18 includes reactor walls 19 which are surrounded by a physical support structure such as metal mesh 36. The particular material used to construct mesh 36 is not critical as long as it provides sufficient strength to counteract the forces experienced by reaction walls 19 during the presence of RF power within resonator 30. Also, it is readily understood by those skilled in the art that the interstices formed by mesh 36 must be of sufficient spacing so as to permit RF energy to pass by the mesh (and enter into reaction chamber 18) while still giving ample support to walls 19.
Resonator 30 is defined by resonator walls 32 which form resonating cavity 34. RF energy enters into resonating cavity 34 by way of transmission line 12, and exits therefrom by transmission line 13, and is terminated into beam dump 38. RF energy residing within resonating cavity 34 freely passes through reactor walls 19 to act on base material 20 as base material passes through resonating cavity 34. As has already been explained, the RF energy acts to sublimate, vaporize, or otherwise separate constituents from the base material. If this separation gives rise to creation of gases, these gases are drawn from reaction chamber 18 by way of off gas pump 24. Off gas pump 24 also acts to create a pressure vacuum (less than atmospheric pressure) within reaction chamber 18.
It is important to note that reactor walls 19 are uninterrupted (continuous) at all locations within resonating cavity 34 and thus form a hermetic seal with respect to transmission line 12 and source 10. Thus, there is no passageway provided whereby base material 20 (or any constituents freed from base material) can escape from reaction chamber 18 to enter into the portion of resonating cavity 34 not confined by reaction chamber 18. Thus, with the system set forth in FIG. 2, the portion of resonating cavity 34 surrounding reaction chamber 18, transmission line 12, and RF energy source 10 are kept free from any base material or constituents freed therefrom.
It is readily seen from FIG. 2 that the surface area of reactor walls 19 confined within resonating cavity 34 is much greater than the surface area of a hypothetical window which would otherwise be used in this process. It is by this difference in surface area that the present invention allows the use of much higher power levels from RF energy source 10 than would otherwise be possible. Preferably, reactor walls 19 are shaped to form a circular cylinder geometry. However, a circular cylinder might not be the only acceptable geometry, and accordingly, many other geometries may exist which optimize the mechanical, electrical, thermal, and other physical properties which reactor walls 19 must possess in order to function as described herein.
Preferably, off gas pump 24 generates a vacuum in the range of 10 -10 torr.
In its preferred embodiment, reactor walls 19 are surrounded by heat exchanger 40 having inlet port 42 and outlet port 44. Heat exchanger 40 defines a fluid tight chamber surrounding a predetermined segment of walls 19 wherein a dielectric fluid, such as FLUORINERT® (manufactured by Minnesota, Mining & Manufacturing Co.) is passed therethrough conducting heat away from reactor walls 19. FLUORINERT® is a family of completely fluorinated organic compounds derived from common organic compounds by replacement of all carbon bound hydrogen atoms with fluorine atoms.
Now referring to FIG. 5, in a second embodiment of the present invention, three systems, each one identical to that shown in FIG. 2, are stacked one on top of the other, to form a serial processing system. The advantage of the system shown in FIG. 5, is that it is capable of targeting a plurality of constituents to be separated from a base material. For example, a base material 20 is stored in upper bin 25 having certain known impurities. These impurities are known to be released from the base material when subjected to RF energy at a given frequency and a predetermined power level. RF energy source 46 is set at a first predetermined frequency and power level which is known to sublimate the first impurity which will be drawn off by pump 48. The second impurity is known to sublimate at a second predetermined frequency and power level and RF energy source 50 is so adjusted such that the second impurity is sublimated and drawn off by pump 52 as base material passes through resonator 51. Likewise, the third RF energy source 54 is set to a third predetermined frequency and power level such that the third targeted impurity is drawn by pump 56 as it sublimates within resonating cavity 55. Thus the system set forth in FIG. 5 is effective for removing at least three impurities found within base material 20 and also is effective for rendering purified product 58.
It is well known to those skilled in the art that the resonating cavities 47, 51, and 55 must be electrically isolated from one another to prevent crossover of the electromagnetic energy between the cavities. Techniques for preventing this crossover are well known.
While the foregoing description of the invention has been made with respect to preferred embodiments, persons skilled in the art will understand in light of the present disclosure, that numerous changes, modifications and alterations may be made therein without departing from the spirit and the scope of the present invention. For example, out of convenience, when describing the present invention herein, the gas sublimated or vaporized from the base material has been referred to as the impurity. This convention has simply been adopted out of convenience and it is well recognized that the gas released from the base material may in fact be a valuable byproduct. Also, although not specifically disclosed herein, it is also recognized that introducing gases into reaction chamber 18 may provide certain advantages such as accelerating sublimation/vaporization, cooling reaction chamber 18, etc. Therefore, all such changes, modifications, and alterations are deemed to be within the scope of the invention as defined in the following claims. | A system for separating constituents from a base material using RF energy which is coupled to a reaction chamber by way of a windowless transmission line. By eliminating the need for a window, traditional limitations placed on the maximum power delivered to the resonating cavity are eliminated. Thus, the only practical limitation on the RF energy which can be delivered to a resonating cavity are the ability of RF energy source to produce that energy and the ability of the resonating cavity to manage that energy. | 8 |
BACKGROUND
[0001] Environment variables are a set of dynamic values that may affect the way running processes will behave on a computer. In Unix and Unix-like systems, each process has its own private set of environment variables. By default, when a process is created it inherits a duplicate environment of its parent process, except for explicit changes made by the parent when it creates the child. Alternatively, from shells such as bash, an environment variable may be changed for a particular command invocation by, for example, indirectly invoking it via env or using the ENVIRONMENT_VARIABLE=VALUE<command>notation.
[0002] Regular expressions are a context-independent syntax that may represent a wide variety of character sets and character set orderings, where these character sets are interpreted according to the current locale. While many regular expressions may be interpreted differently depending on the current locale, many features, such as character class expressions, provide for contextual invariance across locales.
[0003] In computing, regular expressions may provide a concise and flexible means for identifying strings of text of interest, such as particular characters, words, or patterns of characters. Regular expressions are written in a formal language that may be interpreted by a regular expression processor, a program that either serves as a parser generator or examines text and identifies parts that match the provided specification.
SUMMARY
[0004] A method for selecting at least one smart card reader from a list of smart card readers includes receiving a parameter indicative of a reader selection criteria, setting an environment variable that specifies a reader filtering library, and executing an application that uses a smart card access library. The smart card access library presents smart card access infrastructure to the application. The method also includes interposing the reader filtering library between the application and the smart card access library to filter the list according to the reader selection criteria to select at least one of the smart card readers.
[0005] A method for selecting at least one smart card reader from a list of smart card readers includes receiving a first environment variable indicative of a reader selection criteria, setting a second environment variable that specifies a reader filtering library, and executing an application that uses a smart card access library that implements a smart card API. The method also includes proxying the reader filtering library between the application and the smart card access library to filter the list according to the reader selection criteria to select at least one of the smart card readers.
[0006] A system for selecting at least one smart card reader from a list of smart card readers includes one or more computers configured to receive a parameter indicative of a reader selection criteria, set an environment variable that specifies a reader filtering library, and execute an application that uses a smart card access library that implements a smart card API. The one or more computers are further configured to interpose the reader filtering library between the application and the smart card access library to filter the list according to the reader selection criteria to select at least one of the smart card readers.
[0007] While example embodiments in accordance with the invention are illustrated and disclosed, such disclosure should not be construed to limit the invention. It is anticipated that various modifications and alternative designs may be made without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram of an embodiment of an Integrated Circuit Card (ICC) environment.
[0009] FIG. 2 is a block diagram of another embodiment of an ICC environment.
[0010] FIG. 3 is a flow chart depicting an example algorithm for selecting at least one ICC from a list of ICCs.
DETAILED DESCRIPTION
[0011] Referring now to FIG. 1 , an embodiment of an Integrated Circuit Card environment 10 includes a plurality of Integrated Circuit Cards (ICCs) 12 each inserted into a respective interface device (IFD) 14 . The IFDs 14 are in communication with one or more computers 16 .
[0012] Each of the ICCs 12 , or smart cards, includes a credit card-sized plastic case 18 with an embedded microprocessor chip 20 . In certain embodiments, the microprocessor chip 20 may have the ability to store large amounts of data, carry out on-card functions, e.g., encryption and mutual authentication, and interact intelligently with an IDF 14 . Of course, in other embodiments the ICCs 12 may instead include a memory chip. The ICCs 12 of FIG. 1 conform physically and electrically to the ISO 7816-1, 7816-2, and 7816-3 standards. In other embodiments, the ICCs 12 may be contactless and communicate with the IFDs 14 using, for example, radio frequencies. Any suitable ICC configuration, however, may be used. For example, the ICCs 12 may take the form of fobs, subscriber identification modules used in GSM mobile phones, or USB-based tokens.
[0013] As known in the art, the ICCs 12 may be used as digital identification cards. In this application, the cards are used for authentication of identity. A common use example is in conjunction with a PKI. An ICC 12 may store an encrypted digital certificate issued from the PKI along with any other relevant or needed information about the card holder.
[0014] The IFDs 14 , or smart card readers, are physical interface devices through which the ICCs 12 may communicate with the one or more computers 16 . The IFDs 14 may provide DC power to the microprocessor chips 20 . Also, the IFDs 14 may provide clock signals which step the program counters of the microprocessor chips 20 , as well as an I/O line through which digital information may be passed between the IFDs 14 and the ICCs 12 .
[0015] The IFDs 14 may have one or more slots to read the ICCs 12 and may also support some extended capabilities such as display or PINpad. The IFDs 14 may use a variety of physical access ports to the one or more computers 16 . Typically, these will be the keyboard port, a serial line port, a PC Card (PCMCIA), or the Universal Serial Bus (USBport). In some embodiments, the IFDs 14 may conform to the ISO 7816-1, 7816-2 and 7816-3 standards. In addition, the IFDs 14 may support synchronous cards or the ISO/IEC 14443 or 15693 protocol for contactless cards.
[0016] The one or more computers 16 of FIG. 1 include a plurality of Interface Device Handlers (IFD Handlers) 22 and an ICC Resource Manager 24 . The IFD Handlers 22 may encompass the software to map the native capabilities of the IFDs 14 to the IFD Handlers 22 . In certain embodiments, the IFD Handlers 22 are low-level software within the one or more computers 16 that support the specific I/O channels used to connect the IFDs 14 to the one or more computers 16 and may provide access to specific functionality of the IFDs 14 .
[0017] The IFDs 14 and IFD Handlers 22 may handle the protocols necessary for the ICCs 12 and map Application Data Units (APDUs) given by an application to the corresponding ICC commands. For contactless ICCs 12 , implementation of the IFDs 14 and IFD Handlers 22 may emulate basic functional requirements such as card insertion and removal events, etc. The IFDs 14 and IFD Handlers 22 may also take care of the initialization, selection and communication processes with the ICCs 12 . In different embodiments, the IFDs 12 may vary in their implementations. For the simplest devices, an IFD 14 may provide little more than electrical connectivity and I/O signal passing between the ICC 12 and the one or more computers 16 . In more complex configurations, for example, an IFD 14 may support the data link layer protocols defined in the ISO 7816-3 standard.
[0018] The ICC Resource Manager 24 may be responsible for managing ICC-relevant resources and for supporting controlled access to the IFDs 14 and, through them, individual ICCs 12 . The ICC Resource Manager 24 may perform several access management functions for the ICCs 12 and IFDs 14 . First, the ICC Resource Manager 24 may be responsible for identification and tracking of resources. This may include tracking installed IFDs 14 and making this information accessible to other applications, tracking known ICC types, along with their associated service providers 26 (discussed below) and supported Interfaces, and making this information accessible to other applications, and tracking ICC insertion and removal events to maintain accurate information on available ICCs 12 within the IFDs 14 . Second, the ICC Resource Manager 24 may be responsible for controlling the allocation of IFDs 14 and resources (and hence access to ICCs 12 ) across multiple applications. In certain embodiments, the ICC Resource Manager 24 may do this by providing mechanisms for attaching to specific IFDs 14 in shared or exclusive modes of operations. Additionally, the ICC Resource Manager 24 may support transaction primitives on access to services available within a given ICC 12 . This may be important, as some ICCs 12 are single-threaded devices, which may require execution of multiple commands to complete a single function. Transactions may allow multiple commands to be executed without interruption, ensuring that intermediate state information is not corrupted.
[0019] The one or more computers 16 may further include service providers 26 (e.g., ICC Service Provider (ICCSP) 28 and IFD Service Provider (IFDSP) 30 ) and one or more ICC Aware Applications 32 . The service providers 26 may encapsulate functionality exposed by a specific ICC 12 or IFD 14 , and make it accessible through high-level programming interfaces. These interfaces may be enhanced and extended to meet the needs of specific application domains. In certain embodiments, the service providers 26 may be client/server components. Any suitable configuration, however, may be used.
[0020] The ICCSP 28 interfaces ICC functionality. As known in the art, there may be several different types of ICCSP 28 . As an example, ICC Operating System Service Providers (ICCOSSPs) may encapsulate access to functionality from a specific ICC Operating System (ICCOS) through high-level programming interfaces. An ICCOSSP may need to be introduced to the ICC Resource Manager 24 to map it to a particular ICCOS. There may be a one-to-one relationship between the ICCs 12 and their ICCOSSP. As another example, Application Domain Service Providers (ADSPs) interface a particular on-card application. This may differentiate the ADSPs from other ICCSP 28 which interface to an ICC-type or ICCOS. As yet another example, Application Domain Service Provider Locators (ADSPL) allow dynamic assignment of certain ICCSP 28 because the static linking between ICC-Type and available ICCSPs 28 , as performed by the ICC Resource Manager 24 , may not be possible in a multi-application card environment. The ADSPL may be loaded by the ICC Resource Manager 24 and may allow ICC Resource Manager 24 to provide off-card applications with, for example, a way of listing on-card applications and a way of retrieving a reference to the appropriate ADSP implementation related to a chosen on-card application.
[0021] Generally, the ICCs 12 may be identified by the ATR String they present to the off-card system. All information regarding the identification of an ICC 12 may be available on the ICC 12 itself. Identity information is stored in an ICC Info Structure, or “extended” ATR. The information may be placed, for example, in a file or applet depending on the ICC technology. The ICCs 12 may include a command in the ATR's historical bytes, which may be used by the off-card system, e.g., the ICC Resource Manager 24 , to retrieve the ICC Info Structure.
[0022] In embodiments having this type of enhanced ICC 12 , the ICC Resource Manager 24 may interpret the historical bytes of the ATR, send the included command back to the ICC 12 , and retrieve the ICC Info Structure. The information from this structure may then be used by the ICC Resource Manager 24 to identify the ICC 12 .
[0023] When one of the ICCs 12 is, for example, inserted into one of the IFDs 14 , the ICC Resource Manager 24 may retrieve the ICC Info, get the ADSPL reference from the ICC Info Structure and load the ADSPL. If appropriate, the ICC Resource Manager 24 may retrieve the list of on-card applications from the ADSPL. The off-card application may get this list from the ICC Resource Manager 24 . It may then choose from this list the appropriate on-card application and load the corresponding ADSP to interact with the on-card application.
[0024] If extended IFD 14 capabilities are available, they may be presented to the ICC Aware Applications 32 or ICCSP 28 through high level programming interfaces implemented in the IFDSP 30 . The IFDSP 30 may encapsulate access and interface with IFD functionality in the same way the ICCSP 28 interface with ICC functionality.
[0025] For each Application Context (which may define some type of functionality), the IFDSP 30 may provide different interfaces. The interface implementation by the IFDSP 30 may interact with the implementation of the IFD Handler 22 in a mode that is transparent to the ICC Resource Manager 24 . In certain embodiments, the IFDSP 30 may be composed of modular components. As such, the services associated with an IFD 14 may evolve, as in an IFD 14 with download capability.
[0026] The ICC Aware Application 32 may be an arbitrary software program within the operating environment of the one or more computers 16 that wants to make use of the functionality provided by one or more of the ICCs 12 . In the embodiment of FIG. 1 , the ICC Aware Application 32 is running as a process within a multi-user, multiprocess, multiple-threaded, and multiple device environment. Application requests may be mapped to the ICCs 12 .
[0027] In certain circumstances, the ICC Aware Application 32 may assume that only one IFD 14 is available or may select the first IDF 14 presented by an ICC library. For example, as illustrated in FIG. 1 , each of the IFDs 14 has an ICC 12 . Only one of the ICCs 12 may be viable for logging in. If the incorrect IFD 14 is selected, an attempt to log in may be unsuccessful.
[0028] Referring now to FIG. 2 , numbered elements that differ by 100 relative to the numbered elements of FIG. 1 have similar descriptions to the numbered elements of FIG. 1 . Another embodiment of an Integrated Circuit Card environment 110 may be presented as a peer-to-peer communication protocol. For example, data may be exchanged between an IFD 114 and ICC Communication Controller 134 as controlled by the ISO 7816 protocol. APDUs may be passed between an ICC Service Provider 128 and an ICC Operating System 136 (also controlled by the ISO 7816 protocol). Service requests may be passed between an ICC Aware Application 132 and an ICC Application 138 . Of course, other configurations are also possible.
[0029] Referring now to FIGS. 1 and 3 , a user specifies a reader selection criteria in, for example, an environment variable as a regular expression as indicated at 40 . The regular expression may determine which IFDs 14 from among a list of available IFDs 14 will be matched and selected for further processing. (The unmatched IFD names in the list may be discarded.) As indicated at 42 , another environment variable, e.g., LD_PRELOAD, is set to indicate the location (directory path and file name) in the file system where a filtering library is located. Other suitable techniques, however, may be used.
[0030] As indicated at 44 , an application 32 is started that loads, for example, the PC/SC-lite library. Any suitable library, however, may be loaded. As known to those of ordinary skill, this library presents an ICC access Application Programming Interface (API) via which the IFDs 14 may be located and accessed, and through which the ICCs 12 may be communicated with programmatically.
[0031] As indicated at 46 , the filtering library is interposed between the application 32 and the ICC access library. In certain embodiments, when the application 32 is launched, the filtering library specified in the LD_PRELOAD environment variable is loaded by the operating system, before any of the libraries used by the application 32 are loaded. This filtering library, or interposing library, may be librdrselect.so.1, which defines a single function named SCardListReaders( ). A function by the same name, SCardListReaders( ) is also defined in the ICC library, libpcsclite.so.1, (a library that implements and exposes the PC/SC-lite API). Because librdrselect.so.1 (the interposing library) and libpcsclite.so.1 (the ICC library being interposed upon) both expose a function of the same name, i.e., SCardListReaders( ), the interposing library's differing implementation of the identically named function will be called anytime the application 32 invokes SCardListReaders( ) (instead of the ICC library's implementation of SCardListReaders( ) getting called, due to library interpositioning managed by the operating system in a way transparent to the application 32 ).
[0032] When such a preloaded library's function intercepts a function call, and then the preloaded function invokes the function it intercepts (in this example, when SCardListReaders( ) defined in librdrlist.so.1 invokes SCardListReaders( ) in libpcsclite.so.1), the intercepting function may be said to be “interposing” or “proxying” because the interposer is effectively juxtaposed between the calling application and the application's intended target library (in this case the ICC library). Such an interposing library function may be in a position to collect, analyze, filter, process and modify data that flows between the application 32 and the intercepted function.
[0033] When the interposing SCardListReaders( ) function is called, it may perform a service of filtering the list of IFD names returned by the original SCardListReaders( ) function in the ICC library according to the following example algorithm:
1. The environment variable LIBRDRSELECT is read by the interposer and the regular expression that determines the reader selection criteria is extracted from it. 2. The interposer collects the SCardListReaders( ) function parameters sent by the application 32 and uses them as arguments in a forward call to SCardListReaders( ) in the ICC library. 3. The ICC library returns a list of IFDs 14 to the immediate caller, which is, in this example, the interposer library. 4. The list of reader names returned from SCardListReaders( ) in the ICC library is iterated through by SCardListReaders( ) in the interposer library, in a loop to find those names that match the regular expression selection criteria described in 1 by invoking a function that processes regular expressions against a string, returning a match or non-match indication. 5. The list of matching IFDs 14 , i.e., the filtered IFD list, is returned to the application 32 , which is the immediate caller of the interposer library.
[0039] As apparent to those of ordinary skill, the algorithms disclosed herein are explained within the context of a UNIX system. Of course, the algorithms may be implemented in other suitable operating system environments. Furthermore, the algorithms may be deliverable to a processing device in many forms including, but not limited to, (i) information permanently stored on non-writable storage media such as ROM devices and (ii) information alterably stored on writeable storage media such as floppy disks, magnetic tapes, CDs, RAM devices, and other magnetic and optical media. The algorithms may also be implemented in a software executable object. Alternatively, the algorithms may be embodied in whole or in part using suitable hardware components, such as Application Specific Integrated Circuits (ASICs), state machines, controllers or other hardware components or devices, or a combination of hardware, software and firmware components.
[0040] While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. | A method for selecting at least one smart card reader from a list of smart card readers includes receiving a parameter indicative of a reader selection criteria, setting an environment variable that specifies a reader filtering library, executing an application that uses a smart card access library, and interposing the reader filtering library between the application and the smart card access library. | 6 |
CROSS REFERENCE
This application claims priority to German Patent Application No. 10 2012 101434.5, filed Feb. 23, 2012, which is expressly incorporated in its entirety by reference herein.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a lens bracket for accommodating a lens in a headlamp, said headlamp being formed substantially by a housing made of a base body and a lens cover, and wherein the lens bracket is made of a plastic body.
BACKGROUND OF THE INVENTION
In the case of headlamps, which in particular have an inclined lens cover, light rays from the sun can radiate in obliquely from above through the lens cover into the housing. A portion of the light rays from the sun can arrive through the lens and be focused by the lens on the plastic body of the lens bracket. By this means, damage to the plastic body can occur.
DE 198 03 986 A1 shows, for example, a headlamp for a vehicle, and the headlamp has a projection module with a projector lens, and the lens has a processed region in the upper region thereof, through which the radiation from the sun can arrive. The processed region can, for example, be sand blasted or stone-blasted, or a coating is provided in the upper region, wherein, due to the measures listed, a passing through of the solar radiation is prevented by the lens. Disadvantageously, during installation of the lens in the light module, the rotational position of the lens must be considered so that the processed region is located upward in the installed position of the lens. Further, the processed region is visible for an observer from the outside of the headlamp, which can be perceived as disruptive in relation to the desired appearance of the headlamp.
DE 299 12 504 U1 proposes a headlamp with a light module, in which a plano-convex lens is incorporated, and the plano-convex lens has a surface structure on the inner face, by means of which structure a scattering of sunlight incoming into the lens is generated. By this means, a focusing of the sunlight is avoided, for example, on the inner side of the lens bracket produced from plastic. Admittedly, this measure is no longer visible for an observer from the outside of the headlamp; however, the region having the altered surface structure on the face of the lens can disturb the beam path from the headlamp light in the light module.
In DE 10 2005 021 704 A1, an anti-dazzle device is proposed, and further components in the light module are screened from sunlight incoming through the lens by means of the anti-dazzle device. The shade is thereby implemented as a complex stamp-bent component and must be complexly disposed separately on a component.
SUMMARY OF THE INVENTION
The underlying problem of the invention is protecting a headlamp from incoming solar radiation in a simple way. It is in particular the object of the invention to create a protector of a lens bracket disposed in the headlamp, which lens bracket is produced from a plastic body, wherein the protection is preferably not visible from the outside of the headlamp, and in particular does not disturb the beam path of the light provided by the headlamp and is easily implemented.
This problem is solved proceeding from a lens bracket as well as a headlamp in connection with the respective characterizing features.
The invention includes the technical teaching that the plastic body has a metal surface element which is designed in such a manner that the plastic body is protected from radiation incoming into the housing through the lens cover and entering through the lens.
Inventively, the lens bracket is designed as a hybrid component, and the lens bracket consists of a base body made of plastic and a metal surface element applied at least partially to the surface of the base body. The invention thereby provides that the solar radiation can arrive through the lens, and further measures to prevent the radiation from entering through the lens are no longer necessary. If a light focusing effect does occur in the solar radiation entering through the lens, then this light focusing effect does not lead to damage of the metal surface element. The disadvantages of the prior art are surmounted as follows by using the inventive arrangement of a metal surface element on the plastic body of the lens bracket. In particular, the lens does not need to have a structured region that would be visible from outside of the headlamp, and the lens can be installed in any random rotational direction in the lens bracket. A further advantage consists in that the beam path of the light emitted by the illumination means present in the headlamp is not impaired. In order to minimize the reflection of scatter effects, the metal surface element on the plastic body forming the lens bracket can have a matte surface.
The plastic body can have an opening region in the interior thereof, in which opening region the lens can be accommodated, and the metal surface element is preferably located on one inner side of the plastic body facing the opening region. The inner side of the plastic body forms the surface that can be damaged by a focusing glass effect in conjunction with the entering solar radiation. Consequently, the metal surface element can preferably be applied at least partially to the inner side of the plastic body, which inner side faces into the opening region for accommodating the lens.
Further, the plastic body can be designed as a freeform body with a freeform contour, and the metal surface element can likewise form a freeform body corresponding to the freeform contour of the inner side of the plastic body. If the freeform contour of the metal surface element corresponds to the freeform contour of the plastic body, in that the metal surface element is to be applied on the plastic body, then the metal surface element forms a body complementary to the corresponding region of the plastic body and requires no substantial additional installation space for the arrangement on the plastic body.
As a particular advantage, the plastic body can be produced by means of an injection molding process and the plastic body can be injected on the metal surface element. For this purpose, the metal surface element can, for example, be inserted into an injection mold in order that the plastic mass can be subsequently injected into the injection mold to form the plastic body. As a result, there exists a connection between the plastic body and the metal surface element so that the lens bracket is designed as a hybrid component.
According to a further embodiment, the metal surface element can be glued, snapped in, or connected, by means of connecting means with the plastic body, to the inner side of the plastic body. For this purpose, the metal surface element can, for example, be designed as a film, but also as a dimensionally stable metal body.
The plastic body can have a section surrounding the opening region on the underside of the plastic body and the metal surface element can be applied advantageously to the inner side of the section on the underside. If the solar radiation infalls from above through the lens cover and through the lens, then a focusing glass effect occurs preferably on the underside section of the plastic body. Thus, the arrangement of the metal surface element on the underside section of the plastic body can be limited.
The invention is directed further at a headlamp having a lens bracket for accommodating a lens, having a housing which is formed substantially from a base body and a lens cover, and wherein the lens bracket is incorporated in the housing and is designed as a plastic body, and it is provided that the plastic body has a metal surface element which is designed in such a manner that the plastic body is protected from radiation incoming into the housing through the lens cover and entering through the lens. The features and advantages of the previously described lens bracket can likewise be used in an inventive headlamp having a lens bracket of this type.
These aspects are merely illustrative of the innumerable aspects associated with the present invention and should not be deemed as limiting in any manner. These and other aspects, features and advantages of the present invention will become apparent from the following detailed description when taken in conjunction with the referenced drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made more particularly to the drawings, which illustrate the best presently known mode of carrying out the invention and wherein similar reference characters indicate the same parts throughout the views.
FIG. 1 shows an embodiment of a headlamp in cross-sectional view having a lens bracket that inventively consists of a plastic body and a metal surface element,
FIG. 2 shows a three-dimensional representation of a plastic body having a metal surface element for forming the lens bracket, and
FIG. 3 shows a cross-sectional shape of a section of the plastic body having an applied metal surface element.
DETAILED DESCRIPTION
In the following detailed description numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. For example, the invention is not limited in scope to the particular type of industry application depicted in the figures. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.
FIG. 1 shows a schematic representation of a headlamp 1 which can, for example, be used for a vehicle. The headlamp 1 has a housing that is substantially formed by a base body 12 and a lens cover 13 on the front side. A light module 18 is arranged in the housing of the headlamp 1 , and the light module 18 can, for example, serve for providing a low beam and/or a high beam light. The light module 18 is substantially formed by a reflector 19 , an illumination means 20 , and a lens bracket 10 arranged on the reflector 19 , in which lens bracket a lens 11 is incorporated. The light module 18 is designed as a projection module, and when the illumination means 20 is operated and light is emitted into the reflector 19 , then the light reflects at the reflector 19 and passes through the lens 11 . Subsequently, the light can exit the headlamp 1 through the lens cover 13 .
The lens bracket 10 has a plastic body 14 which forms the base body of the lens bracket 10 , and the plastic body 14 is implemented with an opening region 16 in which the lens 11 is incorporated. The opening region 16 is limited by an inner side 17 of the plastic body 14 and a metal surface element 15 is inventively located in the lower region of the inner side 17 .
For example, a solar radiation 21 is represented that irradiates in obliquely from above through the lens cover 13 and through the lens 11 to the inner side 17 of the plastic body 14 . Under certain circumstances, as shown, a focusing of the solar radiation 21 can occur on the surface of the inner side 17 , and the metal surface element 15 is inventively arranged on the inner side 17 , which metal surface element is irradiated by the focused, yet also for example by the slightly defocused solar radiation 21 . Due to the embodiment of the lens bracket 10 with a metal surface element 15 on the inner side thereof, the incoming and substantially focused solar radiation 21 cannot damage the surface of the lens bracket 10 because the metal surface element 15 is not damaged by irradiation with the focused solar radiation 21 .
FIG. 2 shows a lens bracket 10 made of a plastic body 14 , which bracket is produced as a freeform body by injection molding. The plastic body 14 has an opening area 16 at the inner side of the plastic body, and a metal surface element 15 is applied on the underside section of the plastic body 14 on the inner side 17 thereof. The metal surface element 15 has a freeform which corresponds to the freeform of the underside section of the inner side 17 of the plastic body 14 . Consequently, the contour of the metal surface element 15 follows the contour of the inner side 17 of the plastic body 14 . The metal surface element 15 is, according to the embodiment shown, insert molded by the plastic body 14 , for example in that the metal surface element 15 is already inserted into an injection molding die for producing the plastic body 14 prior to the injection of the plastic mass.
FIG. 3 shows in a cross-sectional view a partial region of the plastic body 14 with an applied metal surface element 15 . It is thereby conceivable that the shape of the metal surface element 15 follows the contour of the plastic body 14 , and the metal surface element 15 can, for example, be implemented as a film or as a thin metal sheet.
The advantage of a lens bracket 10 implemented as a hybrid body lies in the free configurability of an injection molded plastic body 14 with a low weight. If the metal surface element 15 is merely arranged on the inner side 17 in the opening region 16 of the plastic body 14 , then the lens bracket 10 does not have a large total weight, such that the headlamp 1 does not undergo any substantial addition of weight thereof due to the use of a hybrid lens bracket 10 .
The invention is not limited in its implementation to the previously indicated embodiment. Rather, a number of variants is conceivable, which also make use of the solution represented in fundamentally different embodiments. All features and/or advantages, including design details or spatial arrangements, arising from the claims, the description, or the drawings can be essential to the invention in themselves and also in the most varied combinations. Within the context of the present invention, a direct connection between the metal surface element 15 at the plastic body 14 is, for example, not necessary. For example, the metal surface element 15 can also be arranged at a distance in or on the plastic body 14 without implementing the metal surface element 15 as adjoining with the plastic body 14 across the entire surface of the metal surface element. Further, the metal surface element 15 can be applied as a metal coating to the inner side 17 of the plastic body 14 .
The preferred embodiments of the invention have been described above to explain the principles of the invention and its practical application to thereby enable others skilled in the art to utilize the invention in the best mode known to the inventors. However, as various modifications could be made in the constructions and methods herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by the above-described exemplary embodiment, but should be defined only in accordance with the following claims appended hereto and their equivalents.
LIST OF REFERENCES
1 Headlamp
10 Lens bracket
11 Lens
12 Base body of the housing
13 Lens cover
14 Plastic body
15 Metal surface element
16 Opening region
17 Inner side
18 Light module
19 Reflector
20 Illumination means
21 Radiation, solar radiation | A lens bracket for accommodating a lens in a headlamp and a headlamp having a lens bracket of this type, said headlamp being formed substantially by a housing made of a base body and a lens cover, and wherein the lens bracket is designed as a plastic body. It is inventively provided that the plastic body has a metal surface element which is designed in such a manner that the plastic body is protected from radiation incoming into the housing through the lens cover and entering through the lens. | 5 |
FIELD OF THE INVENTION
The present invention relates to amino acid derivatives and more particularly concerns 1,2-diketo derivatives useful, for example, as renin inhibitors.
BACKGROUND OF THE INVENTION
Szelke et al., in European Patent Application No. 0,104,041 A1, disclose various polypeptide analogues. These analogues, useful as renin inhibitors, include polypeptide 1,2-ketoamides wherein the amide group comprises a peptidic function.
In Australian Patent Abstract No. AU-A-52881/86, Kolb et al. disclose new activated electrophilic ketone-bearing peptidase inhibitors. Among the analogues disclosed are polypeptidyl 1,2-hydroxy esters and 1,2-keto esters useful for renin inhibition.
Kubota et al., in European Patent Application No. 0,190,891 A2, disclose amino acid derivatives of the formula ##STR2## wherein when n=0, polypeptidyl 1,2-hydroxy esters are provided. These compounds are also disclosed as having activity as renin inhibitors.
Matsueda et al., in Japanese Patent No. J6 1078-795-A, disclose peptides of the formula ##STR3##
When X is ##STR4## Y is hydroxy, A is a single bond, and R 3 is optionally protected carboxy, acyl; 1,2-hydroxy esters and 1,2-hydroxy ketones, useful as renin inhibitors, are provided.
SUMMARY OF THE INVENTION
In accordance with the present invention new diketone derivatives useful as renin inhibitors are disclosed. These compounds have the formula ##STR5## wherein X is R 6 --(CH 2 ) m --, ##STR6## R 1 is hydrogen, alkyl, arylalkyl, aryl, heteroalkyl or a fully saturated, partially saturated, or unsaturated monocyclic heterocyclic ring of 5 or 6 atoms. The heterocyclic ring is attached to ##STR7## by way of an available carbon atom. ##STR8## represents a heterocyclic ring of the formula ##STR9## wherein Y is --CH 2 , O, S, or N--R 9 , a is an integer from 1 to 4, and b is an integer from 1 to 4 provided that the sum of a plus b is an integer from 2 to 5;
R 3 , R 4 , R 5 and R 10 are independently selected from hydrogen, lower alkyl, halo substituted lower alkyl, --(CH 2 ) n -aryl, --(CH 2 ) n -heterocyclo, --(CH 2 ) n --OH, --(CH 2 ) n --O-lower alkyl, --(CH 2 ) n --NH 2 , --(CH 2 ) n --SH, --(CH 2 ) n --S-lower alkyl, --(CH 2 ) n --O--(CH 2 ) g --OH, --(CH 2 ) n --O--(CH 2 ) g --NH 2 , ##STR10## and --(CH 2 ) n -cycloalkyl; R 6 and R 6 ' are independently selected from lower alkyl, cycloalkyl, aryl and heterocyclo;
p is zero or one;
q is zero or one;
m and m' are independently selected from zero and an integer from 1 to 5;
n is an integer from 1 to 5;
g is an integer from 2 to 5;
R 7 is ##STR11## R 8 is 2,4-dinitrophenyl, ##STR12## R 9 is hydrogen, lower alkyl, ##STR13## or --(CH 2 ) n -cycloalkyl.
DETAILED DESCRIPTION OF THE INVENTION
This invention in its broadest aspects relates to the compounds of formula I above, to compositions and the method of using such compounds as antihypertensive agents.
The term lower alkyl used in defining various symbols refers to straight or branched chain radicals having up to seven carbons. Similarly, the terms lower alkoxy and lower alkylthio refer to such lower alkyl groups attached to an oxygen or sulfur. The preferred lower alkyl groups are straight or branched chain of 1 to 5 carbons.
The term cycloalkyl refers to saturated rings of 4 to 7 carbon atoms with cyclopentyl and cyclohexyl being most preferred.
The term halogen refers to chloro, bromo and fluoro.
The term halo substituted lower alkyl refers to such lower alkyl groups described above in which one or more hydrogens have been replaced by chloro, bromo or fluoro groups such as trifluoromethyl, which is preferred, pentafluoroethyl, 2,2,2-trichloroethyl, chloromethyl, bromomethyl, etc.
The term aryl refers to phenyl, 1-naphthyl, 2-naphthyl, mono substituted phenyl, 1-naphthyl, or 2-naphthyl wherein said substituent is lower alkyl of 1 to 4 carbons, lower alkythio of 1 to 4 carbons, lower alkoxy of 1 to 4 carbons, halogen, hydroxy, amino, --NH-alkyl wherein alkyl is of 1 to 4 carbons, or --N(alkyl) 2 wherein alkyl is of 1 to 4 carbons, di or tri substituted phenyl, 1-naphthyl or 2-naphthyl wherein said substituents are selected from methyl, methoxy, methylthio, halogen, and hydroxy.
The term heterocyclo refers to fully saturated or unsaturated rings of 5 or 6 atoms containing one or two O and S atoms and/or one to four N atoms provided that the total number of hetero atoms in the ring is 4 or less. The hetero ring is attached by way of an available carbon atom. Preferred hetero groups include 2- and 3-thienyl, 2- and 3-furyl, 2-, 3- and 4-pyridyl. The term hetero also includes bicyclic rings wherein the five or six membered ring containing O, S and N atoms as defined above is fused to a benzene ring. The preferred bicyclic ring is benzimidazolyl.
The compounds of formula I wherein X is ##STR14## can be prepared by treating a compound of the formula ##STR15## with n-butyl lithium and thereafter reacting same with the starting material of the formula
R.sub.1 -Halogen III
to provide a compound having the formula ##STR16##
An N-protected amino acid ester of the formula ##STR17## (wherein Prot is an amino protecting group such as t-butoxycarbonyl) is treated with lithium borohydride to give the alcohol of the formula ##STR18## Treatment of the alcohol of formula VI with pyridine-sulfur trioxide complex or with periodinane reagent (see Dess et al., J. Org. Chem., Vol. 48, p. 5155-5156 (1983)) produces an aldehyde of the formula ##STR19## The aldehyde of formula VII is thereafter reacted with the compound of formula IV in the presence of n-butyl lithium to provide a compound of the formula ##STR20## which can be deprotected such as by treatment with hydrochloric acid to provide the alcohol of the formula ##STR21##
The alcohol of formula IX is thereafter coupled with a peptide of the formula ##STR22## preferably in a solvent such as tetrahydrofuran or dimethylformamide and in the presence of hydroxybenzotriazole, a base such as N-methylmorpholine or diisopropylethyl amine, and a coupling agent such as dicyclohexylcarbodiimide to provide ##STR23##
Compound XI is treated with an oxidizing agent, such as ammonium ceric nitrate or thallic nitrate to provide the hydroxy keto compound of the formula ##STR24## Treatment of the compound of formula XII with, for example, the periodinane reagent (cited above in the formation of compound VII) provides ##STR25## that is, compounds of formula I wherein X is ##STR26## and p is one.
To prepare the compounds of the invention wherein X is ##STR27## and p is zero, the amino alcohol of formula IX can be reacted with the amino acid of the formula ##STR28## to yield the compounds of the formula ##STR29## Compound XV is thereafter treated as compounds XI and XII above to provide the diketone derivatives wherein p is zero.
The compound of formula I wherein X is other than ##STR30## can be prepared by using compounds of formula XI wherein ##STR31## is either t-butoxycarbonyl or benzyloxycarbonyl as the starting material. Removal of the t-butoxycarbonyl or benzyloxycarbonyl by standard amine deprotecting means provides the intermediates of the formula ##STR32## The amine of formula XVI is treated with the halide of the formula
R.sub.6 --(CH.sub.2).sub.m -halo, XVII
particularly where halo is bromine, to provide the product ##STR33## Compound XVIII is thereafter treated as compounds XI and XII above to provide the diketone derivative of formula I wherein p is one and X is R 6 --(CH 2 ) m --.
Similarly, by starting with compound XV where ##STR34## is either t-butoxycarbonyl or benzyloxycarbonyl, and carrying out standard amine deprotection, intermediates XIX can be obtained, ##STR35## The amine of formula XIX can thereafter be reacted with the halide of formula XVII to provide a compound of the formula ##STR36## Compound XX is thereafter treated as compounds XI and XII above to provide the products of formula I wherein X is R 6 --(CH 2 ) m -- and p is zero.
The compounds of formula I wherein X is ##STR37## can be prepared by treating the amine of formula XVI or XIX with the acid chloride of the formula ##STR38## in the presence of a base such as triethylamine, followed by treatment as with compounds XI and XII above.
The compounds of formula I wherein X is R 6 --(CH 2 ) m --SO 2 -- can be prepared by treating the amine of formula XVI or XIX with the substituted sulfonyl chloride of the formula
R.sub.6 --(CH.sub.2).sub.m --SO.sub.2 --Cl, XXII
followed by treatment as with compounds XI and XII above.
The compounds of formula I wherein X is ##STR39## can be prepared by treating the amine of formula XVI or XIX with the acid chloride of the formula ##STR40## in the presence of triethylamine, followed by treatment as with XI and XII. Alternatively, these compounds can be prepared by coupling the carboxylic acid of the formula ##STR41## to the amine of formula XVI or XIX in the presence of a coupling agent, such as dicyclohexylcarbodiimide, and 1-hydroxybenzotriazole hydrate, followed by treatment as with compounds XI and XII.
The compounds of formula I wherein X is ##STR42## and q is one can be prepared by acylating the amino acid of the formula ##STR43## with the acid chloride of formula XXIII in the presence of a base, such as sodium hydroxide, and in a solvent, such as tetrahydrofuran, and water to give the acylated amino acid of the formula ##STR44## The amino acid of formula XXVI is then coupled to the amine of formula XVI or XIX in the presence of dicyclohexylcarbodiimide and 1-hydroxybenzotriazole hydrate followed by treatment as with compounds XI and XII to give the desired compounds of formula I.
The compounds of formula I wherein X is ##STR45## and p is one can be prepared by coupling an amino acid of the formula ##STR46## to the amine of formula XIX in the presence of a coupling agent, such as dicyclohexylcarbodiimide, and 1-hydroxybenzotriazole hydrate, followed by treatment as with compounds XI and XII.
Similarly, the compounds of formula I wherein X is ##STR47## and p is zero can be prepared by coupling an amino acid of the formula ##STR48## to an amino alcohol of formula IX in the presence of a coupling agent, such as dicyclohexylcarbodiimide, and 1-hydroxybenzotriazole hydrate to provide a compound of the formula ##STR49## Compound XXIX can thereafter be treated as compounds XI and XII above to provide the diketo compound of formula I wherein X is ##STR50## and p is zero.
The compounds of formula I wherein X is ##STR51## and p is one can be prepared by coupling an amino acid of the formula ##STR52## to the amine of formula XIX in the presence of a coupling agent and 1-hydroxybenzotriazole hydrate, followed by treatment as with compounds XI and XII. Similarly the compound of formula I wherein X is ##STR53## and p is zero can be prepared by coupling an amino acid of the formula ##STR54## to the amino alcohol of formula IX in the presence of the above-described coupling agent and hydrate to provide a compound of the formula ##STR55## Compound XXXII is thereafter treated as compounds XI and XII above to provide the diketone compounds of formula I wherein X is ##STR56## and p is zero.
The amino acid intermediates of formulas XXVII, XXVIII and XXXI can be prepared by treating an amine R 6 --(CH 2 ) m --NH 2 or ##STR57## with phosgene and N-methylmorpholine followed by reaction with an amino acid methyl ester hydrochloride salt of the formula ##STR58## or of the formula ##STR59## in the presence of N-methylmorpholine. Removal of the methyl ester group by treatment with aqueous sodium hydroxide gives the desired intermediate.
The products of formula I wherein X is ##STR60## can be prepared by coupling the carboxylic acid of the formula ##STR61## to the amine of formula XVI or XIX in the presence of dicyclohexylcarbodiimide and 1-hydroxybenzotriazole hydrate, followed by treatment as with compounds XI and XII. Alternatively, the acid of formula XXXV can be converted to the acid chloride and this acid chloride can then be coupled to the amine of formula XVI or XIX in the presence of triethylamine and tetrahydrofuran and followed by treatment as with compounds XI and XII.
The compounds of formula I wherein X is ##STR62## can be prepared by acylating proline with the acid chloride of formula XXIII in the presence of base such as sodium hydroxide, i.e., a pH of about 8, and a solvent mixture of tetrahydrofuran and water to give ##STR63##
The acylated amino acid of formula XXXVI is then coupled to the amine of formula XVI or XIX in the presence of a coupling agent such as dicyclohexylcarbodiimide and 1-hydroxybenzotriazole hydrate, followed by treatment as with XI and XII.
In the above reactions, if any of R 3 , R 4 , R 5 and R 10 are --(CH 2 ) n -aryl wherein aryl is phenyl, 1-naphthyl, 2-naphthyl substituted with one or more hydroxy or amino groups, --(CH 2 ) n -heterocyclo wherein heterocyclo is an imidazolyl, --(CH 2 ) n --NH 2 , --(CH 2 ) n --SH, --(CH 2 ) n --OH, ##STR64## then the hydroxyl, amino, imidazolyl, mercaptan, carboxyl, or guanidinyl function should be protected during the reaction. Suitable protecting groups include benzyloxycarbonyl, t-butoxycarbonyl, benzyl, benzhydryl, trityl, tosyl, etc., and nitro in the case of guanidinyl. The protecting group is removed by hydrogenation, treatment with acid, or by other known means following completion of the reaction.
The various peptide intermediates employed in above procedures are known in the literature or can be readily prepared by known methods. See for example, the Peptides, Volume 1, "Major Methods of Peptide Bond Formation", Academic Press (1979).
Preferred compounds of this invention are those of formula I wherein
X is ##STR65## R 6 is selected from straight or branched chain lower alkyl of up to 5 carbons, cycloalkyl of 4 to 6 carbons, phenyl, 1-naphthyl, and 2-naphthyl;
m is selected from zero, one and two;
R 1 is alkyl, arylalkyl, aryl, or heteroaryl;
R 3 is straight or branched chain lower alkyl of 3 to 5 carbons, --(CH 2 ) n -cyclopentyl, --(CH 2 ) n -cyclohexyl, or ##STR66## wherein n is an integer from 1 to 3; R 4 is hydrogen, straight or branched chain lower alkyl of up to 5 carbons, --(CH 2 ) 4 --NH 2 , ##STR67## R 5 is straight or branched chain lower alkyl of up to 5 carbons, ##STR68##
Most preferred are those compounds of formula I wherein ##STR69##
The compounds of formula I form salts with a variety of inorganic and organic acids. The nontoxic pharmaceutically acceptable salts are preferred, although other salts are also useful in isolating or purifying the product. Such pharmaceutically acceptable salts include those formed with hydrochloric acid, methanesulfonic acid, sulfuric acid, acetic acid, maleic acid, etc. The salts are obtained by reacting the product with an equivalent amount of the acid in a medium in which the salt precipitates.
The compounds of formula I contain asymmetric centers when any or all of R 3 , R 4 , R 5 and R 10 are other than hydrogen and at the carbon to which the --OH group is attached. Thus, the compounds of formula I can exist in diastereoisomeric forms or in mixtures thereof. The above-described processes can utilize racemates, enantiomers or diastereomers as starting materials. When diastereomeric products are prepared, they can be separated by conventional chromatographic or fractional crystallization methods.
The compounds of formula I, and the pharmaceutically acceptable salts thereof, are antihypertensive agents. They inhibit the conversion of angiotensinogen to angiotensin I and therefore, are useful in reducing or relieving angiotensin related hypertension. The action of the enzyme renin on angiotensinogen, a pseudoglobulin in blood plasma, produces angiotensin I. Angiotensin I is converted by angiotensin converting enzyme (ACE) to angiotensin II. The latter is an active pressor substance which has been implicated as the causative agent in several forms of hypertension in various mammalian species, e.g., humans. The compounds of this invention intervene in the angiotensinogen→(renin)→angiotensin I→(ACE)→angiotensin II sequence by inhibiting renin and reducing or eliminating the formation of the pressor substance angiotensin II. Thus by the administration of a composition containing one (or a combination) of the compounds of this invention, angiotensin dependent hypertension in a species of mammal (e.g., humans) suffering therefrom is alleviated. A single dose, or preferably two to four divided daily doses, provided on a basis of about 100 to 1000 mg, preferably about 250 to 500 mg per kg of body weight per day is appropriate to reduce blood pressure. The substance is preferably administered orally, but parenteral routes such as the subcutaneous, intramuscular, intravenous or intraperitoneal routes can also be employed.
The compounds of this invention can also be formulated in combination with a diuretic for the treatment of hypertension.
A combination product comprising a compound of this invention and a diuretic can be administered in an effective amount which comprises a total daily dosage of about 1000 to 6000 mg, preferably about 3000 to 4000 mg of a compound of this invention, and about 15 to 300 mg, preferably about 15 to 200 mg of the diuretic, to a mammalian species in need thereof. Exemplary of the diuretics contemplated for use in combination with a compound of this invention are the thiazide diuretics, e.g., chlorothiazide, hydrochlorothiazide, flumethiazide, hydroflumethiazide, bendroflumethiazide, methylclothiazide, trichloromethiazide, polythiazide or benzthiazide as well as ethacrynic acid, tricrynafen, chlorthalidone, furosemide, musolimine, bumetanide, triamterene, amiloride and spironolactone and salts of such compounds.
The compounds of formula I can be formulated for use in the reduction of blood pressure in compositions such as tablets, capsules or elixirs for oral administration or in sterile solutions or suspensions for parenteral administration. About 100 to 500 mg of a compound of formula I is compounded with physiologically acceptable vehicle, carrier, excipient, binder, preservative, stabilizer, flavor, etc., in a unit dosage form as called for by accepted pharmaceutical practice. The amount of active substance in these compositions or preparations in such that a suitable dosage in the range indicated is obtained.
The present invention will now be described by the following examples, however, the invention should not be limited to the details therein.
EXAMPLE 1
(S)-[(1,1-Dimethylethoxy)carbonyl]-L-phenylalanyl-N-[1-(cyclohexylmethyl)-2,3-dioxohexyl]-L-leucinamide
A. 2-Propyl-1,3-dithiane
n-Butyl lithium (2.5M, 56.32 ml, 141 mmol) was added dropwise to a 500 ml tetrahydrofuran solution of 1,3-dithiane (15.42 g, 128 mmol) at -20°. After stirring for 2.5 hours at -20°, the solution was cooled to -78° and 1-iodopropane (12.5 ml, 128 mmol) was added to it in one portion. The reaction mixture was left for gradual warming (-78° to 0° C.) and overnight stirring (19 hours). Tetrahydrofuran was removed on the rotary evaporator, residue taken in ether (250 ml) and washed with water (200 ml). The aqueous layer was reextracted with ether (250 ml). Combined ethereal extracts were washed sequentially once with water, once with saturated sodium chloride, dried over anhydrous sodium sulfate and concentrated to give a yellow oil which on distillation under vacuum yielded 19.310 g of the title A compound.
B. [(1S)-1-(Cyclohexylmethyl)-2-hydroxy-2-(2-propyl-1,3-dithian-2-yl)ethyl]carbamic acid, 1,1-dimethylethyl ester
n-Butyl lithium (2.5M, 11.76 ml, 29.4 mmol) was added dropwise at -25° to a 40 ml tetrahydrofuran solution of 2-n-propyl-1,3-dithiane from part A (4.536 g, 28.0 mmol). After stirring for 2 hours at -20° to -25°, the solution was cooled to -78° and (S)-<α-[[(1,1-dimethylethoxy)carbonyl]amino]cyclohexanepropanal (3.57 g, 14.0 mmol) was added as a 20 ml tetrahydrofuran solution. A chromatography check after 1 hour revealed the formation of a complex reaction mixture. It was warmed gradually from -78° to -50° over a period of 18 hours, quenched with saturated ammonium chloride (50 ml) and the two layers separated upon warming to room temperature. The aqueous layer was diluted with water (75 ml, to dissolve the precipitated ammonium chloride) and reextracted with ethyl acetate (2×50 ml). Combined organic extracts were washed with saturated ammonium chloride (1×75 ml), dried over anhydrous sodium sulfate and concentrated to give 7.9 g crude product which upon flash chromatographic purification yielded 1.517 g of the title B compound.
C. α-[(S)-1-Amino-2-cyclohexylethyl]-2-propyl-1,3-dithiane-2-methanol,monohydrochloride
The title B compound (533 mg, 1.278 mmol) was dissolved in ethyl acetate (20 ml), cooled to 0° and the solution saturated by hydrogen chloride by bubbling the gas through it for a period of ˜5 minutes. A chromatography check revealed total disappearance of starting material. Ethyl acetate was removed on the rotary evaporator and the resulting yellow solid triturated with ether and filtered to give the title compound (370 mg) which looked pure by 13 C NMR.
D. t-Butyloxycarbonylphenylalanyl leucine, methyl ester
To a mixture of t-butyloxycarbonyl-L-phenylalanine (13.265 g, 50 mmol), L-leucine methyl ester (9.085 g, 50 mmol) and hydroxybenzotriazole hydrate (7.65 g, 50 mmol) in 100 ml tetrahydrofuran at 0° was added dropwise a solution of diisopropylethylamine (8.7 ml, 50 mmol) in 50 ml tetrahydrofuran. This was followed by addition of dicyclohexylcarbodiimide (10.315 g, 50 mmol). The reaction was stirred at 0° for 2 hours and then left for overnight stirring at room temperature. The precipitated urea was filtered off, solvents stripped down and the residue diluted with ethyl acetate (200 ml). The organic solution was washed sequentially with saturated aqueous sodium hydrogen carbonate (2×100 ml), saturated aqueous sodium chloride (2×100 ml), dried over sodium sulfate, filtered and concentrated to give crude product which on crystallization from ethyl ether gave 7.05 g pure product. Concentration of the mother liquor solution afforded 4.57 g crystalline product. An additional 1.35 g product was obtained by chromatographic purification of the crude product obtained from the left over mother liquors (40 g silica gel, 4:1 hexane/ethyl acetate). Thus, a total of 12.96 g of the title D compound was obtained. m.p.=104°-105°, [α] D =-17.5° (c=1.2, MeOH).
Elemental analysis calc'd for C 24 H 32 N 2 O 5 : C, 64.30; H, 8.15; N, 7.14; Found: C, 64.12; H, 8.16; N, 7.02.
E. t-Butyloxycarbonylphenylalanyl leucine
Sodium hydroxide (1N; 12 ml, 12 mmol) was added to a 40 ml methanol solution of (S)-<α-[[(1,1-dimethylethoxy)carbonyl]amino]cyclohexanepropanoic acid, methyl ester (3.92 g, 10 mmol) and a chromatography check after one hour revealed total disappearance of starting material. The solvents were removed on rotary evaporator. The resulting white solid was suspended in 10 ml of water and 50 ml of ethyl acetate, acidified to pH=3.5 using 1N hydrochloric acid and the two layers separated. The aqueous layer was reextracted with ethyl acetate (3×30 ml), combined organic extracts dried over sodium sulfate and concentrated to give 3.54 g of the title E compound.
F. [(1,1-Dimethylethoxy)carbonyl]-L-phenylalanyl]-N-[(1S)-1-(cyclohexylmethyl)-2-hydroxy-2-(2-propyl-1,3-dithian-2-yl)ethyl]-L-leucinamide
The title E compound (415.8 mg, 1.1 mmol) and the title C compound (388.9 mg, 1.1 mmol) were dissolved in 5 ml dimethylformamide and cooled to 0°. N,N-diisopropylethylamine (191.4 μl, 1.1 mmol) was added and after 5 minutes, this was followed by sequential addition of 1-hydroxy benzoatriazole hydrate (168.3 mg, 1.1 mmol) and dicyclohexylcarbodiimide (227 mg, 1.1 mmol). The reaction was left for gradual warming and overnight stirring. Next day, the reaction mixture was diluted with ethyl acetate (35 ml), the urea filtered off and the filtrate washed sequentially with water (2×20 ml), saturated sodium hydrogen carbonate (2×20 ml), 10 percent citric acid (1×20 ml), and saturated sodium chloride (1×20 ml). Drying with anhydrous sodium sulfate and concentration afforded 821 mg of crude product which upon chromatographic purification yielded 621 mg of the title F compound, m.p.=87°-92°, [α] D =-35.0° (c=0.34, MeOH).
Elemental analysis calc'd for C 36 H 59 N 3 O 5 S 2 .0.6H 2 O: C, 62.77; H, 8.81; N, 6.10; S, 9.31; Found: C, 62.84; H, 8.60; N, 6.00; S, 9.13.
G. [(1,1-Dimethylethoxy)carbonyl]-L-phenylalanyl-N-[(1S)-1-(cyclohexylmethyl)-2-hydroxy-3-oxohexyl]-L-leucinamide
The title F compound (338.5 mg, 0.5 mmol) was dissolved in 12 ml acetonitrile and diluted with 3 ml water. Ammonium ceric nitrate (1.096 g, 2.0 mmol) was added to this solution and after 20 minutes, the reaction mixture was diluted with water (40 ml) and extracted with ether (3×30 ml). The combined organic extracts were dried over anhydrous sodium sulfate and concentrated to give 378 mg of residue which upon chromatographic purification yielded 140 mg of the title G compound, m.p.=149°-152°.
Elemental analysis calc'd for C 33 H 53 N 3 O 6 : C, 67.43; H, 9.09; N, 7.15; Found: C, 67.14; H, 9.40; N, 7.03.
H. (S)-[(1,1-Dimethylethoxy)carbonyl]-L-phenylalanyl-N-[1-(cyclohexylmethyl)-2,3-dioxohexyl]-L-leucinamide
A solution of the title G compound (58.7 mg, 0.1 mmol) in 3 ml methylene chloride was added to a suspension of Dess Martin periodinane (65 mg, 0.15 mmol) and t-butylalcohol (12 mg, 0.15 mmol) in 2 ml methylene chloride. The reaction mixture was vigorously stirred. A TLC check after 6 hours revealed incomplete reaction; hence excess Dess Martin reagent (153 mg, 0.45 mmol) and t-butylalcohol (35 mg, 0.45 mmol) was added along with 5 ml methylene chloride and the reaction mixture left for overnight stirring. Next day, the reaction was judged complete by TLC. The reaction mixture was filtered through celite, the filtrate concentrated and the residue chromatographed to give 51 mg of the title compound. m.p.=134°-143°, [α] D =-36.6° (c=0.61, MeOH).
Elemental analysis calc'd for C 33 H 51 N 3 O 6 : C, 67.66; H, 8.78; N, 7.17; Found: C, 67.52; H, 8.71; N, 7.13.
EXAMPLE 2
(S)-(Cyclopentylcarbonyl)-L-phenylalanyl-N-[1-(cyclohexylmethyl)-2,3-dioxohexyl]-L-leucinamide
A. N-(L-Phenylalanyl)-L-leucine, methyl ester, monohydrochloride
The compound from part D of Example 1 (12.01 g, 31 mmol) was dissolved in hydrochloric acid/acetic acid solution (62 mL), reacted for one hour and concentrated to give an oily residue. It was triturated with toluene (3×60 mL), and concentrated yielding 10 g of the title A compound.
B. N-[N-(Cyclopentylcarbonyl)-L-phenylalanyl]-L-leucine, methyl ester
Cyclopentane carboxylic acid (1.65 mL, 15.2 mmol) was added to a solution of the title A compound (5.0 g, 15.2 mmol) in dimethylformamide (60 mL) and cooled to 0° C. 1-Hydroxybenzotriazole (2.33 g, 15.2 mmol), N,N-diisopropylethylamine (2.93 mL, 17 mmol) and dicyclohexylcarbodiimide (3.14 g, 15.2 mmol) were added sequentially. After 16 hours at 0° C., the reaction mixture was filtered and concentrated. The residue was taken in ethyl acetate (250 mL), washed with water (3×150 mL), saturated sodium bicarbonate (150 mL), saturated sodium chloride (150 mL), dried and concentrated, yielding 6.0 g of crude product. Purification by flash chromatography afforded 3.40 g of the title B compound. m.p.=170°-171° C., [α] D =-23.9° (c=1.18, MeOH).
Elemental analysis calc'd for C 22 H 32 N 2 O 4 .0.13H 2 O: C, 67.60; H, 8.32; N, 7.17; Found: C, 67.57; H, 8.31; N, 7.20.
C. N-[N-(Cyclopentylcarbonyl)-L-phenylalanyl]-L-leucine
Sodium hydroxide (1N; 12.36 mL, 12 mmol) was added to a solution of the compound of part B (2.04 g, 5.3 mmol) in methanol (20 mL). After five hours, the reaction mixture was concentrated and the residue was taken up in a mixture of water (20 mL) and ethyl acetate (50 mL) and acidified to pH 1.8. The layers were separated and aqueous layer was reextracted with ethyl acetate (3×75 mL). The combined organic extracts were dried and concentrated yielding 1.84 g of product, m.p. 148°-151° C. [α] D =-12.9° (c=1.19, MeOH).
Elemental analysis calc'd for C 21 H 30 N 2 O 4 .1.34H 2 O: C, 63.28; H, 8.26; N, 7.03; Found: C, 63.32; H, 7.77; N, 7.01.
D. (Cyclopentylcarbonyl)-L-phenylalanyl-N-[(1S)-1-(cyclohexylmethyl)-2-hydroxy-2-(2-propyl-1,3-dithian-2-yl)ethyl]-L-leucinamide
The compound of part C in Example 1 (707 mg, 2 mmol) was added to a solution of the title C compound from this Example (748 mg, 2 mmol) in tetrahydrofuran (8 mL) and cooled to 0° C. 1-Hydroxybenzotriazole (306 mg, 2 mmol), N,N-diisopropylethylamine (383 μl, 2.2 mmol), and dicyclohexylcarbodiimide (413 mg, 2 mmol) were added sequentially. After 16 hours at 0° C., the reaction mixture was filtered and concentrated. The reaction was taken up in ethyl acetate (50 mL), washed with water (2×30 mL), saturated sodium bicarbonate (2×40 mL), 10 percent citric acid (40 mL), saturated sodium chloride (40 mL), dried and concentrated. Purification of the crude product (1.2 g) by flash chromatography yielded 936 mg of pure product.
Elemental analysis calc'd for C 37 H 60 N 3 O 4 S 2 : C, 65.83; H, 8.96; N, 6.23; Found: C, 65.62; H, 8.78; N, 6.19.
E. (Cyclopentylcarbonyl)-L-phenylalanyl-N-[(1S)-1-(cyclohexylmethyl)-2-hydroxy-3-oxohexyl]-L-leucinamide, isomer A
A 20 ml methanol solution of thallic nitrate trihydrate (1.05 g, 1.18 mmol) was added to a solution of the title D compound (799 mg, 1.18 mmol) in methanol (40 mL) and ethyl acetate (20 mL). After 10 minutes the reaction mixture was filtered, concentrated and residue was taken in ethyl acetate (150 mL) and water (100 mL). The layers were separated and aqueous layer was extracted with ethyl acetate (2×120 mL). The combined organic portions were washed with 10 percent citric acid (150 mL), dried and concentrated affording 2.5 g of crude compound. Purification by flash chromatography yielded 573 mg pure product, m.p. 169° C. [α] D =-61.3° (c=1.19, CH 3 OH).
Elemental analysis calc'd for C 34 N 53 N 3 O 5 .0.63H 2 O: C, 68.62; H, 9.19; N, 7.06; Found: C, 68.79; H, 8.92; N, 6.99.
F. (S)-(Cyclopentylcarbonyl)-L-phenylalanyl-N-[1-(cyclohexylmethyl)-2,3-dioxohexyl]-L-leucinamide
A solution of the hydroxy ketone of part E (268 mg, 0.46 mmol) was added to a suspension of Dess Martin reagent (389 mg, 0.91 mmol) and t-butylalcohol (68 mg, 0.92 mmol) in methylene chloride (40 mL). After five hours, reaction mixture was filtered and concentrated yielding 666 mg of crude product which was subjected to chromatographic purification affording 217 mg of the title compound, m.p.=152°-161° C. [α] D =-59.1° (c=0.45, CHCl 3 ).
Analysis calc'd for C 34 H 51 N 3 O 5 .1.03H 2 O: C, 70.19; H, 8.84; N, 7.22; Found: C, 70.12; H, 8.79; N, 7.12.
EXAMPLE 3
[(1,1-Dimethoxyethoxy)carbonyl]-N-[(1S)-1-(cyclohexylmethyl)-2,3-dioxohexyl]-L-histidinamide
A. N-[(1,1-Dimethoxyethoxy)carbonyl]-1-[(4-methylphenyl)sulfonyl]-L-histidine
N-[(1,1-Dimethoxyethoxy)carbonyl]-L-histidine (12.7 g, 50 mmol) was dissolved in a solution of sodium carbonate (10.6 g, 100 mmol) in 150 ml water and cooled to 10°. p-Toluenesulfonylchloride (12.8 g, 67 mmol) was added in very small portions over a period of 30 minutes while maintaining vigorous stirring and controlling the temperature between 10°-15°. After the addition was complete, the reaction mixture was warmed to room temperature and stirring continued for an additional 4 hours. The reaction mixture was extracted twice with ethyl ether (75 ml) and the organic portions were discarded. The aqueous layer was acidified with 1N hydrochloric acid, extracted twice with ethyl acetate (150 ml) and the combined organic extracts were dried and concentrated to give an oily residue. Crystallization from ethyl acetate afforded 9.42 grams of the title A compound. m.p.=120°, [α] D =15.3° (c=1.66, CH 3 OH).
Analysis calc'd for C 18 H 23 N 3 O 6 S.0.14H 2 O: C, 52.48; H, 5.69; N, 10.20; S, 7.78; Found: C, 52.72; H, 5.70; N, 9.72; S, 8.09.
B. [(1,1-Dimethoxyethoxy)carbonyl]-N-[(1S)-1-(cyclohexylmethyl)-2-hydroxy-2-(2-propyl-1,3-dithian-2-yl)ethyl]-1-[(4-methylphenyl)sulfonyl]-L-histidinamide, isomer A
Triethylamine (108 μl, 0.775 mmol) was added dropwise to a solution of the title A compound (133 mg, 0.325 mmol) and α-[(S)-1-amino-2-cyclohexylethyl]-2-propyl-1,3-dithiane-2-methanol, isomer A, monohydrochloride (88.4 mg, 0.25 mmol) in 2.5 ml methylene chloride at 0°. After 5 minutes diphenylphosphoryl azide (70 μl, 0.325 mmol) was added, and the reaction mixture was stirred for 2 hours at 0° and then overnight at room temperature. Next day, the reaction mixture was concentratd on a rotary evaporator (to remove excess triethylamine), the residue diluted with 15 ml methylene chloride and 15 ml saturated sodium hydrogen carbonate and the two layers were separated. The aqueous layer was reextracted twich with methylene chloride and the combined organic extracts were dried over sodium sulfate and concentrated to give 292 mg residue. Chromatographic purification yielded 125 mg of the title B compound. m.p. 83°-88°; [α] D =-16.5° (c=1.3, MeOH).
Analysis calc'd for C 34 H 52 N 4 S 3 O 6 : C, 57.60; H, 7.39; N, 7.90; S, 13.57; Found: C, 57.71; H, 7.48; N, 7.64; S, 13.71.
C. [(1,1-Dimethoxyethoxy)carbonyl]-N-[(1S)-1-(cyclohexylmethyl)-2-hydroxy-3-oxohexyl]-1-[(4-methylphenyl)sulfonyl]-L-histidinamide, isomer A
Thallic nitrate trihydrate (844 mg, 1.9 mmol) was added in one portion to a 40 ml 1:1 methanol/ethyl ether solution of the title B compound (674 mg, 0.95 mmol) at 0°. After 15 minutes, the reaction mixture was filtered through celite and the solids washed twice with ethyl acetate (25 ml). Concentration of the solid gave a residue which upon chromatographic purification yielded 399 mg of the title C compound. m.p. 67°-76°, [α] D =-42.6° (c=1.21, MeOH).
Analysis calc'd for C 31 H 46 N 4 O 7 S.2.2H 2 O: C, 58.85; H, 7.57; N, 8.86; Found: C, 59.09; H, 7.47; N, 8.56.
D. [(1,1-Dimethoxyethoxy)carbonyl]-N-[(1S)-1-(cyclohexylmethyl)-2,3-dioxohexyl]-1-[(4-methylphenyl)sulfonyl]-L-histidinamide
Dess martin periodinane (308.5 mg, 0.73 mmol) was added to a solution of the title C compound (300 mg, 0.485 mmol) and t-butanol (53 mg, 0.73 mmol) in 5 ml dichloromethane. After 2 hours at room temperature, the reaction mixture was diluted with 20 ml dichloromethane and washed with an aqueous solution of sodium bicarbonate and sodium sulfite. Drying and concentration afforded a residue which upon flash chromatographic purification provided 288 mg of the title D compound, m.p. 60°-67°.
E. [(1,1-Dimethoxyethoxy)carbonyl]-N-[(1S)-1-(cyclohexylmethyl)-2,3-dioxohexyl]-L-histidinamide
1-Hydroxybenzotriazole (12.2 mg, 0.08 mmol) was added in one portion to a solution of the title D compound (12.2 mg, 0.02 mmol) in 2 ml methanol. After 2 hours at room temperature, solvents were removed on rotary evaporator and the residue purified by flash chromatography to provide 10 mg of the title compound.
EXAMPLES 4 TO 25
Following the procedures of Example 1 and outlined above, the following additional compounds of formula I within the scope of the present invention can be prepared. ##STR70##
__________________________________________________________________________Ex.No. R.sub.1 R.sub.3 R.sub.4 R.sub.5 X__________________________________________________________________________4 CH.sub.2CH.sub.2CH.sub.3 ##STR71## ##STR72## ##STR73## ##STR74## ##STR75## ##STR76## ##STR77## ##STR78##6 CH.sub.2CH.sub.2CH.sub.3 ##STR79## ##STR80## ##STR81## ##STR82##7 CH.sub.2CH.sub.2CH.sub.3 ##STR83## ##STR84## ##STR85## ##STR86##8 CH.sub.2CH.sub.2CH.sub.3 ##STR87## ##STR88## ##STR89## ##STR90##9 CH.sub.2CH.sub.2CH.sub.3 ##STR91## ##STR92## ##STR93## ##STR94##10 CH.sub.2CH.sub.2CH.sub.3 ##STR95## ##STR96## ##STR97## ##STR98##11 CH.sub.2CH.sub.2CH.sub.3 ##STR99## ##STR100## ##STR101## ##STR102##12 ##STR103## ##STR104## ##STR105## ##STR106## ##STR107##13 ##STR108## ##STR109## ##STR110## ##STR111## ##STR112##14 ##STR113## ##STR114## ##STR115## ##STR116## ##STR117##15 ##STR118## ##STR119## ##STR120## ##STR121## ##STR122##16 ##STR123## ##STR124## ##STR125## ##STR126## ##STR127##17 ##STR128## ##STR129## ##STR130## ##STR131## ##STR132##18 ##STR133## ##STR134## ##STR135## ##STR136## ##STR137##19 CH.sub.2CH.sub.2CH.sub.3 ##STR138## ##STR139## ##STR140## ##STR141##20 CH.sub.2CH.sub.2CH.sub.3 ##STR142## ##STR143## ##STR144## ##STR145##21 CH.sub.2CH.sub.2CH.sub.3 ##STR146## (CH.sub.2).sub.4NH.sub.2 ##STR147## ##STR148##22 CH.sub.2CH.sub.2CH.sub.3 ##STR149## CH.sub.2CO.sub.2 H ##STR150## ##STR151##23 CH.sub.2CH.sub.2CH.sub.3 ##STR152## CH.sub. 2CH.sub.2CO.sub.2 H ##STR153## ##STR154##24 CH.sub.2CH.sub.2CH.sub.3 ##STR155## ##STR156## ##STR157## ##STR158##25 CH.sub.2CH.sub.2CH.sub.3 ##STR159## ##STR160## ##STR161## ##STR162##__________________________________________________________________________ | Compounds of the formula ##STR1## are disclosed. These compounds interevene in the conversion of angiotensin to angiotensin II by inhibiting renin and thus are useful as anti-hypertensive agents. | 8 |
BACKGROUND OF THE INVENTION
The background of the invention will be discussed in two parts:
Field of the Invention
This invention relates to chairs and more particularly to folding chairs of a particularly unique and aesthetically appealing configuration.
Description of the Prior Art
Folding chairs of various types have become increasingly common. However, most of these chairs are not sufficiently aesthetically pleasing. Such chairs usually look like folding chairs; they are ungainly and convey a temporary feeling when unfolded while they offer projecting legs and open holes of unpleasing shapes and are awkward to store when folded. Most prior art folding chairs are not easily stacked because of their configurations. Folding chairs, in general, are used for temporary purposes and are not designed to match other furniture. They are, in general, less sturdy and durable than most furniture.
The construction of prior art folding chairs is usually quite complicated making such chairs difficult and expensive to assemble.
Attempts to solve these problems have been relatively unsuccessful because the requirement that a chair fold places constraints upon its design which gives rise to the problems.
It is an object of the present invention to provide a new and aesthetically-pleasing folding chair.
It is another object of the present invention to provide folding chairs which fold easily into a small space, are portable, and do not interfere with one another in storage.
It is a further object of this invention to provide folding chairs which may be made to match other furniture and elements of their environment.
Yet another object of this invention is to provide an especially strong and durable, yet comfortable, folding chair.
An additional object of this invention is to provide a folding chair of simple design which is quite easy to assemble.
SUMMARY OF THE INVENTION
The foregoing and other objects of the invention are accomplished in the present invention by a folding chair which has two rectangularly-shaped opposing side members. Each of the side members is formed of four elongated members which may be metallic extrusions, identical in cross section, which abut at forty-five degree angles and are fastened together to form a rectangular frame surrounding and holding a rectangular side piece. The side piece provides superior strength and a surface for various designs. Each of the elongated members is provided with a cover which snaps into place to hide various construction details and to protect the members from wear. The opposing rectangular side members support a folding seat and a folding back. The folding seat is slideably secured to a groove in opposing ones of the vertical elongated member of each side member. A pair of pivoting cross-members are connected in front and back of the seat and to the base of the rectangular side members. The folding back is pivotably secured to the opposing side members at the upper horizontal elongated members and is removably secured on opposite sides of its lower extremities to the folding seat.
The construction is such that by unfastening the folding back from the folding seat and by pressing on the two side members the chair is caused to collapse into a box-like configuration having a volume essentially equal to the combined dimension of the two side members. The folded chair is very thin and, thus, may be easily stacked and stored without the problems of many prior art folding chairs. Holes cut from each of the rectangular side members provide convenient handles for carrying the chair much like a briefcase.
The other objects, features, and advantages of the invention will become apparent from a reading of the specification when taken in conjunction with the drawings in which like reference numerals refer to like elements in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a folding chair constructed in accordance with the invention;
FIG. 2 is a side view of the folding chair shown in FIG. 1;
FIG. 3 is a front view of the folding chair shown in FIG. 1;
FIG. 4 is a cross sectional view of an elongated member used to form the side members of the folding chair of FIG. 1 and of the covers for such elongated member, the cross section being taken generally along line 1--1 of FIG. 2;
FIG. 5 is an enlarged view of a corner of the side member shown in FIG. 2 demonstrating the method by which the elongated members may be connected together;
FIG. 6 is a perspective view showing the details of the connection of the folding seat to the cross members which support the folding seat;
FIG. 7 is a perspective view illustrating the details of the pivotal connection of one side of the folding back to the rectangular sides of the chair shown in FIG. 1;
FIG. 8 is an end view of the connection shown in FIG. 7;
FIG. 9 is a perspective view of a bracket used in the folding chair shown in FIG. 1; and
FIG. 10 is a perspective view of the chair of FIG. 1 shown in the folded condition.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and particularly to FIGS. 1, 2 and 3, there is shown a chair generally designated 10 having two rectangular side members designated 12 and 14. The side members 12 and 14 support a collapsible seat 16 supported at opposite sides by bars 18. Bars 18 are each supported by an elongated member 19 which is open on one side and is connected to cross members 20 which are pivotally secured at their mid-points 22 to one another and are pivotably connected at their lower ends to sides 12 and 14.
A folding back 24 is pivotably connected at its upper extremities to each of sides 12 and 14. The back 24 is also removably secured to the seat 16 at a conveniently inclined resting angle. Both the seat 16 and the back 24 may be made of a fabric such as nylon or an equivalent sewed at the sides and ends in a well-known manner.
As will be seen in FIGS. 1 and 2, each of the sides 12 and 14 has a large rectangular side panel 26 upon which may be placed graphics generally suited to the surroundings in which the chair is to be used. The rectangular side panels 26 each have an opening 28 cut therein which forms a convenient carrying handle when the chair is collapsed. The side panels 26 may preferably be constructed of a plastic material, fiberboard, or some other thin rigid material which is generally light in weight but provides substantial strength in compression thereby offering substantial rigidity to the chair in the open position.
The side panels 26 of the sides 12 and 14 are supported by elongated members 30 shown in cross section in FIG. 4 (taken along section line 4--4 of FIG. 2). Each of the elongated members 30 (which may, for example, be extrusions manufactured in a well known manner from a material such as aluminum) may be cut at a 45° angle as shown in FIG. 5. A right angle bracket 32 inserted in the channel 34 of each member 30 and secured thereto such as by screws or rivets connects the adjoining members 30 to one another. The members 30 so connected form a rectangle surrounding the side panel 26 which rests and is secured in a channel 36 of each member 30, thereby lending affirmative strength to resist bending of the member 30 and distortion of the corners of the rectangle. A flexible cover 38 which may be made of a flexible plastic such as styrene is cut in a length to fit over and cover the members 30 thereby enclosing the brackets 32 and other fittings. The flexible cover 38 provides protection for the chair in the stacked or open conditions, for one sitting in the chair, and for the floor upon which the chair sits.
The bars 18 which hold the folding seat 16 slide vertically in a channel 40 (see FIG. 4) in each of the vertical ones of the members 30. In one exemplary embodiment, the ends of bars 18 are fitted with protective plastic covers 31 (see FIG. 6). A stop 42 is positioned in and secured to each of the vertical members 30 within channel 40 at a position to maintain the folding seat 16 at an appropriate height in the open position.
The cross members 20 are secured to the members 19 in an appropriate manner such as by riveted bracket 44. In the embodiment shown in FIG. 6, the seat 16 is looped about the bar 18 which is held within the member 19 thereby securing the seat 16 to the cross members 20. The cross members 20 are secured to one another such as by a rivet and pivot about their midpoints 22. They are also pivotably secured at a point 46 to a bracket 48 (shown in detail in FIG. 9) which is secured in channel 40 of each of the lower members 30. Consequently, when pressure is applied inwardly on each of the sides 12 and 14, the bars 18 slide upwardly causing the cross members 20 to fold and the seat 16 to collapse. Such inward pressure also causes the back 24 to collapse.
FIG. 7 is a perspective drawing showing details of the connection of the back 24 to the side members 12 and 14 by which such collapse is accomplished. The connection includes a pair of bars 47 each of which is secured to one of the opposite sides of the back 24. Each bar 47 may be constructed of a material such as aluminum which is light in weight but provides substantial rigidity. The bar 47 is secured to a sliding member 49 by a pivot 50. The sliding member 49 is bent at 90° at each end and has holes therein so that a circular bar 52 may slide therethrough. The bar 52 is fixed at its forward end to a right angle bracket 54 which is secured in channel 40 (such as by rivets) of each upper member 30 in which the sides 12 and 14 are constructed. Each bar 52 also passes through an aperture 55 in the rear one of vertical members 30 and is secured thereto.
Each of the bars 47 may be bent at its lower end to provide a hook which fits over and snaps around the member 19 supporting the seat 16. When the chair 10 is opened, each of the bars 47 depends in a generally downward position from the associated upper member 30 and is snapped over the member 19. The length of the bar 47 and the distance between the upper member 30 and the position of the seat 16 in the open position of the chair 10 are such that the seat back is inclined at an angle adapted to provide a comfortable position for an average person sitting in the chair.
When the chair 10 is to be folded, the lower ends of the bars 47 are removed from behind the members 19 and swung upwardly to a horizontal position. As the sides 12 and 14 come together, the sliding member 49 pivots at a right angle about the circular bar 52 as is shown in FIG. 8 thus causing the bar 47 to rotate to a position directly under the bar 52 and under the downward facing channel 40 of the upper member 30. This rotation allows the two sides 12 and 14 to collapse until the flexible covers 38 covering each of the members 30 forming the sides 12 and 14 touch one another. Consequently, the chair 10 folds into a very thin shape which is essentially rectangular in all directions. The openings 28 being positioned together in the closed position of the chair 10 provide a convenient handle and allow the chair 10 to be easily carried from place to place. Means (not shown) may be provided to secure the two sides together when closed. The very narrow width of the chair 10 when folded (see FIG. 10) allows it to be easily stacked with a number of like chairs without protruding legs and arms interfering with those of other chairs. The plastic protector surrounding the edges protects the entire chair in the folded state.
Especially important to the structure of the folding chair is the strength provided by the side panels 26 contained within the rectangle formed by the members 30. In one of the chairs known in the prior art has such strength been provided in such a light collapsible chair. Moreover, the same side panels 26 may be stylishly decorated so that such chairs will fit into the decor of a modern office or an apartment.
The ease with which the chair 10 of this invention may be constructed should be noted. As explained above, each of the members 30 is identical except in length and each may be cut at a 45° angle at each end. Prior to assembling the members 30 using right angle brackets 32, the brackets 48 holding the base of cross members 20, the brackets providing the stops 42, and those securing the circular bars 52 are positioned within the associated members 30. With these brackets in place, the members 30 may be secured to one another surrounding the side members 26. Cross members 20 are secured to the members 19 which receive the bars 18 to attach the seat 16; these are then inserted in the channels 40. The bars 47 may be secured to the brackets 54 by the circular members 50 connected to the sliding members 49, and the seat back 24 may be slipped over the two bars 47. Flexible coverings 38 may then be snapped into place over the elongated member 30 and the chair is completely assembled and ready to be used.
Such ease of manufacture is unusual with folding chairs which are normally constructed of many variously shaped parts offering a number of different types of operation in the construction.
While there has been shown and described a preferred embodiment, it is to be understood that various other adaptations and modifications may be made within the spirit and scope of the invention. | A chair having two rectangular side members with grooves therein, a folding seat the opposite sides of which slide vertically in said grooves, pivoting cross member supports for the seat, the upper ends of each carrying opposite sides of the seat and the lower ends of each being pivotably affixed to the side members, a folding back, and means pivotably connecting opposing upper extremities of the back to opposite side members and removably positioning the lower opposite extremities of the back at an angle to the vertical whereby the entire chair may be folded to a width approximating the sum of the least dimensions of the two side members. | 8 |
BACKGROUND OF THE INVENTION
Reference is particularly made to a support ring which is inserted in a wheel tire to guarantee that even in the event of a sudden loss of pressure in the tire, the vehicle can proceed safely.
A tire of this type exists in the prior art. It is distinguished by the fact that it does not flatten, even on loss of pressure, thanks to a rigid ring inserted by force on the rim of the wheel. In this case the spare wheel is no longer necessary. Before mounting the tire on the rim, the support ring is inserted into the tire. Generally the tire is of a special type, in which the diameters of the beads are different, making it easier to insert the support ring through the larger-diameter bead.
The main aim of the present invention to provide a device for rendering insertion of the support ring into the tire easier.
The invention also has the aim of making extraction of the ring from the tire easier, using known means.
An advantage of the invention is to realise a device by which it is possible to insert the ring very rapidly and efficiently.
A further advantage of the invention is the simplicity of use of the device.
A further advantage is to provide a device which is constructionally simple and economical.
These aims and advantages and others besides are all achieved by the present invention, as it is characterised in the claims that follow.
SUMMARY OF THE INVENTION
The invention consists in a device for inserting and extracting a support ring in a tire, comprising: a base for stably positioning and centring the tire in such a way that a central opening of the tire is accessible; a support arranged by a side of the base which is positionable by nearing and distancing to and from a center of the base; a lever moveably pivoted to the support, which can be fixed in positions along a plane passing through the central opening of the tire and arranged radially with respect to the center of the base, an active end of the lever being able to assume at least one external position, in which the active end is outside the central opening of the tire, and at least one internal position, in which the active end is internal of the central opening of the tire and in contacting interaction with an internal surface of a part of the support ring; the active end, by effect of activation of the lever, pressing the part of ring against the inside of the tire with a force having at least one radial component.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the present invention will better emerge from the detailed description that follows of a preferred but non-exclusive embodiment of the invention, illustrated purely by way of non-limiting example in the accompanying figures of the drawings, in which:
FIG. 1 is a perspective view of an embodiment of the invention;
FIG. 2 is a side view in vertical elevation, with some parts in section, of the device of FIG. 1 while it is being applied to insert a ring in a tire;
FIGS. 3 , 4 and 5 show three successive stages of the insertion of the support ring in a tire;
FIG. 6 shows the ring inserted in the tire.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the figures of the drawings, 1 denotes in its entirety a device for favouring insertion of a safety support ring 2 inside a tire 3 . The tire 3 is preferably of a type having two beads of different diameters so that it presents on one side a central opening which is larger than the other, through which the support ring 2 can be inserted. At a later stage of the process the support ring is mounted on the rim (a stage which does not directly involve the present device), to be force-inserted about the rim.
The insertion device 1 comprises a base 4 for stably positioning and centring the tire 3 so that the central opening of the tire 3 faces the operator and is easily accessible from the outside. In the preferred embodiment the base 4 comprises a rest plane arranged oblique with respect to the horizontal so that once the tire 3 is centered on the base 4 , the central opening is facing upwards.
In the following description reference will be made to the tire 3 arranged centered on the base 4 ; the term external bead will refer to the bead of the tire 3 which is facing upwards and which delimits the opening for introduction of the ring, while the term internal bead will refer to the opposite bead, facing downwards and towards the base 4 .
The base 4 for positioning and centring is provided with a centring system having three radially-mobile organs, which are coordinated with each other and with the center of the base by means of, for example, a handle.
The insertion device 1 comprises a support 5 arranged side-by-side with the base 4 , which is positionable by distancing and nearing to and from the center of the base 4 .
A lever 6 is pivoted on the support 5 and can move and be fixed in position along a preferably vertical plane which passes through the central opening of the tire and which is arranged radially with respect to the center of the base 4 . The lever 6 exhibits an active end 6 a which can assume at least one external position, in which it is outside the central opening of the fire, and at least one internal position, in which it is internal of the opening and interacts contactingly with the internal surface of a part of the support ring 2 inserted in the opening; also, by effect of the activating of the lever 6 , the active position 6 a presses the part of the ring 2 against the inside of the tire 3 with a force having at least one radial component.
The active end 6 a of the lever is located on a tract of end of the lever which is bent towards the inside of the tire centered on the base 4 . This bend is L-shaped.
The base 4 is oblique with respect to both the sliding axis of the horizontal guide 8 and the sliding axis of the vertical guide 10 .
The lever 6 is a first-class lever and comprises two arms 61 and 62 , one transversal with respect to the other, in which the arm 61 bearing the active end is mobile in order to vary the distance between the active end and the pivot 7 .
The support 5 is mounted on a fine and can be displaced along a plane which is parallel to the movement plane of the lever 6 ; it can also be fixed in position. The displacements of the support 5 are along two mutually-transversal sliding axes. An axially-sliding first guide 8 is horizontal and solidly constrained on the base 4 ; a slide 9 can be positioned along the first guide 8 ; the slide 9 bears a second guide 10 which can move axially and vertically; the lever support 5 is slidable along the second guide 10 .
The support 5 frontally bears a pusher tool 11 facing towards the center of the base 4 and arranged between the lever 6 and a part of the external bead of the tire. The tool 11 has two lateral horns internal parts of which, by effect of movement of the support 5 , can partially enter the central opening and keep the part of external bead pushed outwards so that the tire central opening is made larger.
The device 1 further comprises a sliding plane 12 to guide the support ring, located on the base 4 in such a way as to cover at least a part of the centered tire opening opposite to the opening of the tire through which the ring is mounted.
The sliding plane 12 is located so as to cover a part of the internal bead of the tire opposite to a part of the external bead of the tire at which the support ring will be partially inserted into the opening.
The support 5 is fixable in position along the vertical guide 10 by means of a clamping system 13 (enlarged in the detail of FIG. 2 ), comprising a holed plate element 14 hinged at 15 , with the hole inserted with modest play in the vertical guide 10 ; a spring 16 keeps the support 5 blocked in position by effect of the friction between the inside rim of the hole and the slide 10 ; to unblock the support it is sufficient to press down on the spring 16 . An upwardly-directed elastic force produced by a spring 17 acts on the support.
The means for removably fixing the slide 9 in position on the guide 8 are of known type and are not illustrated, as are the means for removably fixing the rotation of the lever 6 about the pivot 7 , as indeed are the means for removably fixing the arm 61 of the guide situated in the zone where the arms 61 and 62 meet.
During operation, after the tire 3 has been arranged on the base 4 , the support 5 is neared to the center of the base 4 by sliding the horizontal-axis lower slide 9 . In this nearing stage by horizontal movement, the active end 6 a of the lever 6 and the pusher tool 11 are located at a height which enables passage through the obliquely-arranged opening of the tire 3 . When the pusher tool 11 , during the nearing operation, passes through the lower part of the external bead, the tool 11 is lowered (by movement of the support 5 along the vertical guide 10 in the direction of arrow F) and distanced (by moving the slide 9 along the horizontal guide in the direction of arrow G), until the two external projections of the tool 11 , horn-shaped, push the lower part of the external bead outwards, in the direction of arrow G. The slide 9 and the support 5 are fixed in these positions so that the lower part of the external bead remains pushed and deformed towards the outside and during the subsequent operations the tire opening is stretched and enlarged.
At this point the support ring 2 can be partially inserted (see FIG. 3 ) between the tool 11 and the sliding plane 12 which favours the insertion.
The active end 6 a of the lever, which is positioned above and forward of the pusher tool 11 , is pushed downwards in direction J by effect of a rotation of the lever about the pivot 7 (force is applied on the upper arm manually by an operator, as indicated by arrow K). The pivot 7 has a rotation axis which is horizontal and perpendicular to the sliding axes of the guides 8 and 10 . The active end 6 a , in contact with the internal side of the support ring 2 , pushes the ring 2 towards the inside of the tire 3 with a prevalently radially-directed pushing force with respect to the tire 3 . The lever 6 is then fixed in position, generally in a position in which the support ring 2 is not yet fully inserted in the tire 3 ; in this position the lever 6 acts with a certain pressure which tends to force the insertion. In this configuration ( FIG. 5 ) one final action is sufficient, relatively simple and requires a smaller effort on the part of the operator to force insertion of the upper part of the support ring 2 still partly outside the tire 3 . This final action can be advantageously done by using known-type tools for stretching the upper part of the external bead. The support 5 , during the pushing stage of the active end 6 a is subject to a rotational constraint due to the hexagonal shape of the guide 10 . The support 5 is also provided with a device for immediately reaching the maximum height by means of a rotation of the lever 6 in an anti-clockwise direction, freeing the clamping system 13 . When it reaches the maximum height the support 5 unhooks from its rotational constraint originated by the hexagonal guide 10 and can freely rotate to displace the lever 6 and the tool 11 from the work area. | The device comprises a base for positioning a tire and a lever pivoted on a support and able to move and be fixed in position along a plane which is radial with respect to the center of the base. An active end of the lever, located on an L-shaped bend at an end of the lever, can be introduced internally of the opening to interact contactingly with the internal surface of a part of the support ring pre-inserted in the opening. By acting on the lever, the active end presses the ring against the inside of the tire with radial force. The support ring is of a type which when applied on a vehicle wheel enables the vehicle to continue moving for a considerable time even where tire pressure is suddenly lost. | 1 |
BACKGROUND
[0001] It is known that fuel injectors are provided with fuel return lines through which the fuel which is not consumed at the fuel injector is returned to the tank. The fuel injector provides a drain passage for this purpose to which a connector for a retaining clamp can be attached. The retaining clamp for its part possesses a connecting fitting for the fuel return line. In this way, the excess fuel can be drawn off to the tank.
[0002] The retaining clamp is designed as a self-locking clip and has two retaining arms which partially encircle the fuel injector. Since the retaining clamp must not become detached from the fuel injector or loosen its seat during operation, it is seated relatively tightly on the fuel injector, which has the disadvantage that relatively high installation force is necessary to push the retaining clip onto the fuel injector.
[0003] Furthermore, devices for generating negative pressure by utilizing the venturi principle are sufficiently known. A flowing medium is accelerated by means of a restriction in the cross section, which reduces the pressure of the medium. The suction line opens into this area of reduced pressure so that a fluid can be sucked in through this suction line.
[0004] Fuel injectors possess a return line through which excess fuel is transported back to the tank. A slight negative pressure obtains in this return line so that the fuel is, so to speak, suctioned off by the fuel injector. This has the considerable advantage that the fuel injector does not have to build up positive pressure to remove the excessive fuel and that the return line does not have to be designed for pressure. A device which utilizes the venturi system is used to generate the negative pressure in the return line. The high-pressure line in which the pressurized fluid is flowing is connected, for example, to the fuel pump and is supplied with fuel under pressure. This fuel is accelerated in the device and thereby generates the necessary negative pressure for the return line to suction off the excess fuel from the fuel injector.
[0005] It would be desirable to provide a device of the type mentioned above with which, firstly, the installation force to push the device onto a fuel injector is reduced, secondly, the retaining force, or the pull-off force, is increased, or at least not reduced. It would be advantageous if the device consists of only a few parts and is simple to assemble and install.
SUMMARY
[0006] The invention relates to a device to attach a fuel return line to a fuel injector, having a C-shaped main body with two retaining arms which partially encircles the fuel injector, where the retaining arms abut the fuel injector and grip same from the back at least to a small degree, having a connector coacting with a drain passage for the fuel injector and having at least one connecting fitting for the fuel return line, where the connecting fitting and the connector are electrically connected to each other.
[0007] The invention also relates to a device for attaching a fuel return line to a fuel injector having an essentially C-shaped body with two retaining arms which partially encircles the fuel injector, where the retaining arms abut the fuel injector, and having a connector coacting with a drain passage for the fuel injector and having at least one connecting fitting for the fuel return line, where the connecting fitting and the connector are electrically connected to each other.
[0008] Finally, the invention relates to a device for suctioning fuel from a fuel injector, which is electrically connected through a return line to the device, having a first connection for a high-pressure line, a second connection for the return line and a third connection for a drain line, where the connections are connected to a venturi system and the first connection opens into an injector nozzle and the second connection opens in the area of the outlet for the injector nozzle.
[0009] In accordance with the invention the free ends of the retaining arms have a first section in which they are angled towards each other and towards the base of the main body.
[0010] In contrast to Ω-shaped retaining clips, in which the free ends first approach each other and finally spread apart, or in which the free ends finally diverge, the free ends of the device in accordance with the invention converge and are additionally angled towards the base of the main body, or towards the center of the encircled fuel injector, that is to say, of the space for the fuel injector between the two retaining arms. The free ends of the retaining arms forming the first section extend, therefore, essentially radially with reference to the axis of the encircled fuel injector.
[0011] This achieves the considerable advantage that for the same material thickness, that is to say for the same wall thickness in the retaining arms, considerably higher pull-off force is achieved since the retaining arms, or the free ends of the retaining arms, grip the fuel injectors radially with their end faces. To obtain the same pull-off force as with Ω-shaped retaining clips, the wall thickness of the retaining arms can be substantially reduced, which reduces the installation force and thereby makes it easier to push the device onto the fuel injector. Assembly can be performed in this way with smaller equipment or even manually and without the assistance of a tool.
[0012] A refinement calls for the retaining arms to run parallel initially as they depart the base of the main body and then to have a second section in the area of their free ends in which they diverge. As with the Ω-shaped retaining clip, the two diverging areas create a fork-shaped location, which has the advantage that the device in accordance with the invention can easily be placed against the jacket of the fuel injector and, without the risk of slipping off, pushed radially onto the fuel injector and secured. The two diverging areas act as a shoulder and a guide for the device.
[0013] A third section in which the retaining arms run parallel again attaches to the second section. The second and the third section thus form an outer recess on each retaining arm, in which the retaining arms are spaced farther apart from each other. Since the first section attaches to the third section, the former can pivot into this recess or open space when the device is secured to the fuel injector so that the fuel injector can be pushed past the first section.
[0014] In accordance with one aspect, the retaining arms are not as thick in the first, second and/or third section as at the foot, that is to say, in the area of the base of the retaining arms. This has the considerable advantage that the retaining arms are designed to be relatively flexible in the insertion area of the device in accordance with the invention, so that the device can be pushed on the fuel injector with little effort. After the device is pushed onto the fuel injector, it is latched when the free ends assume a position in which they grip the fuel injector from behind and are aligned essentially radially to the longitudinal axis of the fuel injector. If the retaining device is pulled off the fuel injector from this position, the free ends of the retaining arms are not bent into the recess but in the other direction, that is to say, they are spread apart even farther and grip the fuel injector from the back even more.
[0015] Because the thickness of the retaining arms in one aspect of the invention decreases towards their free ends, this creates a situation in which they are relatively rigid in the area of their base, but relatively flexible in the area of their free ends. This also allows the retaining device to be pushed onto, or joined to, the fuel injector relatively easily.
[0016] In accordance with the invention, the retaining arms can be allowed to pivot a very small amount relative to their base by providing a slot between the main body and the retaining arms open at its edges in the direction of the free ends of the retaining arms. The retaining arms are thereby disconnected from the base of the main body to some extent so that the retaining arms not only abut the fuel injector laterally but can also exert a clamping force on the jacket of the fuel injector. This centers the retaining device on the fuel injector.
[0017] A relatively simple adjustment of the stiffness of the retaining arms can be achieved by stiffening ribs running in the longitudinal direction on the oppositely facing outer surfaces of the retaining arms. The width, length and/or height of these stiffening ribs can selected as desired. The ribs may come to a wedge-shaped point towards the free ends of the retaining arms, that is to say, their height and/or width can vary.
[0018] The free ends of the retaining arms can also be connected by a bail gripping the fuel injector from the back.
[0019] In contrast to Ω-shaped retaining clips in which the free ends first come closer together and finally spread apart, or in which the free ends finally diverge, the free ends of the retaining arms on the device in accordance with the invention are connected by means of a bail. This bail grips the fuel injector from the back and tensions the device against the fuel injector.
[0020] This bail preferably has a radius of curvature which is larger than the radius of the jacket of the fuel injector. As a result, the bail abuts the jacket of the fuel injector at several points or in linear fashion so that it has to be bent and thus tensioned in order to connect with the retaining arm.
[0021] In accordance with one aspect, the retaining arms run parallel as far as possible, starting from the base of the main body. In the area of its drain port the fuel injector has two flattened areas opposite each other on the outside onto which the two retaining arms can be pushed. The position of the retaining device against the fuel injector is thereby defined.
[0022] In one aspect, the bail is configured in such a way that it can be connected to both ends of the retaining arms. This bail is a loose component of the device in accordance with the invention and, after the two retaining arms are pushed onto the fuel injector, is slipped onto, latched or otherwise attached to the two free ends of the retaining arms.
[0023] In another aspect, the bail on the end of one retaining arm is formed in one piece, specifically by means of a film hinge. This variant has the considerable advantage that the bail is attached to the device under the invention so that it cannot be lost and it only needs to be swung over after the two retaining arms have been pushed onto the injector and latched onto the free end of the other retaining arm. To accomplish this, the free end of this retaining arm has a locking tab which grips the back of a locking hook provided, for example, on the bail. The locking tab extends radially from the retaining arm, for example, pointing away from the fuel injector.
[0024] In one aspect, the two retaining arms are connected not only at their base but also in an area which lies between the base and the open ends. In this way, the base can be formed by a relatively narrow bridge since the retaining arms are supported in the connecting area, in addition to the base. This area lies preferably in the middle between the base and the end of the retaining arm. The connection can, for example, be formed by a bridge from which the connector extends.
[0025] An optimal flush fit against the fuel injector can be achieved if the bridge is curved concavely in the direction of the connector. The curvature of the bridge essentially matches the diameter, or the outward or projecting convex form of the fuel injector.
[0026] Preferably, the wall thickness of the retaining arms is greater between its end and the connecting area than between the connecting area and the base. This creates relatively stiff free ends, where the section between the connecting area and the base is more flexible. When the two free ends of the retaining arms are spread apart, primarily the thinner-walled sections bend inward slightly so that the connecting area forms a joint. The thicker-walled sections of the retaining arms pivot around this joint.
[0027] In accordance with the invention, the bail is stiffened by providing an additional stiffening rib running in the longitudinal direction. This stiffening rib ensures that the bail lies against the jacket of the fuel injector under pretension after it has been latched to the opposite retaining arm and is holding the retaining device of the invention securely against the fuel injector.
[0028] In accordance with the invention, the device has two housing parts, each provided with a connection to which the high-pressure line and the drain line are attached. Since both the high-pressure line and the drain line carry fluid under pressure, they must be connected relatively tightly to the first and third connection. To achieve this, the connections usually have an outside diameter which is greater than the internal diameter of the lines. However, this means that the connections are pushed into the lines with a rotating motion. Since the device is constructed of two housing parts, each part of the housing can be handled independently of the other, which renders connecting the individual connection to the high-pressure line or the drain line considerably easier since the other part of the housing and the other line do not present any interference. Once the parts of the housing are pushed onto the lines, the parts of the housing can be joined together and the device completed.
[0029] In a refinement of the invention, the injector is a formed part of the first part of the housing. This means that the entire device in accordance with the invention consists of two components: the first housing part with the injector and first connection and the second housing part with the third connection. This reduces not only production costs but also assembly and warehousing costs.
[0030] Under the invention, the first housing part is configured essentially cartridge-shaped, with the injector located coaxially in the first housing part. The cartridge-shaped structure has the advantage that it is easily possible to manufacture the first housing part using injection molding technology, and there is no problem in forming the injector on the first housing part.
[0031] The second connection is preferably formed either at the first or at the second housing part. If the second connection is located on the second housing part, the latter can also easily be manufactured as an injection molded part, particularly from two housing shell halves which are joined by friction welding or ultrasonic welding.
[0032] The second housing part preferably has a cartridge-shaped axial extension which encircles the injector nozzle and locates same. When the first and second housing parts are joined, the injector nozzle is carried in the axial extension which defines the precise position of the outlet for the injector nozzle in the second housing part. This is achieved by the extension centering the injector nozzle in the radial direction, that is to say, aligning it coaxially and additionally defining the depth of insertion.
[0033] In accordance with one aspect, retaining arms extending in the axial direction are provided on the first housing part which partially overlap the second housing part and. In another embodiment, these retaining arms are provided on the second housing part and extend over the first housing part in the axial direction. In a preferred variant, the retaining arms are configured as locking arms. The two housing parts are connected to each other by means of these retaining arms, specifically they are latched together. For this reason, no tool is required for assembly and assembly can be carried out specifically by machine.
[0034] Optimal distribution of force and symmetrical design of the housing parts is achieved by providing two oppositely located retaining arms. These two retaining arms also ensure that the two housing parts are connected in a fluid-tight manner, so that no fuel escapes at the joint and no air is sucked in.
[0035] To position the retaining arms on the other housing part, it has retaining means in accordance with the invention. The possibility also exists that the two housing parts are not locked together but, for example, are joined by means of friction welding or ultrasonic welding. However, it is then no longer possible to separate the two housing parts, whereas with a latch fitting the two housing parts can be separated at any time.
[0036] In one aspect, the retaining means have locking tabs or locking slots and the retaining arms have locking slots or locking tabs. Such simply designed retaining means are inexpensive to produce, are easy to engage and are reliable, even over a long period, with respect to their engagement, the retaining force and any possible play.
[0037] In one aspect, the second housing part is provided with longitudinal guides for the retaining arms. When the two housing parts are joined, these longitudinal guides allow the retaining arms to be positioned easily against the other housing part and pushed onto same. The retaining arms specifically possess bevels at their free ends and may be configured in such a way that the two housing parts can be joined only when aligned to each other in one way, thereby precluding incorrect assembly.
[0038] The longitudinal guides preferably abut the retaining arms laterally. The possibility also exists that the longitudinal guides engage the retaining arms, specifically in the form of ribs in grooves which are provided on the radially inward longitudinal surfaces of the retaining arms.
[0039] In accordance with the invention, at least two longitudinal guides position a retaining arm between themselves. These longitudinal guides form, so to speak, a channel into which the retaining arm can be introduced. The longitudinal guides additionally support the retaining arm in the peripheral direction, which has the substantial advantage that torsional forces impinging on one housing part are not transferred to the other housing part by the latched connection but by the longitudinal guide. This is important, for example, after the housing parts have been joined, that is to say, with a completely assembled device, when the high-pressure line and/or the return line is pushed on or pulled off, since torsional forces affect the housing parts during this procedure. In this instance, the longitudinal guide serves to provide lateral support and protection for the latched connection.
[0040] In accordance with the invention, the longitudinal guide is formed by a radial projection or recess running in the longitudinal direction. As already mentioned, if the longitudinal guide is a projection, it can form part of a channel, whereas if the longitudinal projection is configured as a recess, it forms a guide groove which is formed into the housing wall in the longitudinal direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Additional advantages, features and details of the invention can be found in the dependent claims and the subsequent description, in which particularly preferred embodiments are described in detail with reference to the drawing. The features shown in the drawing and mentioned in the description and the claims may be fundamental to the invention either individually or in any combination.
[0042] In the drawing:
[0043] FIG. 1 is a perspective view of a retaining device in accordance with the invention;
[0044] FIG. 2 is a plan view from FIG. 1 in the direction of arrow II;
[0045] FIG. 3 is a perspective view of a retaining device in accordance with the invention;
[0046] FIG. 4 is a plan view from FIG. 3 in the direction of arrow IV;
[0047] FIG. 5 is a perspective schematic representation of a fuel return system with four retaining devices of a suction device to be attached to fuel injectors, including return lines;
[0048] FIG. 6 is a side view of the device;
[0049] FIG. 7 is a perspective view of a first housing part to be connected to a high-pressure line;
[0050] FIG. 8 is a perspective view of a second housing part to be connected to a return line;
[0051] FIG. 9 is a section IX-IX from FIG. 8 through the second housing part;
[0052] FIG. 10 is a section X-X from FIG. 7 through the second housing part; and
[0053] FIG. 11 is a section XI-XI from FIG. 8 through the second housing part.
DETAILED DESCRIPTION
[0054] FIG. 1 shows a retaining device identified overall as 10 which can be attached to a fuel injector (see FIG. 2 ). The device 10 has a base 14 which is flanked on both sides by retaining arms 16 and 18 . On the side facing the fuel injector 12 , the base 14 has a concavity 20 which abuts the jacket of the fuel injector 12 when the retaining device 10 is installed. A connector 22 , which is sealed by an O-ring 24 and sits in a return passage 26 for the fuel injector 12 , projects radially from the concavity 20 . The excess fuel from the fuel injector 12 is taken through this return passage 26 from the fuel injector 12 and to the connector 22 .
[0055] The base 14 and the two retaining arms 16 and 18 form a main body 28 from which two connecting fittings 30 and 32 project onto which fuel return lines leading to the tank can be installed. The connecting fittings 30 and 32 are electrically connected to the connector 22 so that the excess fuel can drain through the connecting fittings 30 or 32 . The retaining device 10 can therefore be integrated into a common line.
[0056] It can be seen from FIG. 2 that a slot open at the edge 34 is provided between the retaining arms 16 and 18 and the base 14 , creating a somewhat flexible connection for the retaining arms 16 and 18 to the base 14 . The two retaining arms 16 and 18 can be bent open slightly, or abut the outer surface of the fuel injector 12 under pretension.
[0057] It can be seen further from the drawing that the two retaining arms 16 and 18 run essentially parallel to each other, or converge slightly, and have a first thickness D. At the end of their parallel sections, the retaining arms 16 and 18 have a second section 36 , where the retaining arms 16 and 18 diverge in this section. A third section 38 in which the retaining arms 16 and 18 run parallel to each other again attaches to this second section. The free ends of the retaining arms 16 and 18 are formed by a first section 40 which points essentially at the axis 41 of the fuel injector 12 , that is to say, the free ends of the retaining arms 16 and 18 converge and are inclined towards the base 14 . The free ends of the retaining arms 16 and 18 in the area of the first section 40 run essentially radially with respect to the fuel injector 12 .
[0058] It can be seen clearly from the drawing that the wall thickness d of the retaining arms 16 and 18 in the area of the first, second and third section 40 , 38 and 36 is less than in the area connected thereto. This provides increased flexibility for the retaining arms in the area of the free ends.
[0059] When the retaining device 10 is pushed onto the fuel injector 12 , the first section 40 initially forms a funnel, or a pilot fork, so that the retaining device 10 cannot slip off. The free ends of the first section 40 are bent into the recess identified by reference numeral 40 until the free ends align with the inside surface of the parallel section of the retaining arms 16 and 18 . The retaining device 10 can then be pushed fully onto the fuel injector 12 . Then the free ends of the first section 40 swing back into their initial position and now stand radially to the axis 41 of the fuel injector 12 , that is to say, perpendicular to its outer jacket. The installation force, or the force necessary to push the retaining device 10 on, is reduced because of the inventive design of the retaining device 10 compared with the prior art, whereas the pull-off force is increased since the free ends in the first section are not bent in when the retaining device is pulled off the fuel injector 12 , but are subjected to force in the longitudinal direction through their faces.
[0060] Preferably the retaining device in accordance with the invention is made of PPA or fiberglass-reinforced PPA.
[0061] Finally, it can be seen from FIG. 1 that stiffening ribs 46 are provided on the outer surface 44 of the retaining arms 16 and 18 which run in the direction of the longitudinal axis and come to a point towards the free ends of the retaining arms 16 and 18 . The width and the height of the stiffening ribs 46 can decrease.
[0062] FIG. 3 shows a retaining device identified overall as 110 which may be attached to a fuel injector 112 (see FIG. 4 ). The device 110 has a base 114 which is flanked by two retaining arms 116 and 118 . The base 114 is formed by a bridge from which a connecting fitting 130 protrudes for a return line (not shown). This connecting fitting 130 is electrically connected to a connector 122 which is sealed with an O-ring 124 and sits on return passage 126 for the fuel injector 112 . The excess fuel is taken through this return passage 126 from the fuel injector 112 and to the connector 122 .
[0063] In a center area 128 the two retaining arms 116 , 118 are connected to each other through a bridge 120 , where this bridge 120 is bent concavely and the connector 122 projects on its concave side. The curve matches the curvature of the fuel injector 112 . It can be seen clearly that the wall thickness b of the retaining arms 116 and 118 in the section between the base 114 and the center area 128 is less than the wall thickness B in the section between the center area 128 and the individual free end.
[0064] In the area of the base 114 , an additional connecting fitting 132 which is fluidically connected to the connecting fitting 130 projects from the retaining arm. A bail 136 , whose curvature is less than the curvature of the jacket of the fuel injector 112 , is formed onto the free end of the retaining arm 118 by means of a film hinge 134 . The free end of the bail 136 is formed by a locking hook 138 which, when the bail 136 is closed, engages a locking tab 140 provided on the free end of the retaining arm 116 facing away from the fuel injector. In the inside of the bail 136 a locating section 142 is provided, by way of which the bail 136 butts against the fuel injector 112 . This locating section 142 projects slightly above the slightly concavely curved inner surface. On the outside there is a stiffening rib 144 running in the longitudinal direction of the bail 136 which ensures that the bail 136 engaged in the locking tab 140 butts against the fuel injector 112 under pretension.
[0065] With the retaining device 110 in accordance with the invention, it is ensured that the installation force needed to push the retaining device 110 onto the fuel injector 112 is kept low and that, by closing the bail 136 and engaging the locking hook 138 onto the locking tab 140 , it is ensured that the retaining device 110 does not detach itself from the fuel injector 112 or loosen. It is possible to pull the retaining device 110 from the fuel injector 112 only after the bail 136 has been opened.
[0066] FIG. 5 shows a fuel return system for a 4-cylinder engine identified overall as 210 which has a total of four fuel injectors (not shown) to which retaining devices 212 are clipped. These retaining devices 212 possess connectors 214 which engage a matching socket in the fuel injector. The excess fuel which is taken through the return lines 216 to be suctioned off is taken to the connectors 214 through these sockets. This suction device 218 is attached by a suitable retaining clip 220 to the engine or in the engine compartment.
[0067] As can be seen from FIG. 6 , the suction device 218 has a first connection 222 to which a high-pressure line 224 can be connected. Fuel under pressure is transported in this high-pressure line 224 towards the suction device 218 . In a center area of the suction device 218 , there is a second connection 226 to which the return line 216 is connected. A third connection 228 is provided opposite the first connection 222 to which a drain line 230 can be connected. The fuel brought in through the high-pressure line 224 and the return line 216 of the suction device 218 is taken away through this drain line 230 , for example, to the tank.
[0068] The suction device 28 consists of a housing part 232 , shown in FIG. 7 , onto which the first connection 222 is formed and a second housing part 234 , which is shown in FIG. 8 . The second connection 226 and the third connection 228 project radially or axially from this second housing part 234 . In addition, areas 236 can be seen in which housing ribs 238 are provided running in the longitudinal direction, that is to say axially, to which the retaining clip 220 fastens.
[0069] A fuel injector 240 which is aligned coaxially to the longitudinal axis 242 of the first housing part 232 is provided opposite the first connection 222 . The fuel injector 240 is flanked by two retaining arms 244 located opposite each other whose free ends have leading bevels 248 . In addition, the retaining arms 244 are given locking slots 250 which coact, specifically engage, with locking tabs 252 on the second housing part 234 . The slots 250 and the tabs 252 form retaining means 246 for the retaining arms 244 .
[0070] It can be seen from FIG. 6 that the first housing part 232 has an essentially cartridge-shaped configuration, in which the injector nozzle 240 extends coaxially and is electrically connected to the first connection 222 . The injector nozzle possesses a narrow injector opening 254 in which the fluid being carried, specifically the fuel being carried, is accelerated to maximum speed. In the immediate vicinity of this injector opening is the opening 56 of the second connection 226 through which the fuel is suctioned off from the return line 216 through the negative pressure generated. The exact alignment of the opening 256 relative to the nozzle opening 254 is achieved by a stop 258 on the first housing part 232 for an insertion sleeve 260 which is formed coaxially onto the second housing part 234 and surrounds the injector nozzle. The diffuser required for the venturi system can be seen in the second housing part 234 . In addition, two longitudinal guides 264 , which abut the retaining arms 244 laterally when they are latched to the locking tabs 252 , can be seen in the views of the second housing part shown in FIGS. 10 and 11 . These longitudinal guides 264 prevent the two housing parts 232 and 234 from being rotated relative to each other in their latched position.
[0071] The outlet or opening 256 of the second connection 226 , that is the opening 256 in the flow duct 266 of the venturi system, is shown in FIG. 11 . This opening 256 lies in a defined position relative to the nozzle opening 254 when the housing parts 232 and 234 are latched.
[0072] The design of the device 218 with two housing parts 232 and 234 in accordance with the invention has the considerable advantage that it can manufactured and assembled easily and warehousing costs are reduced. | A device to suction fuel from a fuel injector and a device to attach a fuel return line to a fuel injector with a C-shaped main body partially encircling the fuel injector having two retaining arms which abut the fuel injector and grip it from the back at least to a small degree, with a connector coacting with a drain passage of the fuel injector and at least one connecting fitting for the fuel return line. The connecting fitting and the connector are electrically connected. The free ends of the retaining arms have a first section in which they are angled towards each other and towards the base of the main body. | 5 |
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a mechanically stabilized earth (MSE) wall, and more particularly, to a MSE wall system having a double wall structure for preventing deformation of the rear screen, which supports the load of the backfill, from being transferred to the front panel forming the appearance of the retaining wall.
(b) Description of the Related Art
Conventionally, a mechanically stabilized earth (MSE) wall, which was developed in 1960s, has been constructed using a front panel made of a thin steel panel and reinforcing elements such as metal strips. This first-introduced type MSE wall resisted the external loads by minimizing the soil pressure applied to the front panel by the frictional resistance of the reinforcing elements and by structurally strengthening the backfill by compaction along with inserted reinforcements. In addition, the front panel was made using thin steel plates to maximize its functionality by allowing the soil pressure applied thereon to be deformed to minimize the actual load. However, using the thin plates for the front panels brought up secondary problems such as local deformation and corrosion which resulted in poor aesthetic appearance. As a result, the first-introduced type of MSE wall was not widely applied.
Afterwards, relating technologies have been developed, so that the MSE wall structure has been modified as shown in FIG. 1 . Specifically, the front panel is structured in concrete panels or blocks, and then mechanically stabilized by inserting reinforcing elements such as steel strips, fibers or plastic-based reinforcing elements having polymer coatings. The front panel made of a rigid body such as a concrete panel or block may provide excellent appearance. However, it is not structurally stabilized because stress is concentrated on a jointing portion between the rigid front panel and the reinforcing element installed to reinforce the rear ground which structurally exhibits flexible behavior. As a result, fracture may be generated in the jointing portion. In addition, considering that the entire structure should exhibit flexible behavior, the rigid front panel is not advantageous to the safety of the entire structure. For this reason, the conventional MSE structure has various problems such as local deformation, fracture in the jointing area, and global deformation due to long-time creep. Continuous development in technologies promotes complementary countermeasures such as slide joints, separated front panels, etc. in order to solve such problems. Unfortunately, such countermeasures proved to be not a substantial solution but just variations of specifications to alleviate the problems.
SUMMARY OF THE INVENTION
The present invention has been made to solve the aforementioned problems, and the object of the invention is to provide a mechanically stabilized earth (MSE) wall system having a double wall structure, in which a vacant space is provided between the rear screen for supporting the backfill and the front panel for forming exterior of the retaining wall. This invention allows the rear screen to deform to a certain degree enabling flexible behavior which can improve the safety of the retaining wall without having the deformation of the screen generating deformation of the front panel.
According to an aspect of the present invention, there is provided a mechanically stabilized earth (MSE) wall system for preventing collapse of a retaining wall, the MSE wall system comprising: at least two pillars installed on a front surface of the retaining wall; a plurality of screens installed on a rear surface of the pillar and arranged along a vertical direction to intercept a space between the adjacent pillars; at least a connector installed between the adjacent pillars to secure spacing between the adjacent pillars and prevent the screens from being separated into a front direction; and at least a front panel installed in front of the screen with a spacing in between.
The connector may be positioned at the adjoining line of the screens.
The MSE wall system may further comprise an upper cover installed on top of the pillars to cover a space between the screen and the front panel.
The MSE wall system may further comprise at least a reinforcing element installed on the pillar and deeply inserted into the backfill.
The MSE wall system may further comprise a reinforcing element installed on the connector and deeply inserted into the backfill.
The front panel may be installed on a front surface of the pillar.
The screens may be installed on a front surface of the pillars with a predetermined interval, the front panel may be installed on a spacing member provided on the pillar with a predetermined interval, and the spacing member may protrude from the pillar.
The screens may be installed between the pillar and the connector with a predetermined interval, the front panel may be installed on a spacing member provided on the pillar with a predetermined interval, and the spacing member may protrude from the pillar.
The spacing member may be an anchor bolt.
The pillar, the connector, and the front panel may be prefabricated as a single unit.
The MSE wall system may further comprise a reinforcing element installed on the screen and deeply inserted into the backfill.
Connecting members may be installed on a front surface of the pillar with a predetermined interval, and the front panel may be combined with the connecting member.
According to the present invention, an MSE wall system can be constructed by directly assembling together each factory manufactured parts at the construction site allowing the benefits of easier and faster construction of the retaining wall. Accordingly, the construction period can be significantly reduced. In addition, in the MSE wall system according to the present invention, the front panels can be easily replaced and seldom experience deformation. Therefore, the front panel can be variously modified depending on consumer's desire.
Furthermore, according to the present invention, it is possible to improve safety, which is most important factor in a retaining wall structure, by advantages such as the flexible behavior of the entire structure, reduction of the water pressure through entire surface drainage at the rear screen, excellent adaptive response to dynamic load such as an earthquake or to uneven settlements, alleviation of the stress concentration on reinforcing elements and jointing portions by allowing deformation of the backside screens. Furthermore it is possible to prevent effluent groundwater from harming appearance of the retaining wall and to obtain a drainage path through the vacant space between the front panel and the rear screen.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
FIG. 1 is a set of photographs taken of conventional mechanically-stabilized earth (MSE) walls;
FIG. 2 is an exploded perspective view illustrating an MSE wall system having a double wall structure according to an exemplary embodiment of the present invention;
FIG. 3 is a perspective view illustrating an example of installation of a retaining wall system shown in FIG. 2 ;
FIG. 4 is a top plan view of FIG. 3 ;
FIG. 5 is a set of photographs taking various shapes of front panels installed in a retaining wall system of FIG. 2 ;
FIG. 6 is a front view illustrating arrangement of pillars and connectors in a mechanically stabilized earth wall system according to another embodiment of the present invention;
FIG. 7 is an exploded perspective view illustrating a unit entity of a mechanically stabilized earth wall system according to another exemplary embodiment of the present invention; and
FIG. 8 is a perspective view illustrating a mechanically stabilized earth wall system according to another exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
FIG. 2 is an exploded perspective view illustrating a mechanically stabilized earth (MSE) wall system having a double wall structure according to an exemplary embodiment of the present invention. FIG. 3 is a perspective view illustrating an example of installation of a retaining wall system shown in FIG. 2 . FIG. 4 is a top plan view of FIG. 3 . FIG. 5 is a set of photographs taking various shapes of front panels installed on a retaining wall system of FIG. 2 .
As shown in FIG. 2 , a retaining wall system according to the present invention includes pillars 10 , screens 20 , connectors 30 , and front panels 40 .
The pillar 10 is a member for supporting pressure of the reinforcing earth. A plurality of pillars are arranged with a predetermined interval along the side surface of the backfilling soil 100 . Although an H-shape beam is used as a pillar 10 in this embodiment, various types or shapes of members can be adapted if they provide a sufficient spacing between the screen 20 and the front panel 40 . Preferably, the pillar 10 may have various cross-sectional shapes such as an H-shape beam, a rectangular beam, and a C-shape beam. In addition, according to the present embodiment, a spacing member (not shown) capable of providing a predetermined interval may be combined with the pillar 10 having a flat shape, and then the front panel 40 may be installed in the end of the spacing member to provide a spacing between the front panel 40 and the screen 20 . The spacing member may include an anchor bolt.
A plurality of fixing holes 12 and 14 may be provided in the front and rear surfaces of the pillar 10 along its longitudinal direction with a predetermined interval. In this case, the fixing holes 12 provided in the rear surface of the pillar 10 may be horizontally wide to obtain mobility of the screen 20 .
The screen 20 is a member for preventing collapse of the backfilling soil 100 . The screen 20 has breaches in order to prevent local landslide and soil run out but to allow drainage. According to the present embodiment, the screen 20 having a mesh shape is provided to achieve the aforementioned function. Both ends of the screen can be provided with fixing holes 22 . Accordingly, the screen 20 is installed between two different pillars 10 by means of the bolts jointed with the fixing holes 12 and 22 . Meanwhile, the screen 20 is preferably made of a soft material to absorb the pressure of the reinforcing soil a little.
The connector 30 prevents the screen 20 from being broken away by the pressure of the backfilling soil 100 . It also serves to control deformation of the screen 20 , transfer loads between the pillars, and control shearing deformation (i.e., uneven settlement in a longitudinal direction) in the front portion of the retaining wall. For this purpose, the connectors 30 are spaced with a predetermined interval in a longitudinal direction of the pillar 10 to support the front surface of the screen 20 . The narrower interval between the adjacent connectors would provide a strong support. However, if the interval is excessively narrow, the screen 20 is seldom deformed by the pressure of the backfilling soil. If this is the case, the pressure of the backfilling soil 100 is not absorbed into the screen 20 , and directly transferred to the pillar 10 , so that safety of the retaining wall weakened. Therefore, as shown in the present embodiment, the connector 30 is preferably installed in the adjoining line of the screens 20 to allow deformation of the screen as large as possible and prevent separation of the screen 20 . Various members such as an L-shape beam, an H-shape beam, a steel beam, a rectangular steel beam, and a C-shape beam can be used as the connector 30 .
The front panel 40 hides the inner structure of the retaining wall having pillars 10 , screens 20 , and connectors 30 so that we cannot see them from external to provide excellent appearance. The front panel 40 may be made of a material that can be easily painted or figured, such as wood, steel plate, concrete, stainless steel, and plastic. Furthermore, the front panel 40 may be finished in various shapes such as embossment or ripples to provide excellent appearance. The rear side of the front panel 40 is provided with a plurality of protrusions 42 . Accordingly, the front panel 40 can be combined with the pillars 10 by means of the protrusions 42 .
In addition, a reinforcing element 60 may be provided in the rear side of the pillar 10 , the connector 30 , or the screen 20 . As shown in FIGS. 3 and 4 , the reinforcing element 60 is deeply inserted into the backfilling soil 100 to prevent the pillar from falling down.
Such a retaining wall system according to the present embodiment can provide excellent appearance as shown in FIG. 3 . Therefore, the retaining wall system according to the present invention can be installed anywhere with a harmonized appearance. In addition, an upper cover 50 may be provided on the retaining wall to prevent a landslide or rainwater from flowing into a gap between the screen 20 and the front panel 40 .
Meanwhile, unlike a conventional retaining wall, since the screen 20 and the front panel 40 are spaced with a predetermined interval in the retaining wall according to the embodiment of the present invention, the front panel 40 is seldom deformed. Conventionally, as shown in FIG. 4 , the retaining wall was susceptible to deformation due to the pressure of the backfilling soil 100 because the screen 20 was not spaced from the front panel. Furthermore, in a conventional retaining wall, the front panel installed in front of the screen 20 intercepts a drainage path of rainwater or groundwater, so that the entire load applied to the retaining wall increases.
However, according to the embodiment of the present invention, as shown in FIG. 4 , the screen 20 is spaced from the front panel with a predetermined interval. Therefore, the rainwater or groundwater drained through the screen 20 can be appropriately discharged. In addition, since the deformation of the screen 20 is not propagated to the front panel 40 , the front panel can remain in its initial shape. Since the front panel 40 is not susceptible to deformation by the backfilling soil 100 , the front panel 40 can be made of various materials with various colors and shapes as shown in FIG. 5 unlike the conventional ones. The front panels 40 shown in FIG. 5 are just exemplary, but other shapes or colors may be used in the front panel 40 .
FIG. 6 is a front view illustrating arrangement of pillars and connectors in an MSE wall system according to another exemplary embodiment of the present invention. FIG. 7 is an exploded perspective view illustrating a unit entity of an MSE wall system according to another exemplary embodiment of the present invention.
According to another embodiment of the present invention, the pillars 10 and the connectors 30 are crossed with each other to consolidate their engagement structure as shown in FIG. 6 . In this case, the pillars 10 are connected with each other by engaging bolts or rivets with the connecting plate 70 interposed, and the connectors 30 are connected with each other by engaging bolts or rivets with the connecting plate 70 interposed.
Further, according to another embodiment of the present invention, the pillar 10 , the connector 30 , and the front panel 40 may be previously manufactured in a factory as a single unit kit 200 as shown in FIG. 7 , and a plurality of unit kits 200 may be assembled in the construction site using the connecting plates 70 , and bolts or rivets. In this case, it is preferable to separately manufacture the screen 20 and then assemble them in the construction site. This is because it would be difficult or impossible to assemble the unit kits 200 with each other if the screen 20 is previously combined. The screen 20 may be combined with the unit kit 200 using bolts or through welding.
Meanwhile, in the embodiments shown in FIGS. 2 and 3 , since the front panel 40 is installed between two adjacent pillars 10 , the length of the front panel 40 may be adaptively adjusted depending on the interval between the adjacent pillars 10 .
Typically, the interval between the adjacent pillars is adjustable. However, if the interval is set to be shorter, more pillars 10 should be accordingly used. It may cause cost increase in materials and installation. For this reason, in most of the cases, the front panel 40 is constructed as long as possible depending on the interval between the adjacent pillars 10 .
If the front panel 40 is too long, since bending moment may be easily generated even by a small external force or weather changes, the front panel 40 should be thicker. However, if the front panel 40 is constructed in a larger thickness, the manufacturing cost and its weight accordingly increase.
The embodiment shown in FIG. 8 is made to consider such a problem.
In this embodiment, connectors 32 are further provided in the front surfaces of the pillars 10 as shown in FIG. 8 .
The front panel 40 is constructed in an appropriate size and combined with the connector 32 . In the present embodiment, the length of the front panel 40 is set to a half of the interval between the adjacent pillars 10 . As such, if the length of the front panel 40 is reduced, the bending moment of the front panel can be accordingly reduced, and thus, the thickness of the front panel 40 can be smaller. If the front panel 40 becomes thin, its conveyance and installation may be easier, and thus, the retaining wall system can be completed earlier.
While an MSE wall system having a double wall structure according to the present invention has been particularly shown and described with reference to exemplary 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 spirit and scope of the invention as defined by the appended claims. The exemplary embodiments should be considered in descriptive sense only and not for purposes of limitation. Therefore, the scope of the invention is defined not by the detailed description of the invention but by the appended claims, and all differences within the scope will be construed as being included in the present invention. | Disclosed is a mechanically stabilized earth (MSE) wall system for preventing collapse of a retaining wall. The MSE wall system includes: at least two pillars installed on a front surface of the retaining wall; a plurality of screens installed on a rear surface of the pillar and arranged along a vertical direction to intercept a space between the adjacent pillars; at least a connector installed between the adjacent pillars to preserve a space between the adjacent pillars and prevent the screens from being separated into a front direction; and at least a front panel spaced from a front surface of the screen. Since deformation of the screen which supports the load of the backfilling soil is not transferred to the front panel, it is possible to provide excellent appearance. | 4 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to an expansion device for a heat pump.
[0002] Heat pumps employ a compressor, an indoor heat exchanger, an outdoor heat exchanger, an expansion device and 4-way reversing valve, to switch operation between cooling and heating modes. Heat pumps utilize an expansion device through which the refrigerant flow expands from high pressure and temperature to low pressure and temperature. Different size restriction of the expansion device is required for proper system operation depending upon whether the heat pump is in a cooling or heating mode of operation. Obviously, when the system is operating in cooling or in heating mode, the direction of the refrigerant flow through the expansion device is reversed.
[0003] Prior art heat pump systems with single expansion devices use a moveable piston that moves in a first direction in which its flow resistance is substantially higher than when it is moved in an opposite second direction. The first direction corresponds to the heating mode and second direction corresponds the cooling mode. The piston is prone to wear, which adversely effects the operation and reliability of the system due to undesirably large tolerances and contamination. Furthermore, modern heat pump systems are incorporating alternate refrigerants, such as R410A, and POE oils. The system utilizing R410A refrigerant operate at much higher pressure differentials than more common R22 and R134A refrigerants employed in the past within the system. This adversely impacts the expansion device wear, lubrication and results in higher loads during transient conditions of operation.
[0004] Therefore, there is a need for a single reliable, inexpensive expansion device for the heat pump systems that is not as prone to wear and reliability problems.
SUMMARY OF THE INVENTION
[0005] The inventive heat pump expansion device consists of a flow resistance device that has a different resistance to flow depending on the flow direction through this device. The flow resistance device is fixed or rigidly mounted relative to first and second fluid passages so that it avoids the wear problems of the moveable piston in the prior art. The fluid flow resistance device in several examples of the invention is a fixed obstruction about which the refrigerant must flow when traveling through the expansion device. The flow resistance device has features on one side that create a low drag coefficient when the refrigerant flows in one direction but a high drag coefficient when the refrigerant flows in the opposing direction.
[0006] Accordingly, the present invention provides a reliable, inexpensive expansion device that is not as prone to wear and reduces reliability problems.
[0007] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic view of a heat pump having the inventive expansion device.
[0009] FIG. 2 to a cross-sectional view of a first example of the inventive expansion device.
[0010] FIG. 3 is a cross-sectional view of second example of the inventive expansion device.
[0011] FIG. 4 is a cross-sectional view of a third example of the inventive expansion device.
[0012] FIG. 5 is a cross-sectional view of a fourth exampled of the inventive expansion device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] A heat pump 10 utilizing the present invention and capable of operating in both cooling and heating modes is shown schematically in FIG. 1 . The heat pump 10 includes a compressor 12 . The compressor 12 delivers refrigerant through a discharge port 14 that is returned back to the compressor through a suction port 16 .
[0014] Refrigerant moves through a four-way valve 18 that can be switched between heating and cooling positions to direct the refrigerant flow in a desired manner (indicated by the arrows associated with valve 18 in FIG. 1 ) depending upon the requested mode of operation, as is well known in the art. When the valve 18 is positioned in the cooling position, refrigerant flows from the discharge port 14 through the valve 18 to an outdoor heat exchanger 20 where heat from the compressed refrigerant is rejected to a secondary fluid, such as air. The refrigerant flows from the outdoor heat exchanger 20 through a first fluid passage 26 of the inventive expansion device 22 . The refrigerant when flowing in this forward direction expands as it moves from the first fluid passage to a second fluid passage 28 thereby reducing its pressure and temperature. The expanded refrigerant flows through an indoor heat exchanger 24 to accept heat from another secondary fluid and supply cold air indoors. The refrigerant returns from the indoor exchanger 24 to the suction port 16 through the valve 18 .
[0015] When the valve 18 is in the heating position, refrigerant flows from the discharge port 14 through the valve 18 to the indoor heat exchanger 24 where heat is rejected to the indoors. The refrigerant flows from the indoor heat exchanger 24 through second fluid passage 28 to the expansion device 22 . As the refrigerant flows in this reverse direction from the second fluid passage 28 through the expansion device 22 to the first fluid passage 26 , the refrigerant flow is more restricted in this direction as compared to the forward direction. The refrigerant flows from the first fluid passage 26 through the outdoor heat exchanger 20 , four-way valve 18 and back to the suction port 16 through the valve 18 .
[0016] Several examples of the inventive expansion device are shown in FIGS. 2-6 . The inventive expansion device 22 includes a flow resistance device 30 that is arranged between the first 26 and second 28 fluid passages. Unlike the prior art moveable piston, the flow resistance device 30 is fixed relative to the fluid passages 26 and 28 so that it does not have any features that are subject to damage, wear or contamination. The flow resistance device 30 is shown schematically supported by a pin. The flow resistance device 30 has lower fluid resistance when the refrigerant is flowing in the forward or cooling direction than when refrigerant is flowing in the reverse or heating direction, acting as a fluid diode. This variable fluid resistance is achieved by providing different features on either side of the flow resistance device 30 that increases the fluid resistance in one direction and provides lower fluid resistance in the other direction.
[0017] Referring to FIG. 2 , the flow resistance device 30 includes a barbed end 32 facing the second fluid passage 28 . When the refrigerant is flowing in the forward or cooling direction, the refrigerant flows about smooth surfaces of the flow resistance device 30 so that the arrangement of the flow resistance device 30 between the passages 26 and 28 creates relatively little resistance. However, when the refrigerant flows in the reverse order or heating direction, the refrigerant flows into the barbed end 32 creating a very high drag or resistance to the fluid flow.
[0018] Another example of the invention is shown in FIG. 3 , which utilizes an angled fluid passage 34 as the flow resistance device 30 . The angled fluid passage 34 is arranged such that refrigerant flowing in the cooling direction generally bypasses the angled fluid passage 34 flowing more directly through to the second fluid passage 28 . However, when the refrigerant flows in the heating direction the refrigerant more easily flows into the angled fluid passage 34 due to its orientation relative to the second fluid passage 28 . Fluid flow from the second fluid passage 28 into the entry of the angled fluid passage 34 is better maintained due to the shallow angle of the wall between the second fluid passage 28 and the wall at the opening of the angled fluid passage 34 . The refrigerant exits the angled fluid passage 34 in such a manner that it is directed back into the flow of refrigerant flowing from the second fluid passage 28 to the first fluid passage 26 creating turbulence and generating an increased flow resistance as compared to refrigerant flowing in the cooling direction.
[0019] Referring to FIGS. 4 and 5 , the flow resistance device 30 is arranged between the fluid passages 26 and 28 in a similar manner to that shown in FIG. 2 . As shown in FIG. 4 , the flow resistance device 30 is an open faced hemisphere 38 , and the flow resistance device 30 shown in FIG. 5 is a C-shaped channel 40 arranged between the fluid passages 26 and 28 . As the refrigerant flows in the cooling direction, the smooth rounded surface of the flow resistance devices 30 have a relatively low drag coefficient. However, when the refrigerant flows in the heating direction into the cupped area of the flow resistance devices 30 , a relatively high drag coefficient is experienced increasing the flow resistance in the heating direction.
[0020] It should be appreciated that the flow resistances can be expressed using various terminology. For example, the flow resistances can be expressed as drag coefficients. The flow resistances can also be expressed as relative degrees of turbulent or laminar flows. In any event, the change in flow resistance based upon the direction of refrigerant flow is achieved by utilizing a fixed flow resistance device.
[0021] Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. | An expansion device for the heat pump applications consists of a flow resistance device that has a different resistance to refrigerant flow depending on the flow direction through this device. The flow resistance device has no moving parts so that it avoids the damage, wear and contamination problems of the moveable piston in the prior art. The flow resistance device is a fixed obstruction about which the fluid must flow when traveling through the expansion device. | 5 |
RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S. Patent Application 61/782,429, entitled “Three-phase Power Conversion with Power Factor Correction Operational Day and Night,” which was filed on Mar. 14, 2013, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] Reactive power is a significant issue for power providers as it reduces real power delivery and increases power loss. Systems that can correct for reactive power are of increasing interest. Regulations are emerging in some countries to oblige large power generation plants such as utility-scale solar installations to introduce specified amounts of corrective reactive power when instructed to do so.
[0003] One method of introducing corrective reactive power (or Power Factor Correction) is to switch in large banks of reactive components such as capacitors. An alternative approach is to use active electronics to introduce reactive power. It is common to use a 3-phase H-bridge to produce 3-phase reactive power.
SUMMARY
[0004] In accordance with the presently claimed invention, a system and method are provided for controlling power factor correction (PFC) for three-phase AC power conveyed via a three-phase AC power grid. Currents and voltages on the grid are monitored and used to generate waveform data enabling dynamic control of switching circuitry used in controlling one or more phase offsets between the currents and voltages.
[0005] In accordance with one embodiment of the presently claimed invention, a system for controlling power factor correction (PFC) for three-phase AC power having a power signal frequency and one or more voltage-current (V-I) phase offsets, comprising:
[0006] frequency control logic responsive to a plurality of data by providing frequency control data, by processing at least one of initial frequency data and aggregate phase data for the three-phase AC power with
first measured power data related to respective phases of one of voltage and current of the three-phase AC power, and synthesized frequency data corresponding to the power signal frequency;
[0009] frequency synthesizer logic coupled to the frequency control logic and responsive to the frequency control data by providing the synthesized frequency data;
[0010] phase control logic coupled to the frequency synthesizer logic and responsive to another plurality of data by providing phase control data, by processing at least one of initial phase offset data and desired phase offset data for the three-phase AC power with the synthesized frequency data and second measured power data related to another of the voltage and current of the three-phase AC power; and
[0011] waveform synthesizer logic coupled to the phase control logic and responsive to the phase control data by providing synthesized waveform data corresponding to respective phases of the three-phase AC power.
[0012] In accordance with another embodiment of the presently claimed invention, a method for controlling power factor correction (PFC) for three-phase AC power having a power signal frequency and one or more voltage-current (V-I) phase offsets, comprising logic circuitry programmed to:
[0013] respond to a plurality of data by providing frequency control data, by processing at least one of initial frequency data and aggregate phase data for the three-phase AC power with
first measured power data related to respective phases of one of voltage and current of the three-phase AC power, and synthesized frequency data corresponding to the power signal frequency;
[0016] respond to the frequency control data by providing the synthesized frequency data;
[0017] respond to another plurality of data by providing phase control data, by processing at least one of initial phase offset data and desired phase offset data for the three-phase AC power with the synthesized frequency data and second measured power data related to another of the voltage and current of the three-phase AC power; and
[0018] respond to the phase control data by providing synthesized waveform data corresponding to respective phases of the three-phase AC power.
[0019] In accordance with another embodiment of the presently claimed invention, a method for controlling power factor correction (PFC) for three-phase AC power having a power signal frequency and one or more voltage-current (V-I) phase offsets, comprising:
[0020] responding to a plurality of data by providing frequency control data, by processing at least one of initial frequency data and aggregate phase data for the three-phase AC power with
first measured power data related to respective phases of one of voltage and current of the three-phase AC power, and synthesized frequency data corresponding to the power signal frequency;
[0023] responding to the frequency control data by providing the synthesized frequency data;
[0024] responding to another plurality of data by providing phase control data, by processing at least one of initial phase offset data and desired phase offset data for the three-phase AC power with the synthesized frequency data and second measured power data related to another of the voltage and current of the three-phase AC power; and
[0025] responding to the phase control data by providing synthesized waveform data corresponding to respective phases of the three-phase AC power.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 depicts an overall architectural for a system for power factor correction in accordance with exemplary embodiments of the presently claimed invention.
[0027] FIG. 2 depicts a DC to AC Block suitable for use in the system of FIG. 1 .
[0028] FIG. 3 depicts a Filter Block and Voltage and Current Transducer Blocks suitable for use in the system of FIG. 1 .
[0029] FIG. 4 depicts a Control Unit suitable for use in the system of FIG. 1 .
[0030] FIG. 5 depicts a logic diagram for implementing the Control Unit in the system of FIG. 1 in accordance with exemplary embodiments of the presently claimed invention.
[0031] FIG. 6 depicts a logical flow for Power Factor Correction control in accordance with exemplary embodiments of the presently claimed invention.
[0032] FIG. 7( a ) depicts voltage and current waveforms for the 3 phases.
[0033] FIGS. 7( b ) and 7 ( c ) depict examinations of phase 1 with two different values of desired PFC phase offset.
[0034] FIG. 7( d ) depicts powers of the 3 phases.
[0035] FIG. 8 depicts Sine/Cosine Correlator logic suitable for use in the logic of FIG. 5 .
DETAILED DESCRIPTION
[0036] As discussed in more detail below, exemplary embodiments of the presently claimed invention provide control for a standard 3-phase H-bridge to enable: generation of reactive AC 3-phase power from a power conversion system using a novel control, and production of reactive power independently of whether the system is making DC to AC power conversion or not.
Architecture
[0037] The overall approach is shown in overview form in FIG. 1 . A DC input ( 211 A), for example from an array of solar panels or batteries, is converted from DC to AC ( 101 A), filtered and measured ( 102 A), and controlled ( 103 A) to produce power suitable for the 3-phase AC electrical grid ( 345 A). This system is capable of Power Factor Correction (PFC).
[0038] In a previous patent application (U.S. Patent Publication 2010/0308660, the contents of which are incorporated herein by reference) we detailed a power conversion scheme where a preferred implementation is partly reproduced here as FIG. 2 . This shows the DC to AC Block ( 101 B) in detail, and refers to the Filter & V, I Transducer Block ( 102 B) (detailed in FIG. 3 ) and the Control Unit block ( 103 B) (detailed in FIG. 4 ).
[0039] Control of the system is novel, and is detailed in FIG. 5 . An advantageous aspect of the invention is an ability to take instruction on the amount and type (leading or lagging) of power factor correction to apply independently of whether the system is making a DC to AC conversion or not; a logical flow detailing this is shown in FIG. 6 .
[0040] The DC to AC Block is described in detail in the previous patent application v .
[0041] In FIG. 3 : 3-phase voltages ( 341 C, 342 C, 343 C) from the DC to AC Block ( 101 A, 101 B) enter the Filter Element ( 335 ). The Filter Element ( 335 ) is comprised of an energy storage inductor and optional smoothing capacitor, and an optional LC low pass filter, per phase. Each output of the Filter Element is connected to a voltage transducer ( 337 , 339 , 344 ) and a current transducer ( 336 , 338 , 340 ). The output of each current transducer ( 336 , 338 , 340 ) connects ( 332 C, 333 C, 334 C) to the 3-phase AC grid ( 345 C). Voltage transducer measurement outputs ( 326 C, 327 C, 328 C) and current transducer measurement outputs ( 329 C, 330 C, 331 C) connect to the control block ( 103 A, 103 D).
[0042] The Control Unit ( 103 D) is detailed in FIG. 4 : Voltage transducer measurement outputs V 1 , V 2 , V 3 , ( 326 D, 327 D, 328 D) are connected to inputs In 1 , In 2 , In 3 of the multi-channel ADC ( 449 ). Current transducer measurement outputs I 1 , I 2 , I 3 ( 329 D, 330 D, 331 D) are connected to inputs In 4 , In 5 , In 6 of the same multi-channel ADC ( 449 ). The output of the multichannel ADC is connected to the micro-processor ( 450 ) and the FPGA ( 451 ).
[0043] The micro-processor ( 450 ) has ROM ( 453 ) and RAM ( 454 ) and is capable of bi-directional digital communication ( 447 , 448 ). The micro-processor ( 450 ) is connected to the multi-channel ADC ( 449 ) and the FPGA ( 451 ).
[0044] The FPGA ( 451 ) receives digitized measurement data from the multi-channel ADC ( 449 ). It is connected to the micro-processor ( 450 ). The Chopper Bridge ( 201 B in FIG. 2 ) is controlled by the FPGA ( 451 ) using output Out 7 ( 226 B, 226 D); the Chopper Bridge ( 201 B) is turned on when the converter is generating and off when the converter is not making a DC to AC power conversion. The FPGA is connected ( 401 D- 406 D) to MOSFET drivers ( 452 ). The MOSFET drivers ( 452 ) drive switches SW 1 -SW 6 ( 213 - 218 in FIG. 2 ) through outputs Out 1 -Out 6 ( 220 D- 225 D).
[0045] The FPGA ( 451 ) and micro-processor ( 450 ) have a global clock (not shown) that times all internal operations.
[0046] In FIG. 5 the control logic used by the control unit ( 103 D in FIG. 4 ) is shown. The control logic is implemented in the micro-processor ( 450 ) and FPGA ( 451 ) in the preferred implementation. It could be implemented entirely in the micro-processor ( 450 ) or entirely in the FPGA ( 451 ), the exact apportionment of tasks is an implementation detail not material to the overall control.
[0047] In the block diagram of FIG. 5 , a variety of functional blocks are connected together to form the Direct Digital Synthesis block (DDS) ( 512 E) and Sine Waveform Generators ( 520 E), controlled by the Grid Sync Servo Loop ( 510 E) and Phase Offset Servo Loop ( 524 E) respectively.
DDS Block
[0048] DDS is formed by an adder ( 561 E) and phase accumulator ( 562 E). The output of the phase accumulator ( 562 E) is connected to one input of the adder ( 561 E). The other input of the adder ( 561 E) receives the frequency tuning word ( 511 E). The output of the adder ( 561 E) is connected to the input of the phase accumulator ( 562 E). The output of the phase accumulator ( 562 E) is called DDS Phase ( 518 E).
Grid Sync Servo Loop Block
[0049] Digitized measurement data from voltage transducers V 1 , V 2 , V 3 ( 326 E, 327 E, 328 E) provide inputs to Voltage Zero Crossing Detectors 1 , 2 , 3 ( 580 E, 581 E, 582 E) each of which provide clock to Latch 1 , 2 , 3 ( 583 E, 584 E, 585 E). The data input to each latch is connected to DDS Phase ( 518 E). The outputs of latches ( 583 E, 584 E, 585 E) connect to three inputs of an adder ( 586 E). The fourth input of the adder ( 586 E) is connected to the Aggregate Phase Offset Register ( 525 E). The output of the adder ( 586 E) connects to a Proportional-Integral-Derivative (PID) Servo Loop Filter ( 587 E), the output of which generates the Frequency Tuning Word Correction ( 517 E).
[0050] The Frequency Tuning Word Correction ( 517 E) feeds an adder ( 516 E). The other input of the adder ( 516 E) is connected to the Initial Frequency Tuning Word register ( 526 E). The output of the adder ( 516 E) is called the Frequency Tuning Word ( 511 E) and feeds an input of an adder ( 561 E).
Phase Offset Servo Loop Block
[0051] DDS Phase ( 518 E) is connected to the input of an adder ( 563 E). Phase Correction ( 513 E) is applied to the other input of the adder ( 563 E). DDS Phase ( 518 E) is also connected to an input of adders ( 564 E, 565 E). A second input on each adder ( 564 E, 565 E) is connected to Phase Correction ( 513 E). The third input of each adder ( 564 E, 565 E) is connected to the output of Phase Offset registers 2 , 3 ( 521 E, 522 E) respectively.
[0052] The output of each adder ( 563 E, 564 E, 565 E) is connected to the input of Sine Lookup Table 1 , 2 , 3 ( 568 E, 569 E, 570 E) respectively. The output of each Sine Lookup Table ( 568 E, 569 E, 570 E) feeds the input of PWM Generator 1 , 2 , 3 ( 573 E, 574 E, 567 E) respectively. The Sine Lookup Tables ( 568 E, 569 E, 570 E) together with the PWM Generators ( 573 E, 574 E, 567 E) form Sine Waveform Generators ( 520 E). The outputs of the PWM Generators ( 401 E to 406 E) are connected to the MOSFET drivers ( 452 ) that connect to switches SW 1 to SW 6 ( FIG. 4 ).
[0053] DDS phase ( 518 E) feeds the input of an adder ( 566 E). The second input of the adder ( 566 E) connects to the Desired PFC Phase Offset Register ( 523 E). The output of the adder ( 566 E) connects to a Sine/Cosine Correlator ( 576 E, discussed in more detail below). The other input of the Sine/Cosine Correlator ( 576 E) receives digitized samples of measurement data from current transducer I 1 ( 329 E). The output of the adder ( 566 E) also connects to inputs of two adders ( 571 E, 572 E). The second input of each adder ( 571 E, 572 E) connects to Phase Offset 2 ( 521 E) and Phase Offset 3 ( 522 E) registers respectively. The outputs of these adders ( 571 E, 572 E) connect to the input of Sine/Cosine Correlator 2 ( 577 E) and 3 ( 578 E) respectively. The outputs of the three Sine/Cosine Correlators ( 576 E, 577 E, 578 E) feed an adder ( 579 E). The output of the adder ( 579 E) is called the Phase Detector Error ( 519 E).
[0054] The Phase Detector Error ( 519 E) feeds the input of a PID Servo Loop Filter ( 567 E). The output of the PID Servo Loop Filter ( 567 E) feeds an adder ( 514 E). The second input of the adder ( 514 E) is connected to the Initial Phase Offset register ( 515 E). The output of the adder ( 514 E) is called the Phase Correction ( 513 E).
Grid Sync Servo Loop
[0055] The DDS Phase word ( 518 E) is generated by the DDS ( 512 E) where the Phase Accumulator ( 562 E) gets added to itself and the Frequency Tuning Word ( 511 E). The Frequency Tuning Word ( 511 E) is the sum of the Initial Frequency Tuning Word ( 526 E) and the Frequency Tuning Word Correction ( 517 E). The Frequency Tuning Word Correction ( 517 E) is generated as follows: DDS Phase ( 518 E) gets latched by Latches 1 , 2 , 3 ( 583 E, 584 E, 585 E) for phases 1 , 2 , 3 respectively, during every zero voltage crossing which are supplied by Voltage Zero Crossing Detectors 1 , 2 , 3 ( 580 E, 581 E, 582 E). Outputs of Latches 1 , 2 , 3 ( 583 E, 584 E, 585 E) get combined into composite phase offset by an adder ( 586 E) along with the Aggregate Phase Offset ( 525 E). The output of the adder ( 586 E) is proportional to a mismatch of timing between the AC grid voltage zero crossings and the DDS Phase ( 518 E). This output gets filtered by the PID (proportional-integral-derivative) Servo Loop Filter to produce the Frequency Tuning Word Correction ( 517 E). The Frequency Tuning Word Correction is fed back to the DDS forming a negative feedback loop, which keeps the DDS phase and frequency synchronous to the AC grid.
Phase Offset Servo Loop
[0056] DDS Phase ( 518 E) word gets added to the phase correction word ( 513 E) and applied to the Sine lookup table 1 ( 568 E), which provides a value to the PWM Generator 1 ( 573 E). The PWM Generator 1 ( 573 E) generates duty-cycle modulated signals to drive the 3-phase H-bridge switches (SW 1 -SW 2 ) through MOSFET drivers ( 401 E to 402 E) (see FIG. 4 ). Phases 2 and 3 are done the same way but Phase Offsets 2 , 3 ( 521 E, 522 E) are added ( 564 E, 565 E) to the inputs of Sine Lookup Tables 2 , 3 ( 569 E, 570 E). Phase Correction ( 513 E) is generated as follows: DDS Phase gets added ( 566 E) to Desired PFC Phase Offset ( 523 E) which provides the phase reference input to Sine/Cosine Correlator 1 ( 576 E). The input of Sine/Cosine Correlator 1 ( 576 E) gets digitized measurement data from current transducer I 1 ( 329 E). Other phases 2 , 3 are done the same way but the Phase Offsets 2 , 3 ( 521 E, 522 E) are added ( 571 E, 572 E) to the phase reference inputs of Sine/Cosine Correlators 2 , 3 ( 577 E, 578 E). Outputs of all three Sine/Cosine Correlators get added together by an adder ( 579 E) and produce the Phase Detector Error ( 519 E). The Phase Detector Error ( 519 E) is proportional to a mismatch between the Desired PFC Phase Offset ( 523 E) and the phase offset being generated by the power converter and measured by the current transducers (I 1 , I 2 , I 3 , 329 E, 330 E, 331 E). This is fed back to Sine Waveform Generators ( 520 E) forming a negative feedback loop, keeping the generated output current phase shift equal to the Desired PFC Phase Offset ( 523 E).
[0057] Phase Offset 2 , 3 ( 521 E, 522 E) provide a benefit that the order of phases of the 3-phase output of the power converter ( 332 B, 333 B, 334 B) may be altered during power-up time; this enables a user to connect the power converter to the AC grid with the three phases in any order, the power converter then adjusts the values in the registers Phase Offset 2 , 3 ( 521 E, 522 E) to adapt. This is accomplished by the micro-processor ( 450 ) in the following way: Phase 1 ( 580 E) is taken as the reference. The phases of phase 2 and 3 are compared to DDS Phase ( 518 E) in Latches 2 , 3 ( 584 E, 585 E) with Phase Offset registers ( 521 E, 522 E) at default values and the error measured. The register ( 521 E, 522 E) values are then swapped and the errors measured. The register ( 521 E, 522 E) values that gave the lowest error are then used as the correct ones.
[0058] The reactive power factor value may be set using the Desired PFC Phase Offset register ( 523 E). The logical flow controlling this is shown in FIG. 6 . Two methods are described in the preferred implementation, one that sets a direct value externally ( 693 F) by reading it from the Bi-directional Digital Communications connection ( 447 ). The other ( 692 F) makes the amount of power factor applied dependent on the line frequency of the AC grid. The grid frequency is read by the micro-processor ( 450 ) from the frequency tuning word ( 511 E). This method accommodates situations where the grid frequency changes to communicate that a generation plant needs to apply set amounts of correction.
Power Factor Correction
[0059] A preferred implementation of the architecture described in the previous section produces the 3-phase AC voltage and current waveforms shown in FIG. 7( a ). The thinner line of each color represents the voltage of each phase; the thicker line of the same color represents current.
[0060] The traces of phase 1 are used as an example in FIGS. 7( b ) and ( c ). The voltage waveform ( 701 , 702 ) is identical between pictures (b) and (c). The current waveform ( 703 , 704 ) in each case is different—the phase relationship has been changed between voltage and current from 90 degrees lagging to 90 degrees leading, which means that the power factor has been changed.
[0061] Plots (b) and (c) document a change from leading to lagging current due to a sign change if Desired PFC Phase Offset ( 523 E) value.
[0062] FIG. 7( d ) shows the power delivered into each phase ( 710 , 711 , 712 ). In this case the power converter is not generating power, but instead is steering power between phases. This is evidenced by the composite power ( 713 ), which is near zero. The process is not lossless, which accounts for the composite power not being exactly zero.
[0063] The architecture described in this invention and in the previous patent is unique to be able to provide power conversion (for example as a solar inverter) and to also provide power factor correction through novel control. In addition it is able to provide power factor correction when the converter is not making a DC to AC power conversion ( FIG. 7( d )), for example at night when the power converter applied as part of a solar system. It is able to provide variable amounts of correction ( FIG. 6) within the current handling capabilities of the H-bridge. Unlike dedicated systems for the generation of reactive power, this invention does not require additional power circuitry beyond that already in use for power conversion.
[0064] Referring to FIG. 8 , Sine/Cosine Correlators used in the preferred implementation can be executed as shown. The function of the Sine/Cosine Correlator ( 810 ) is to determine the phase shift between two inputs. In this implementation ADC samples of current from Current Transducers I 1 , I 2 or I 3 ( 329 C, 330 C, 331 C in FIG. 3 ) feed input In 10 ( 821 ). The second input, In 20 ( 822 ) is a reference phase word. Input In 10 ( 821 ) feeds one input of each of two multipliers ( 813 , 814 ). The second input of each multiplier is connected to the output of a lookup table, Sine Lookup Table ( 815 ) and Cosine Lookup Table ( 816 ). Input In 20 ( 822 ) feeds the input of each lookup table ( 815 , 816 ). The output of each multiplier ( 813 , 814 ) connects to the ‘a’ ( 817 ) and ‘b’ ( 818 ) inputs of the A tan 2 block ( 819 ) respectively. The A tan 2 block ( 820 ) outputs the phase shift ( 820 ) between inputs In 10 ( 821 ) and In 20 ( 822 ). Various other modifications and alternations in the structure and method of operation of this invention will be apparent to those skilled in the art without departing from the scope and the spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. It is intended that the following claims define the scope of the present invention and that structures and methods within the scope of these claims and their equivalents be covered thereby. | System and method for controlling power factor correction (PFC) for three-phase AC power conveyed via a three-phase AC power grid. Currents and voltages on the grid are monitored and used to generate waveform data enabling dynamic control of switching circuitry used in controlling one or more phase offsets between the currents and voltages. | 8 |
FIELD OF THE INVENTION
[0001] The invention pertains to the field of scraped surface heat exchangers. More particularly, the invention pertains to the mounting of blades for a scraped surface heat exchanger onto the central drive shaft.
BACKGROUND OF THE INVENTION
[0002] Scraped surface heat exchangers are in wide use in industry, for example in the processing of foodstuffs. A scraped surface heat exchanger generally includes a long cylindrical outer tube having a material inlet at one end and a material outlet at the other end. A central drive shaft extends inside the outer tube and is coaxial with the outer tube and is driven to rotate inside the outer tube. An annular space between the outer tube and central drive shaft receives the material, such as a foodstuff, which is pumped in the inlet and allowed to travel the length of the tube and escape out the outlet at the other end of the outer tube. Heating or cooling is generally provided to the outer tube so that material changes temperature as it traverses the length of the scraped surface exchanger. Further, radially extending paddles, also referred to as blades, are hingedly connected to the central drive shaft in order to help mix the material and/or scrape the inside surface of the outer tube to prevent material buildup.
[0003] In one known way of mounting the blades to the tube, the blade is in the form of a generally rectangular relatively thin flat blade member, with a scraping edge along one side, and an opposed hinge side which is hingedly connected to the drive shaft by means of pins. The pins are items welded onto the drive shaft and generally have a narrow protruding finger as well as an opposed wider finger. The thickness of the blade is dimensioned to slide between the two figures of the pin at an installation angle, and a hole is provided in the blade to which the inner finger can pass through. After the blade is inserted at the installation angle, it is pivoted to a much more shallow angle more tangential with drive shaft, at which point the inner finger protrudes through the hole in the blade thereby restraining the blade from lateral movement and permitting only angular movement. A blade typically has two such mounting connections, i.e., two pin receiving holes. The shaft is provided with pins at appropriate locations so that each blade is typically restrained by two, or sometimes more, of these hinged pin connections.
[0004] The blades are generally installed on the drive shaft in this manner at a time when the drive shaft is removed from the outer tube of the scraped surface heat exchanger. Installation occurs not only at initial setup, but also after each cleaning cycle of the device, which can occur frequently. During insertion of the drive shaft into the scraped surface heat exchanger tube, it is desirable that the blades remain at the shallow angle so that the fingers are protruding through the holes in the blades and the blades are retained in place during installation. Further, the blades need to be held at their relatively shallow angle during installation so that they fit within the diameter of the outer tube and the drive shaft can be slid into the outer tube.
[0005] In the case of a horizontally and vertically arranged scraped surface heat exchanger, this practice may be somewhat cumbersome and require tying strings around the blades to hold the blades in, or may be accomplished by the user holding the blades in with their hands as the drive shaft is inserted into the outer tube.
[0006] Due to the length of a drive tube, there are typically several blades arranged at regular intervals longitudinally along a single drive shaft. Also, the blades are generally arranged with four blades, each at a 90° angle to each other, around the circumference of the drive tube, at each blade location.
[0007] It would be apparent that if the blades are permitted to swing outwardly to their installation position, depending on their orientation, they may be able to freely slide away from the pin, since the inner finger is not restraining them by engagement with the hole in the blade. This problem becomes even more severe in the case of a vertically arranged scraped surface heat exchanger. In order to permit a shaft, which in some instances may be 7-8 feet long, to fit within a tube of the same length, it is known to mount the tubes quite high above the floor surface, and insert the drive shaft using a hydraulic lift controlled by a manually actuated lever at the floor level. With a vertically oriented tube in this configuration, during installation if the blades swing out to their installation angle position, they will then fall freely downward, which is undesirable and requires the operator to reposition them again before proceeding.
[0008] Accordingly, is would be desirable to have a method and apparatus to facilitate the mounting of a scraped surface heat exchanger blade onto a drive shaft, while still using a pin type connection.
SUMMARY OF THE INVENTION
[0009] The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect an apparatus is provided that in some embodiments facilitates the mounting of a scraped surface heat exchanger blade onto a drive shaft, while still using a pin type connection.
[0010] In accordance with one embodiment of the present invention, a blade for mounting to a scraped surface heat exchanger drive shaft by pivotal connection with at least one mounting pin, the blade comprising a blade body having a first side and a second side, and a scraper edge and a hinge edge, at least one mounting hole extending through the blade body generally proximate to the hinge edge, a first L-shaped locking track protruding into the first side of the blade, having a first entry track extending from the hinge edge and a first intermediate track extending from the first entry track to the mounting hole, and a second L-shaped locking track protruding into the second side of the blade, having a second entry track extending from the hinge edge and a second intermediate track extending from the second entry track to and past the mounting hole.
[0011] In accordance with another embodiment of the present invention, a scraped surface heat exchanger, comprising a drive shaft having at least one mounting pin mounted to the drive shaft, and a blade having, a blade body having a first side and a second side, and a scraper edge and a hinge edge, at least one mounting hole extending through the blade body generally proximate to the hinge edge, a first L-shaped locking track protruding into the first side of the blade, having a first entry track extending from the hinge edge and an intermediate track extending from the entry slot to the mounting hole, and a second L-shaped locking track protruding into the second side of the blade, having a second entry track extending from the hinge edge and an intermediate track extending from the second entry track to and past the mounting hole.
[0012] In accordance with another embodiment of the present invention, a blade for mounting to a scraped surface heat exchanger drive shaft by pivotal connection with a mounting pin, the blade comprising a blade body having a first side and a second side, and a scraper edge and a hinge edge at least one receiving means extending through the blade body generally proximate to the hinge edge, a first L-shaped locking means protruding into the first set of the blade, having an entry track extending from the hinge edge and an intermediate slot extending from the entry track to the pin receiving means, and a second L-shaped locking means protruding into the second side of the blade, having a second entry track extending from the hinge edge and a second intermediate track extending from the second entry slot to and past the pin receiving means.
[0013] In accordance with another embodiment of the present invention, a method for mounting a blade to a scraped surface heat exchanger drive shaft by pivotal connection with a mounting pin, comprising providing a blade body having a first side and a second side, and a scraper edge and a hinge edge with at least one mounting hole extending through the blade body generally proximate to the hinge edge, and locking the blade against longitudinal movement in one direction while permitting pivoting movement relative to the drive shaft, using tracks on both sides of the blade interfering with the pin.
[0014] There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
[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 embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
[0016] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of a scraped surface heat exchanger blade according to a preferred embodiment of the invention.
[0018] FIG. 2 is a plan view of the blade of FIG. 1 showing a first, inner side thereof.
[0019] FIG. 3 is a plan view of the blade of FIG. 1 showing a second, outer side thereof.
[0020] FIG. 4 is a side view of the blade of FIG. 1 .
[0021] FIG. 5 is a side view of the blade of FIG. 1 taken from the opposite side of FIG. 4 .
[0022] FIG. 6 is an end view of the blade of FIG. 1 .
[0023] FIG. 7 is an end view of the blade of FIG. 1 taken from an opposite end thereof.
[0024] FIG. 8 is a plan view of a pin used in a preferred embodiment of the invention.
[0025] FIG. 9 is a front view of the pin of FIG. 8 .
[0026] FIG. 10 is a side of the pin of FIG. 8 .
[0027] FIG. 11 is a perspective view of a blade and pin assembly at the beginning of the installation process.
[0028] FIG. 12 is a perspective view of a blade and pin assembly at the beginning of the installation process.
[0029] FIG. 13 is a perspective view of a blade and pin assembly during a next step of the installation process.
[0030] FIG. 14 is perspective view of a blade and pin assembly at the step of FIG. 13 .
[0031] FIG. 15 is a perspective view of a blade and pin assembly during a next step of the installation process.
[0032] FIG. 16 . is a perspective view of a blade and pin assembly at the step of FIG. 15 .
[0033] FIG. 17 is a perspective view of a blade and pin assembly at a final step of the installation process and in an operative position.
[0034] FIG. 18 . is a side view of a blade and pin assembly in the installed orientation corresponding to FIG. 17 .
DETAILED DESCRIPTION
[0035] Referring now to the drawings, in which like reference numerals refer to like parts throughout, a blade 12 according to the preferred embodiment is illustrated in FIGS. 1-7 . The blade 12 includes a first side 14 , which is a radially inwardly facing side of the blade in the installed operative state, and a second outwardly facing side 16 , which is outwardly facing in the installed state.
[0036] A blade edge 18 is provided at one side of the blade, and is opposite to a hinge edge 20 . A pair of mounting holes 22 are provided in the blade as shown. Each mounting hole 22 extends completely through the thickness of the blade 12 . Turning to FIG. 2 , in particular, one of the holes 22 has adjacent to it a L-shaped track 24 , which includes an entry track 26 and intermediate track 28 . FIG. 2 illustrates a blade with 2 mounting holes 22 , having a first track 24 associated with one mounting hole 22 and a second slot 30 associated with the other mounting hole 22 . The second track 30 is substantially identical to the track 24 and includes an entry track 26 and an intermediate track 28 .
[0037] Turning to FIG. 3 , on the other side of the blade, one mounting hole 22 is shown with a locking track 34 , which includes an entry track 36 and an intermediate track 38 . Intermediate track 38 is present on both sides of the hole 22 . Associated with the other hole 22 is another locking track 38 , which is substantially identical to locking track 34 , and includes an entry track 36 and a intermediate track 38 .
[0038] Turning to FIG. 8 , a representative pin 40 is illustrated. The pin 40 includes an inner finger 42 as well as an outer finger 44 and a base 46 which is mounted to the drive shaft of the scraped surface heat exchanger, usually by welding. FIGS. 9 and 10 show further details of the pin 40 .
[0039] The mode of installation of a blade 12 onto a shaft by virtue of the locking tracks will now be described with reference to FIGS. 11-18 . FIGS. 11 and 12 show the blade 12 at the beginning of the installation sequence. The blade 12 is placed at an angle relative to the pins 40 corresponding to the angle illustrated in FIG. 10 . Turning back to FIGS. 11 and 12 , can be seen in FIG. 11 that the upper fingers 44 are each aligned with respective entry tracks 36 . The entry tracks 36 have a width that is preferably just slightly greater than the width of the outer finger 44 . Turning to FIG. 12 , it is appreciated that the inner fingers 42 are aligned with respective entry tracks 26 , with the entry tracks 26 having a width slightly greater than the width of the fingers 42 .
[0040] Turning to FIGS. 13 and 14 the blade is now being inserted between the fingers 44 and 42 of the pin 40 . FIG. 13 illustrates the outer finger 44 sliding into the entry tracks 36 . FIG. 14 illustrates the inner finger 42 sliding into the entry tracks 26 . At this point, due to the angled surface of the inner finger 42 , the blade is held at angle alpha by contact between the fingers 42 and 44 .
[0041] Turning now to FIGS. 15 and 16 , the blade has been moved longitudinally so that the inner fingers 42 are now aligned with the mounting holes 22 . The inner fingers 42 have traversed the intermediate tracks 28 . The outer finger 44 has traversed the intermediate track 36 . It would be appreciated that the intermediate slot 28 extends only as far as to the hole 22 , because the inner finger 42 will now fit within the mounting hole 22 . However, the intermediate slot 38 extends past the hole 22 , to accommodate the width of the outer finger 44 .
[0042] In the position shown in FIGS. 15 and 16 , the blade 12 is illustrated at the angle alpha. In this position, the blade 12 could be slid back towards the position shown in FIGS. 13 and 14 . However, travel in the opposite direction is prevented due to the fact that the intermediate track 28 does not extend past the hole 22 . In the case of a vertically oriented scraped surface heat exchanger, the arrangement would be positioned so that direction shown by the arrow U in FIG. 16 refers to upward, and the direction indicated by the arrow D would refer to downward. In the case of either a horizontal or vertical heat exchanger, the direction indicated by U would typically indicate a direction of insertion of the drive shaft, and the direction indicated by D would indicate a direction of removal.
[0043] Turning to FIGS. 17 and 18 , the blade 12 is now shown located longitudinally in the position shown in FIGS. 15 and 16 , i.e., with the inner fingers 42 aligned with the mounting holes 22 , but has now been angularly rotated downward into an installation position, as particularly seen in FIG. 18 , wherein the blade 12 is at a sufficiently shallow angle to fit within an outer tube 50 of the heat exchanger of being mounted to the drive shaft 52 by the pins 40 .
[0044] Looking particularly at FIGS. 15, 16 , and 17 , it will be appreciated that, especially in a vertical orientation, the blades will not fall downward off the pins no matter what angle they are at. That is, even if the blade is at the installation angle alpha, shown in FIGS. 15 and 16 , it still cannot travel downward in the direction D, due to interference present on both sides of the blade. Primarily, the blade is restrained by interference between the top of the finger 42 and the top edge of the opening 22 . On the other side, the blade can also be restrained from vertical travel by the interference between the top edge of the outer finger 44 , and the top of the intermediate track 38 .
[0045] This provides a significant benefit of at least some embodiments of the invention, wherein, where the heat exchanger is vertically, each blade can be positioned at the installation angle, slid onto the pins, and then slid downwardly along the pins, until reaching the position shown in FIGS. 15-17 . At this point, even if the blades are left free to pivot about any angle in the range of pivot permitted by the pin, the blades will still stay oriented (with their holes 22 aligned with the inner fingers 42 ) and will not be able slide down or otherwise fall off the pins.
[0046] Another advantage of this embodiment is that the entry track 26 is a different width than the entry track 36 . As a result, the blade can only be slid onto a pin with the inner side 14 facing downward, i.e., facing towards the inner finger 42 , and with the outer side of the blade 16 facing upward, i.e., facing the upper finger 44 . This ensures that the blade will be installed with the correct side facing up, and hence in the case of the scraper design shown in FIG. 18 , that the scraper edge will be correctly oriented against the inside of the outer tube 50 of the scraped surface heat exchanger.
[0047] The only way to remove a blade in this configuration, is to raise the blade, i.e., translate it in the direction shown by arrow U in FIG. 16 , until the blade reaches the positions shown in FIGS. 13 and 14 , at which point they can be slid off the pins into the positions shown in FIGS. 11 and 12 .
[0048] Another advantage of the illustrated embodiment, is that the provision of locking tracks is accomplished using tracks on both sides of the blades. This is an advantage because in order to preserve the structural rigidity of the blade, it is desirable that as much of the blade as possible be of the greatest thickness, i.e., close to the same as the overall blade thickness. In order to accomplish the sliding along the tracks, as well as the interference locking features, the blade tracks on the fingers must be dimensioned with some degree of clearance to permit sliding, but with sufficient degree of interference to prevent any out of track movements. By putting tracks on both sides of the blade, each track can be made roughly half as thick as would be required for a single track on one side of the blade. Over time, both blades and pins are subject to wear, and providing the tracks on both sides permits acceptable performance while reducing the amount of thinned track blade area compared to what would be necessary in an arrangement utilizing the tracks only on one side of the blade.
[0049] The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A blade for mounting to a scraped surface heat exchanger drive shaft by pivotal connection with a mounting pin has a blade body having a first side and a second side, and a scraper edge and a hinge edge. At least one mounting hole extends through the blade body generally proximate at the hinge edge. An L-shaped locking track protrudes into the first set of the blade, having an entry track extending from the hinge edge and an intermediate track extending from the entry track to the mounting hole. An L-shaped locking track also protruding into the second side of the blade, has an entry track extending from the hinge edge of the blade and an intermediate track extending from the entry track to and past the mounting hole. | 8 |
PRIORITY DATA
This application is a U.S. National Phase application of International Patent Application No. PCT/US2003/017882 filed Jun. 6, 2003, which claims priority from U.S. Provisional Application Ser. No. 60/435,680 filed Dec. 20, 2002, which is incorporated hereby by reference.
BACKGROUND OF THE INVENTION
Biofilm may be defined as an undesirable accumulation of microorganisms on a surface and in flocculent masses. It is estimated that more than 99% of all the planet's bacteria live in biofilm communities. Biofilm consists of cells immobilized in a substratum, frequently embedded in an organic polymer matrix of microbial origin, which can restrict the diffusion of substances and bind antimicrobials. In flowing aquatic environments, a biofilm consists of a sticky and absorptive polysaccharide matrix encompassing microorganisms. Biofilm bacteria are morphologically and metabolically distinct from free-floating bacteria. Their structural organization is a characteristic feature and distinguishes biofilm cultures from conventional planktonic organisms.
Biofilms create problems for industry from corroding water pipes to computer-chip malfunctions. Any man-made device immersed in an aquatic habitat is susceptible to colonization by microbial biofilm. For example, biofilm may be present on the surfaces of ship bottoms, industrial pipelines, household drains, and artificial hip joints. For the industrial manufacturer, biofilm clusters represent a source of microbial inoculation in a system and may cause plugging problems. In water treatment facilities, the formation of suspended biofilm produces a bulked biological sludge which settles poorly and is difficult to compact in the clarification process. Both non-filamentous and filamentous bulk forms are prevalent in which numerous bacteria permeate the floc. In addition to their role as fouling agents, biofilms may also have adverse effects on people, including altering their resistance to antibiotics and affecting the immune system. Thus, there exists a need in the art for developing effective methods of removing biofilm.
The dynamic nature of biofilms makes it difficult to measure and monitor biofouling. Biofilms often include embedded inorganic particles such as sediments, scale deposits, and corrosion deposits. Moreover, biofilms continuously change in thickness, surface distribution, microbial populations and chemical composition, and respond to changes in environmental factors such as water temperature, water chemistry and surface conditions. Thus, the complexity of biofilms has reduced the effectiveness of treatment and removal strategies.
Even though most microorganisms in industrial systems are associated with biofilm, they have historically received less attention than planktonic microorganisms. However, it has been shown that various biocides are less effective against biofilm than dispersed cells of the same organism. The most common biocides used in biofilm control are pure free halogen donors such as NaOCl and NaOCl/NaOBr. These, however, must be used in high quantities to be effective. In addition, several recent studies evaluating halogen efficacy on biofilms showed an increased disinfection resistance of attached bacteria to free chlorine. Free chlorine treatment at concentrations usually effective against planktonic microorganisms has little effect on the number of attached bacteria or on their metabolic activity. The data indicate that the transport of free chlorine into the biofilm is a major rate-limiting factor, and increasing concentrations did not increase biocidal efficiency. Griebe, T., Chen, C. I., Srinavasan, R., Stewart P., “Analysis of Biofilm Disinfection By Monochloramine and Free Chlorine,” Biofouling and Biocorrosion In Industrial Water Systems (edited by G. Geesey, Z. Lewandowski, and H-C. Flemming), pp. 151-161, Lewis Publishers (1994).
Excessive reactivity of pure free halogen donors was overcome by using bromochlorodimethylhydantoin (BCDMH). The published study by M. Ludyansky and P. Himpler entitled “The Effect of Halogenated Hydantoins on Biofilms,” NACE, Paper 405 (1997), demonstrated higher efficacy on biofilms compared to pure free halogen donors. However, while effective, it is still not an efficient halogen source when applied to biofilm.
Others have attempted to suppress biofilm growth in aquatic systems by using an oxidizing halogen with the addition of adjuvant. U.S. Pat. No. 4,976,874 to Gannon et al., incorporated herein by reference, discloses a method and formulation for the control of biofouling using an oxidizing halogen in combination with a non-oxidizing quaternary ammonium halide. However, this method poses environmental issues.
Thus, the control of biofilm in aquatic systems has typically involved the addition of oxidizing and non-oxidizing biocides to bulk water flow. However, high levels of these expensive chemicals are needed because their effectiveness is rapidly reduced as a result of exposure to the various physical and chemical conditions in specific applications since the concentration of the biocides is considerably reduced by the time the biocides reach the biofilm.
SUMMARY OF THE INVENTION
The present invention is directed to a method of disintegrating biofilm present in aqueous medium and controlling the odor attendant to its formation. The method comprises adding one or more chlorinated hydantoins, specifically, monochlorodimethylhydantoin (MCDMH) or dichlorodimethylhydantoin (DCDMH), to the aqueous medium. Of particular importance is that the chlorinated hydantoins' activity against biofilm is not lessened in the presence of sunlight, since the halogen-stabilized active chlorine solutions are strikingly photostable. The concentration of the chlorinated hydantoins maintained in the aqueous medium generally ranges from about 0.01 to about 100 ppm (expressed as Cl 2 ) for biofilm inhibition.
In a concentrate, the concentration of the chlorinated hydantoins generally ranges from about 0.1 up to 100% by weight based on the total weight.
The present invention has application to essentially all aqueous systems containing or having the potential to contain biofilm. These may be cooling water; pulping or papermaking systems, white water treatment, including those containing bulked activated sludge; and air washer systems; as well as agricultural potable and drainage systems; food preparation and cleaning systems; brewery, dairy and meat-producing systems; and oil industry systems. Aqueous systems also include any potable water systems, including drinking water systems; as well as recreational water systems, such as swimming pools and spas; household water-related systems, including toilet bowls, drains, sewers, shower stalls, bathtubs, and sinks; as well as institutional “water-related” systems, hospital systems, dental water systems and any system where a medical device is in contact with an aquatic medium; ornamental fountains, aquariums, fisheries, in aquaculture, and any other system subject to the growth of biofilm. The biofilm may comprise different forms and species of pathogenic microorganisms, e.g., Legionella pneumophila, adhered or not adhered to surfaces, such as mats, flocs and slime.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates the effect of NaOCl on heat transfer resistance (HTR) which correlates to biofilm formation and accumulation and dissolved oxygen (DO) level in an aqueous system.
FIG. 2 illustrates the effect of NaOBr on heat transfer resistance (HTR) and dissolved oxygen (DO) level in an aqueous system.
FIG. 3 illustrates the effect of BCDMH/MEH on heat transfer resistance (HTR) and dissolved oxygen (DO) level in an aqueous system.
FIG. 4 illustrates the effect of MCDMH on heat transfer resistance (HTR) and dissolved oxygen (DO) level in an aqueous system.
FIG. 5 illustrates the effect of DCDMH on heat transfer resistance (HTR) and dissolved oxygen (DO) level in an aqueous system.
DETAILED DESCRIPTION OF THE INVENTION
The extent and nature of biofilm removal and disintegration, of course, vary with the context of the problem. The diverse nature of the problems and the diverse environments in which biofilms grow call for a variety of tactics and strategies for biofilm removal. With respect to an established biofilm, it is often desirable to remove it rather than to merely sterilize and leave it in situ. In addition, it may be important to kill the cells forming the biofilm and prevent them from spreading to other locations. Thus, for purposes of the present invention, the term “disintegration” of biofilm includes the removal and break-up of existing biofilm and the prevention of biofilm microorganism regrowth in a treated system. This is a more difficult task than “biofilm control” which includes both the prevention of biofilm growth from a clean system and the prevention of continued growth in a treated system upon which biofilm has already formed.
The term “chlorinated hydantoin” refers to an hydantoin which may be in the form of a pure compound, such as monochlorodimethylhydantoin or an admixture of hydantoins, i.e., monochlorodimethylhydantoin and dichlorodimethylhydantoin mixtures, or mixtures of hydantoins with degree of halogenation between 0.1 and 2.0.
The alkyl moieties of the chlorinated hydantoin may be the same or different, preferably alkyl groups having 1 to 6 carbon atoms.
Preferred chlorinated hydantoins include, but are not limited to, dichloro-5,5-dimethylhydantoin (DCDMH), monochloro-5,5-dimethylhydantoin (MCDMH), dichloro-5-methyl-5-ethylhydantoin (DCMEH), monochloro-5-methyl-5-ethylhydantoin (MCMEH), and any combination of any of the foregoing. The chlorinated hydantoin may be in the form of a solid, liquid, slurry, or gel. The term “solid” includes powders, granules, tablets, briquettes and slurries.
Concentrates of the chlorinated hydantoin have concentrations of active ingredients greater than typical biofilm control concentrates. For example, a solid concentrate of chlorinated hydantoin typically contains 70% by weight of active ingredient (expressed as Cl 2 ) based upon 100% total weight of concentrate. In contrast, liquid concentrates of sodium hypochlorite typically comprise only about 12% by weight of active ingredient based upon 100% total weight of concentrate. Additionally, the chlorinated hydantoins of the present invention are stable, unlike most bleaches currently sold.
While the above discussion refers to the treatment of an aqueous system containing biofilm with the chlorinated hydantoin, it is also contemplated that the aqueous system be formed after a dry biofilm or biofilm in a non-aqueous medium is brought in contact with a solid or granular halogenated hydantoin. In such instance, the aqueous system may be formed by the addition of water or water vapor to the two solids or water-free materials.
The amount of the chlorinated hydantoin added to the aqueous medium is sufficient to disintegrate the biofilm. This is generally from about 0.01 to about 100 ppm (expressed as Cl 2 ), preferably from about 0.05 to about 25 ppm (expressed as Cl 2 ).
In addition to adding the pre-formed halogenated hydantoin to the aqueous system, it may be desirable to form the halogenated hydantoin in situ. This can be done by adding an hydantoin and an halogenating agent to the biofilm containing aqueous system separately in the appropriate molar ratio. For example, an alkali metal hypochlorite (e.g., NaOCl) or chlorine gas or another active chlorine source and dimethylhydantoin can be added in a molar ratio sufficient to form in situ the desired amount of the halohydantoin. Broadly, the molar ratio of chlorine (from the chlorine source) to alkylated hydantoin is from 1:100 to 100:1, preferably from 1:10 to 10:1.
In some systems, such as cooling water systems, additives are always used. In other systems, such as swimming pools, there may be no performance additives.
Performance additives (i.e., compositions that enhance the quality and use of the chlorinated hydantoins) include, but are not limited to, cleaning agents, biodispersants, solubility modifiers, compaction aids, fillers, surfactants, dyes, fragrances, dispersants, lubricants, mold releasers, detergent builders, corrosion inhibitors, chelants, stabilizers, bromide sources, and scale control agents. An important requirement is that the material be compatible with the chlorohydantoin composition.
Solubility modifiers which may be added to chlorinated hydantoins described herein include, for example, sodium bicarbonate, aluminum hydroxide, magnesium oxide, barium hydroxide, and sodium carbonate. See U.S. Pat. No. 4,537,697. Solubility modifiers can be used in the compositions in an amount ranging from 0.01% to 50% by weight.
Examples of compaction aids are inorganic salts including lithium, sodium, potassium, magnesium, and calcium cations associated with carbonate, bicarbonate, borate, silicate, phosphate, percarbonate, and perphosphate. See U.S. Pat. No. 4,677,130. Compaction aids can be used in the compositions in an amount ranging from 0.01% to 50% by weight.
Fillers which may be added to the chlorohydantoins include, for example, inorganic salts, such as lithium, sodium, potassium, magnesium and calcium cations with sulfate, and chloride anions, as well as other inorganics such as clays and zeolites. Fillers are used in compositions to reduce product costs and can be added in an amount ranging from 0.01% to 50% by weight.
The biodispersant enhances the efficacy of the chlorinated hydantoin as a biofilm control agent and assists in maintaining the surfaces of the container in which the aqueous medium is contained clean. They are typically surfactants and preferably surfactants with a non-biocidal effect on microorganisms and biofilms. Examples of biodispersants include Aerosol OTB (sodium dioctyl sulfosuccinate), disodium lauryl sulfosuccinate, sodium lauryl sulfoacetate, as well as other sulfonates. Surfactants are used in the compositions to enhance cleaning performance and can be added in an amount ranging from 0.01% to 20% by weight. Generally, such a mixture contains from about 80% to about 99.99% by weight of chlorinated hydantoin and from about 0.01% to about 20% by weight of biodispersant, based upon 100% total weight of mixture; preferably, from about 90 to about 99.99% by weight of chlorinated hydantoin and from about 0.01% to about 10% by weight of biodispersant.
An aqueous solution of the desired non-chlorinated hydantoin(s) at the desired mole ratios may be prepared by the methods described in U.S. Pat. No. 4,560,766, and Petterson, R. C., and Grzeskowiak, V., J. Org. Chem., 24,1414 (1959) and Corral, R. A., and Orazi, O. O., J. Org. Chem., 28, 1100 (1963), both of which are hereby incorporated by reference.
EXAMPLE 1
Biofilm Inhibition Control Efficacy
The efficacy of biocides and biocides with dispersants was estimated by a reduction of biofilm dry weight in test flasks, compared to untreated controls. Biofilm development was determined gravimetrically by the methods described in Ludyansky, M., Colby, S., A Laboratory Method for Evaluating Biocidal Efficacy on Biofilms, Cooling Tower Institute, Paper TP96-07 (1996).
The sheathed Sphaerotilus natans (ATCC 15291), which is known to be very resistant to any chemical control and found in a variety of applications (cooling water systems, paper process waters, and sewage treatment processes), was used in the tests.
The bacteria were cultivated at 25-30° C. in a 5% CGY medium which contained: 5 g of casitone (Difco), 10 g of glycerol, and 1 g of yeast autolysate (Difco) per liter of DI water. The inocula contained approximately 10 6 cells per milliliter. 8 oz. flasks were filled with 150 ml of 5% CGY media and 1 ml of Sphaerotilus natans inoculum. The flasks were filled with the test biocides, namely, NaOCl, NaOBr, MCDMH. Additional flasks, not containing a biocide, served as controls. The flasks were installed on a shaker and maintained at 22-30° C. rotating at 100-200 rpm for 48-72 hours. The contents were dried for 5 hours at 105° C. and cooled overnight. The difference between the weight of the flasks containing the dried biomass and the tare weight of the flasks represented the dry biofilm mass.
The effectiveness of biofilm prevention was calculated as a percent change in growth based on the difference between the average dried biofilm weight in the untreated controls and in the treated flasks, according to the following formula:
E %=(B control avg −B avg )/B control avg *100, where E %=percent reduction of biofilm growth, B=Biofilm weight, and
B control =Biofilm weight in the control flask.
The results of the experiments, including the concentration of the biocides, are set forth in Table 1:
TABLE 1 Biocide Concentration, ppm B avg, g B control avg, g E, % NaOCl 10 0.0028 0.0185 84.86 NaOBr 10 0.0013 0.0185 92.97 MBDMH 10 0.0008 0.0185 95.7 MCDMH 10 0.0005 0.0185 97.3 DCDMH 10 0.0005 0.0173 97.1 NaOCl 5 0.009 0.0144 37.5 NaOBr 5 0.0021 0.0144 85.4 MBDMH 5 0.0081 0.0152 46.7 MCDMH 5 0.0007 0.0144 95.1 DCDMH 5 0.0009 0.0173 94.8
The results show that chlorinated hydantoin (MCDMH) was a superior biofilm inhibition agent over free halogen donors (NaOCl or NaOBr).
EXAMPLE 2
Biofilm Removal Control Efficacy
Sphaerotilus natans (ATCC 15291), as in Example 1, was used in the tests described below.
Biofilm Test System
An on-line testing system for chlorinated biocide efficacy testing was used to provide a real-time, non-destructive method for biofilm monitoring and measurement. The system monitors the heat transfer resistance (HTR) which correlates to biofilm formation and accumulation, and dissolved oxygen (DO) level in the bulk water which correlates with changes in biofilm activity. The system design, parameters and growth conditions are disclosed in Ludensky, M., “An Automated System for Biocide Testing on Biofilms.” Journal of Industrial Microbiology and Biotechnology, 20:109-115 (1998).
The system consisted of a continuous-flow heat-exchange loop, a biological growth reactor (chemostat) and subsystems for life support, biofilm measurement, and environmental control. All system parameters, including water flow, temperature, dilution rate and nutrient concentration, were optimized for obtaining fast, heavy and reproducible biofilm growth. The system make-up water was kept at constant oxygen saturation (by continuous sparging of air), temperature, and pH conditions. Thus, any changes in DO concentrations or pH levels in the recirculating water were considered due to biofilm activity. All monitoring and control parameters were calculated in the data acquisition system, which was controlled by a custom-designed computer software program. Data was collected every 15 seconds, with averages calculated and recorded every 3 to 60 minutes in a spreadsheet for subsequent graphical analysis. The program was designed so that the system was able to function continuously under constant conditions for several weeks. Biocide efficacy testing was conducted through analysis and comparison of the shape and values of the corresponding curves of HTR and DO. Analysis included consideration of curve patterns corresponding to biocide treatment, as well as biofilm recovery (regrowth).
Growth Conditions
The sheathed Sphaerotilus natans (ATCC 15291), known to form a tenacious biofilm on heat exchanger surfaces in cooling water systems and papermaking machines, was selected for biofilm growth. Inocula were pumped into the microbial growth reactor and allowed to sit at room temperature overnight. The next day, make-up water and nutrient (CGY media) were added. Selection of initial growth conditions and parameters of the system was based on previous experience, laboratory limitations, geometric size of the system's components, and the desire to promote a growth of biofilm. Shifting of growth conditions from planktonic growth to attached filamentous growth was obtained by lowering media concentrations to less than 5% and maintaining dilution rates higher than maximum specific rate. Test conditions are shown in Table 2.
TABLE 2 Bioflim System On-Line Test Conditions Parameter Conditions pH 7.2-8.5 Temp., circulating water 74-76° F. Temp., wall 85° F. Makeup water Clinton tap Substrate concentration CGY; 30-70 ppm Inoculum S. natans Water flow 3 fps Dilution rate 0.9 Make up water 170 ml/min Nutrient addition 1 ml/min System volume 10 liters
Biocidal efficacy of the test solutions was determined by analysis of the shape of the HTR and DO curves indicating the biofilm's response to biocidal treatments.
Treatment Programs
During treatment programs, the system was continuously fed with nutrient and make-up water (constant chemistry, oxygen and temperature). Three modes of treatments were tested, namely, slug, slug plus continuous, and continuous.
Slug treatment was conducted by the addition of a prepared stock solution in a precalculated dose (per volume of the circulating water in the system) to the chemostat. In the slug plus continuous mode, biocide treatment was carried out by an initial slug dose injected to overcome halogen demand, followed by a continuous, 3-hour treatment at a constant concentration based upon the makeup water rate.
Biocide Preparation and Monitoring
All five biocides, NaOCl, NaOBr, MCDMH, BCDMH/MEH, and DCDMH, were prepared as 1000 ppm fresh Cl 2 master solutions. Treatment concentrations for all biocides were calculated from the measurement of free and total residual halogen, as measured by the DPD Cl 2 test, conducted immediately before treatment.
Tests incorporating repeated slug plus continuous treatments at increasing initial concentrations (10, 15 and 20 ppm) were performed for three consecutive days on NaOCl, NaOBr, MCDMH, BCDMH/MEH, and DCDMH. Heat transfer rate and dissolved oxygen levels in the system were automatically monitored and their dynamics were analyzed. Based on obtained parameters, the following conclusions were reached:
NaOCl, NaOBr, and BCDMH/MEH were not able to remove biofilm at any of the tested concentrations. Biofilm recovery was observed 24 hours after the start of each treatment and HTR values were higher than values observed at the start of each treatment, as shown in FIGS. 1 , 2 and 3 .
Dissolved oxygen response to biocide treatment was the strongest in the case of DCDMH, and the weakest in the case of NaOCl. Through analysis of curve patterns ( FIG. 1-FIG . 5 ), it was concluded that biofilm regrowth control could be achieved by a slug plus continuous treatment of 15 ppm BCDMH/MEH or 20 ppm of NaOBr as shown in FIG. 2 and FIG. 3 . However, neither of these biocides was able to initiate biofilm removal.
Testing of chlorinated hydantoins MCDMH and DCDMH demonstrated a unique effect: biofilm sloughing occurred soon after addition of 20 ppm of either MCDMH or DCDMH. The results of the tests are shown in FIG. 4 and FIG. 5 . This effect is not common for any other oxidizing biocides.
The observations set forth above are summarized in the following table:
TABLE 3
Slug Plus Continuous Treatment
Biofilm Control
Biofilm Removal
HTR
DO
HTR
NaOCl
Not effective
Weakest
No
NaOBr
Effective at 20 ppm
Moderate
No
BCDMH/MEH
Effective at 15 ppm
Moderate
No
MCDMH
Effective at 15 ppm
Moderate
Yes at 20 ppm
DCDMH
Effective at 15 ppm
Strongest
Yes at 20 ppm
EXAMPLE 3
This example demonstrates the enhanced photostability of MCDMH as compared to NaOCl when test solutions thereof are exposed to simulated sunlight.
Test solutions were prepared by adding to tap water having a temperature of 22° C. and a pH of 7.8 NaOCl and MCDMH at the concentrations indicated in Table 4 below. These solutions were illuminated by UVA-340 fluorescent lights that simulate the spectral radiance of the sun at the surface of the earth. The test samples were covered with quartz plates, transparent to ultraviolet light, to prevent evaporation. Total halogen concentrations were measured as a function of time. The generated active halogen decay curves were analyzed using first order kinetic algorithms and the corresponding active halogen half-lives calculated. The results are shown in Table 4.
As shown in Table 4, MCDMH provides dramatically superior photostability to NaOCl. The observed active halogen half-life for MCDMH was 108 hours compared to 1.1 hour for NaOCl.
TABLE 4
Photolysis of MCDMH and NaOCl Solutions
Total Halogen
(ppm as Cl 2 )
Delta Time (hr)
NaOCl
MCDMH
0
4.0
5.9
1.5
1.1
5.6
6.5
0.07
5.3
29.5
—
4.1
52.5
—
3.1
100
—
2.3
187
—
1.5
267
—
1.0
First order half-life (hr)
108
1.14
These data clearly show that the activity of MCDMH dropped negligibly for the first 6.5 hours and significant activity remained for the duration of the test, while the NaOCl's activity dropped precipitously in the presence of the simulated sunlight. The comparative half-lives further show the remarkable photostability of the chlorinated hydantoin.
EXAMPLE 4
Hydantoin-stabilized active chlorine solutions can likewise be generated by combining hydantoins with NaOCl. As shown in Table 2, combinations of DMH and NaOCl produce greater photostability than even combinations with cyanuric acid, a well-known chlorine photostabilizer for the recreational water market. The test conditions were the same as those of Example 3.
TABLE 5
Photostability of Hydantoin and Cyanuric Acid Stabilized Hypochlorite
Solutions
Total Halogen (ppm as Cl 2 )
NaOCl +
NaOCl +
Delta Time (hr)
30 ppm DMH
30 ppm Cyanuric acid
0
4.6
4.3
1.5
4.3
4.1
6.5
4.05
3.6
29.5
3.6
2.0
52.5
3.0
0.78
100
2.2
0.07
187
1.68
—
267
1.19
—
First order half-life (hr)
141
17
The data in Table 5 show that DMH dramatically enhances the photostabilization of NaOCl and the combination performs better that the NaOCl and cyanuric acid. The observed active halogen half-life for the NaOCl+DMH stabilized solution was 141 hours as compared to 17 hours for cyanuric acid stabilized NaOCl. | The present invention provides a method for the removal of biofilm, flocculent bulked sludge or bulked biologically active sludge from an aqueous system. The method involves adding one or more chlorinated hydantoins, such as dichloro- or monochlorodialkylhydantoin, to the aqueous system. Alternatively, the chlorinated hydantoin may be formed in situ by adding a chlorine source and an alkylated hydantoin separately to the aqueous system. The invention is particularly advantageous because of the outstanding photostability of the chlorinated hydantoin solutions even when exposed to sunlight. | 3 |
BACKGROUND OF THE INVENTION
This invention relates generally to techniques in moving and shifting large and heavy objects and more particularly to a novel method and apparatus for moving heavy built structures by flotation thereof.
Heretofore, it has been a common practice in moving large and heavy built structures such as buildings to resort to hoisting and hauling machines such as cranes in instances where such machines can be used.
In the case where a large and heavy built structure (hereinafter referred to simply as "structure") such as a house is to be moved over substantially level ground, a widely used method for this purpose comprises laying spheres or rollers between the structure or a supporting base on which the structure rests and the level ground thereby to reduce the frictional resistance to movement and pulling the structure or its base to the desired position by means of a device such as a winch.
The necessity of shifting heavy structures arises in a wide variety of forms and ways in many fields. However, all of the known moving methods, such as those briefly described above, are based on the principle of supporting the total weight of a structure, and research effort has been directed toward ways and means to reduce frictional resistance at the time of movement of the structure. One of the resulting requirements for this purpose is the smoothening of the frictional surfaces, for which considerably large-scale equipment become necessary, and, moreover, extraordinary precision has been required. Furthermore, it cannot be denied that these known methods have been accompanied by numerous difficulties, especially problems relating to efficiency of moving work and ensuring of safety in the work.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a method for moving large and heavy structures safely and easily to objective positions, particularly by floating these structures on water and moving them in floating state.
Another object of the invention is to provide a method for moving by flotation on water not only structures which are flotable on water but also large and heavy structures which are not flotable on water as they are.
Still another object of the invention is to provide an enclosure of cutoff walls or water-retaining walls suitable for use in the practice of the method for flotation moving on water of a structure as described above, which enclosure of walls does not impose any limitation on the environment of the structural space of the structure and on the work efficiency during this operation and, moreover, can be readily installed and dismantled, and which has no detrimental effect on the necessary flotation moving of the structure.
A further object of the invention is to provide a method of installing the above set forth enclosure of water-retaining walls (hereinafter referred to as walls).
A further object of the invention is to provide a flotation moving method which is efficient and can be practiced at relatively low cost.
According to this invention in one aspect thereof, briefly summarized, there is provided a method for moving a built structure from a first position to a second position both on a common supporting surface, which method comprises installing on the supporting surface a water-retaining wall enclosure to surround commonly the built structure at the first position and the second position, supplying water into the enclosure thereby to raise the built structure by flotation off the supporting surface, applying force to move the built structure in the raised state to a position immediately above the second position, and removing the water out of the enclosure thereby to cause the built structure to descend onto the second position.
In this method, a buoyant built structure is floated as it is, while a non-buoyant structure is provided with auxiliary flotation means. A structure which must not be wetted is built beforehand in a tray-like vessel of sufficient buoyancy.
According to this invention in another aspect thereof, there is provided a method as set forth above in which the wall enclosure is characterised in that it can be readily and rapidly installed and subsequently dismantled and comprises a plurality of wall panels or segments which are joined edge-to-edge at their sides, secured at their foot edges to the supporting surface, and held at their upper parts by brace struts.
The nature, utility, and further features of the invention will be apparent from the following detailed description with respect to preferred embodiments of the invention when read in conjunction with the accompanying drawings, throughout which like parts are designated by like reference numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a plan view showing a structure and an enclosure of walls for an exposition of the principle of a first moving method according to this invention;
FIG. 2 is an elevation in vertical section taken along the line II--II in FIG. 1 as viewed in the arrow direction;
FIGS. 3 and 4 are elevations similar to FIG. 2 respectively for expositions of the principles of second and third methods according to the invention;
FIG. 5 is a fragmentary plan view showing a corner part of an enclosure of walls;
FIG. 6 is an elevation in vertical section taken along the line VI--VI in FIG. 5 as viewed in the arrow direction; and
FIGS. 7A through 7D are fragmentary, relatively enlarged plan views respectively showing different examples of packings between wall panels.
DETAILED DESCRIPTION
The principle feature of this invention lies in the balancing of the weight of a structure with buoyant force and moving the structure in a state of flotation on water.
Of course, there are some kinds of structures which cannot be floated on water and even some kinds of structures which should not be placed in contact with water or be subjected to immersion in water. In the former case, floats are used to impart only the necessary buoyancy, while in the latter case, the structure is erected beforehand in a tray-like vessel and is thus moved without coming into contact with the water.
If it were merely a matter of moving by flotation on water, the quickest and simplest procedure would be to construct the structure in a dry dock and to introduce water into the dock after the construction thereby to move the structure by flotation. This method, however, would greatly restrict the places to which the structure can be moved. Another important feature of this invention is that this restriction and the limitation of place of construction work are avoided by installing as necessary an enclosure of a walls commonly surrounding the structure and the objective place to which it is to be moved, filling the enclosure with water to float the structure and move the same to the objective position, and thereafter draining the water and dismantling the wall enclosure thereby to leave the construction space in its original dry, level, and obstruction-free state.
Referring to FIGS. 1 and 2 indicating the principle of the method of flotation moving a structure 1, the structure 1 is to be moved from a level construction space 2 to an objective position 3. For this purpose, a wall enclosure 4 is assembled around both positions 2 and 3. While a sidewise movement, wherein the structure 1 is moved is moved sidewise between parallel orientations, is illustrated in FIG. 1, the movement need not be so limited. The floor or ground surface of the construction space 2 is required to have strength to withstand the water pressure when the enclosure 4 is filled with water to the level necessary for flotation moving, water resistance, and impermeability to water. Ordinarily, a concrete floor covered with a water-proof film is laid.
The specific details of construction of the wall enclosure 4 commonly and widely surrounding the structure 1 and the objective position 3 and the method of installation thereof will be described hereinafter. A required feature of this wall enclosure 4 is that it be of takedown type which can be readily installed and dismantled. For example, during the period of construction of the structure 1, the wall enclosure 4 is kept in dismantled state so that it will not hinder the work, and only during the moving work, the wall segments or panels are joined in a desired layout to erect the enclosure. Another required feature of this wall enclosure 4 is that, once it has been erected, it will retain watertightness to an extent such as to maintain the water level necessary for flotation moving with the available water supply flow rate although there may be some leakage of water.
As indicated in FIG. 2, the flotation moving method of this invention, in principle, comprises causing the structure 1 to float at the position where it was constructed in water accumulated by supplying water into the wall enclosure 4, moving the structure in its floating state by towing means such as a winch to a position directly above the objective position 3, and then gradually lowering the water level to cause the structure to settle on the ground. Thereafter, the next work process can be started or anchoring of the structure can be carried out.
Furthermore, a drainage trench 5 is dug completely around the outside of the wall enclosure 4 whenever possible for disposal of leakage water and discharge of water after the flotation moving.
In another embodiment of this invention as indicated in FIG. 3, the flotation moving method is applied to a structure 6 which cannot float by itself and, moreover, must be prevented from being immersed in water. In this case, the structure 6 is constructed beforehand in a tray-like vessel 7. This vessel 7 is of pressure resisting and waterproof construction and has a flotation displacement such as to safely carry the structure 6. The succeeding steps of the procedure for floating and moving this vessel 7 and the structure 6 are the same as those described above in connection with the preceding example.
In still another embodiment of this invention as indicated in FIG. 4, the method thereof is applied to a structure 6a which also cannot float by itself but which may be immersed in water without harm. In this case, the structure 6a is constructed in the ordinary manner in the construction space 2. Then, at the time of moving, suitable floats 9 are secured to the lower part of the structure 6a to impart the required buoyancy in water thereto. Thereafter, the same succeeding steps as in the first example are carried out to float and move the structure 6a.
In the practice of the flotation moving method according to this invention, the construction of the wall enclosure 4 and the methods of installing and dismantling this enclosure are important considerations. The method of this invention can be practiced with full effectiveness, of course, in a pool or dock which has already been built or has been specially built. In this sense, the water retaining wall enclosure in the practice of this invention is not necessarily a prefabricated structure intended for temporary erection purposes, and there is no reason for it to be of takedown type. The wall enclosure may be a fixed enclosure of permanently installed type or it may be a combination of a temporary construction type structure and a permanent construction type structure.
One example of a wall enclosure of temporary erection character which can be readily installed and dismantled will now be described with reference to FIGS. 5, 6, and 7A through 7D.
As is indicated in FIG. 6, buttress blocks 10 and 11 are installed around the periphery of the construction space 2 to clamp the foot of each wall 4 from the outer and inner sides thereof as foundation for installing the wall enclosure 4. These outer and inner buttress blocks 10 and 11 may be installed integrally with the floor of the construction space 2, or, by utilizing anchor means 12 and 13, separate buttress blocks may be fixed in place by a method such as bolting. In this connection, it is important to make the outer buttress block 10 amply strong since most of the force due to water pressure will be applied directly thereto.
The foot of each part of the wall enclosure 4 is then placed between the outer and inner blocks 10 and 11 thus installed, and spacers 14 such as wedges are forced into the space between the foot and the inner block 11 thereby to fix the foot. Prior to this step, means such as a packing 15 of high strength to withstand pressure is installed beforehand between the outer block 10 and the foot of each wall part. Furthermore, when necessary, embedded packings 16 can also be installed beforehand. Since the packing 15 is subjected to water pressure tending to force it upward, it is necessary to provide means for preventing the outer block 10 from rising.
The upper part of each wall of the wall structure 4 thus set in place is held by bracing struts 17 which will not buckle under the load imposed thereon. The lower ends of these bracing struts 17 are held by support fittings 18 installed on the foundation, while the upper ends of the bracing struts 17 are connected to brackets 19 fixed to the upper parts of the wall enclosure 4. The support fittings 18 may be installed beforehand integrally with the foundation, or they may be installed by utilizing anchor means 20.
As indicated in FIG. 5, the wall enclosure 4 is built by assembling in consecutive edge-to-edge arrangement a plurality of wall panels or segments 4A, 5B, 4C, 4D, . . . , each of which is a division of the entire enclosure of a size which will facilitate erection and subsequent dismantling of the wall enclosure 4.
When a wall enclosure 4 is thus assembled with the wall segments 4A, 4B, 4C, 4D, . . . , each edge joint between adjacent segments is sealed against leakage of water by a molded packing 21. Specific examples of preferred packings are a packing 21 of a Vee-shaped cross section as shown in FIG. 7A, a U-shaped packing 22 as shown in FIG. 7B, a Vee-shaped packing 23 with edge flanges as shown in FIG. 7C, and a U-shaped packing 24 with edge flanges as shown in FIG. 7D. In any case, a desirable shape of the packing is such that, upon being subjected to water pressure, the packing will be pressed with great force against the wall joint thereby to afford great water retention. In some cases, water may penetrated and force its way between the packings and the wall, whereby the water holding effect of the packings decreases. When there is such a possibility, the packings can be held against the wall with material such as adhesive tape.
As was mentioned hereinbefore, it is not necessary that the wall enclosure 4 be completely leakproof. The only requirement is that the rate of leakage will not exceed the flow rate of water supply.
Thus, in accordance with this invention as described above, a large and heavy structure can be moved safely and rapidly, with relatively simple equipment and devices and with very little external force, in a manner which was impossible by conventional methods. | A large, heavy built structure is moved safely and rapidly from a first position to a second position both on a common ground surface by installing on the ground surface a temporary water-retaining wall enclosure surrounding commonly the built structure at the first position and the second position, supplying water into the enclosure thereby to raise the structure by flotation off the ground surface, applying force to move the structure in the raised state to a position immediately above the second position, and draining the water out of the enclosure thereby to cause the structure to descend onto the second position. A buoyant built structure is floated as it is, while a non-buoyant structure is provided with floats. A structure which must not be wetted is built beforehand in a tray-like vessel of sufficient buoyancy. | 4 |
This application claims the priority of U.S. Provisional Application No. 60/174,487, filed Jan. 4, 2000 and U.S. Provisional Application No. 60/203,040, filed May 9, 2000.
BACKGROUND OF THE INVENTION
The invention relates to horizontal directional drilling and, in particular, to improvements in bottom hole assemblies for such drilling techniques.
PRIOR ART
Horizontal directional drilling methods are well known and can offer many advantages over traditional open trench digging operations. There remains a need for greater precision in monitoring and guiding the course of the hole as it is being bored. This need is particularly acute in utility easements and like corridors where pre-existing lines are located often without precision in their placement and “as built” records.
As used herein, the terms “sonde” and “monitoring/tracking device” are used interchangeably to mean a device known in the trenchless boring industry as a surveying device for the monitoring and tracking of a bore hole. The term “boring device” refers to equipment such as a rock tricone drill bit, a poly-diamond-crystalline (PDC) bit, or any other device known in the art to drill or lengthen a bore hole. Finally, the terms “entrenching powering device” and “mud motor” are used interchangeably for a device generally known in the art used to rotate a boring device, without turning the drill pipe/drill string, by some type of drilling rig to continue a hole or bore.
Known horizontal directional drilling bottom hole assemblies typically include a sonde that transmits electromagnetic signals indicating the pitch (from horizontal), the clock (roll about a horizontal axis clockwise or counterclockwise from a reference of say 12 o'clock), and the depth of the sonde. The sonde also enables a person sweeping the corridor with a receiver or detector to locate the horizontal or lateral position of the sonde in the specified corridor.
Because of limitations of current tooling, the transmitter/guidance system or sonde is ordinarily located a considerable distance away from the boring device when an entrenching powering device is used. The sonde may only be as close as about 20 feet and as far as about 50 feet from the boring device. This is due to the fact that an entrenching powering device has generally not been designed to integrate a sonde. The distance between the sonde and the boring device is a major concern for drillers in the utility business, especially when they encounter a job with very restrictive parameters in terms of drilling path.
The sonde transmits a signal that indicates where the sonde is located which can be 20 feet+behind the boring device. This type of drilling has been described as driving a car forward, from the back seat looking out the rear window. A driller only “sees” where he has already drilled, not where he is currently drilling. This becomes a major problem if the boring device veers off course and begins boring outside a designated corridor. The operator will not know there is a potential problem until the boring device is 20 feet+off course. If the driller waits longer to see if the boring device steers back on course, the boring device may continue even further off course. This causes a risk that the driller may destroy cable lines, gas lines, or the like and if such destruction occurs it is not only expensive but dangerous as well.
SUMMARY OF THE INVENTION
The invention provides an improved bottom hole assembly for horizontal directional drilling in which the sonde is carried ahead of the power section of the entrenching powering device or mud motor. In a presently preferred embodiment, the sonde is located in a pocket formed in the wall of a housing of the entrenching powering device that surrounds a bearing mandrel or bit driving shaft. More specifically, the sonde receiving pocket is nestled axially between thrust bearings supporting the mandrel and a flex shaft transmission that couples the power section to the mandrel. This forward location of the sonde greatly improves the accuracy of surveying while boring the hole so as to facilitate placement of the hole and ultimate line in the intended path.
The disclosed mounting arrangement for the sonde readily allows the sonde to be adjusted for a proper clock orientation and is somewhat resilient to limit vibrational forces transmitted to the sonde during operation.
Other mounting structures for the sonde are disclosed. Each of these structures offers improved boring accuracy over prior art constructions by enabling the sonde to be positioned relatively close to the boring device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a bottom hole assembly and a portion of a trailing drill string;
FIGS. 2A through 2D is a longitudinal cross sectional view of a mud motor constructed in accordance with the invention;
FIG. 3 is a fragmentary perspective exploded view of a portion of the mud motor and the sonde;
FIG. 4 is a transverse cross sectional view of the mud motor taken in the plane 4 — 4 indicated in FIG. 2B;
FIG. 5 is a side view, partially in section, of a second embodiment of the invention; and
FIG. 6 is a side view, partially in section, of a third embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference particularly to FIGS. 1, 2 A- 2 D, 5 and 6 , parts towards the left are sometimes hereafter referred to as forward parts in the sense of the drilling direction, it being understood that in such figures, the drilling direction is to the left; the rearward or trailing end of such parts, conversely, is shown to the right. The forward direction can be equated with a downward direction and the rearward direction can be equated with an upper direction where drilling is vertical.
Referring now to FIG. 1, a bottom hole assembly 10 comprises a boring device or bit 11 and an entrenching powering device or mud motor 12 having its forward end carrying the bit 11 . A drill string 13 is coupled to a trailing end 14 of the mud motor 12 in a conventional fashion.
The mud motor 12 , as shown in FIGS. 2A-2D includes a hollow cylindrical bearing mandrel 18 having a central through bore 19 . The bit 11 is coupled to a bit box 21 formed in the forward end of the bearing mandrel 18 . Thus, the bearing mandrel 18 is enabled to drive the bit 11 in rotation and to transmit thrust from the drill string 13 .
Adjacent its forward end 22 , the bearing mandrel 18 is rotationally supported in a lower tubular cylindrical housing 23 by a set of radial bearings 24 . A conical shoulder 28 of the bearing mandrel 18 is received in a conical bore 29 of a radial ring 31 . A radial face of the ring 31 is arranged to abut an adjacent one of the set of radial bearings 24 . Male threads 36 of the lower or forward housing 23 couple with female threads 38 in a forward end 39 of an elongated hollow circular outer housing 41 .
Sets of thrust bearings 44 , 46 are assembled on a carrier nut 47 at opposite sides of an annular flange 48 . The carrier nut 47 is threaded onto an externally threaded part 49 of the bearing mandrel 18 . The carrier nut 47 is locked in position on the bearing mandrel 18 by set screws 51 spaced about the periphery of the flange 48 .
Sleeve bearings 53 , of suitable self-lubricating material such as the material marketed under the registered trademark DU® are received in counterbores 54 formed in the outer housing 41 and serve to rotationally support the mid and trailing length of the bearing mandrel 18 . A longitudinal bore 56 in the surrounding outer housing 41 provides clearance for the main length of the bearing mandrel 18 .
An annular piston 59 floats on a rearward part of the mandrel 18 in a counterbore 61 in the outer housing 41 . The piston 59 retains lubricant in the annular zones of the bearings 53 , 44 and 46 . A circular bearing adapter 62 is threaded onto the rear end of the bearing mandrel 18 . A plurality of holes 63 distributed about the circumference of the adapter 62 are angularly drilled or otherwise formed in the adapter to provide mud flow from its exterior to a central bore 64 of the adapter. As shown, the central bore 64 communicates directly with the bore 19 of the bearing mandrel 18 . The bearing adapter 62 is radially supported for rotation in a sleeve-type marine bearing 66 assembled in a counter bore 67 in a rear portion of the outer housing 41 . Ports 68 allow flow of mud through the marine bearing 66 for cooling purposes.
A flex shaft 71 rotationally couples a rotor adapter 72 to the bearing adapter 62 . At each end of the flex shaft 71 is a constant velocity universal joint 73 comprising a series of circumferentially spaced balls 74 seated in dimples in the flex shaft and in axially extending grooves in a skirt portion 76 of the bearing adapter 62 or skirt portion 77 of the rotor adapter 72 . Each coupling or universal joint 73 also includes a ball 78 on the axis of the flex shaft and a ball seat 79 received in the respective bearing adapter 62 or rotor adapter 72 . Each universal joint 73 includes a bonnet 81 threaded into each of the skirts 76 or 77 to retain the joints or couplings 73 in assembly. Cylindrical elastomeric sleeves 82 are disposed within each of the bonnets 81 to retain grease in the area of the balls 74 , 78 and to exclude contamination from this area. A cylindrical tubular flex housing 84 surrounds the flex shaft 71 and is fixed to the rear end of the outer housing 41 by threading it into the latter at a joint 86 . The flex housing 84 is bent at a mid plane 87 such that the central axis at its rear end is out of alignment with its central axis at its forward end by a small angle of, for example, 2°. At its rearward end, the flex housing 84 is fixed to the stator or housing 88 of a power section 89 of the mud motor 12 by a threaded joint 91 . The stator 88 is a hollow internally fluted member in which operates an externally fluted rotor 92 . The power section 89 formed by the stator 88 and rotor 92 are of generally known construction and operation. The rotor adapter 72 is threaded into the forward end of the rotor 92 to rotationally couple these members together. The drill string 13 is threaded on the rear end of the stator with or without the use of an adapter. The flex shaft 71 converts the rotational and orbital motion of the rotor 92 into plain rotation of the bearing mandrel 18 .
Referring particularly to FIGS. 3 and 4, the outer housing 41 is formed with a pocket or elongated recess 101 rearward of the thrust bearing units 44 , 46 . The pocket 101 is milled or otherwise cut out of the wall of the outer housing 41 with an included angle of 90° in the plane of FIG. 4 transverse to the longitudinal axis of the housing 41 . Surrounding the pocket 101 is a relatively shallow seat or recess 102 similarly cut into the wall of the housing 41 . When viewed in the plane of FIG. 4, this seat has a cylindrical arcuate surface area 103 concentric with the axis of the housing 41 and radially extending surfaces 104 .
An elastomeric sarcophagus 106 of polyurethane or other suitable material has exterior surfaces generally conforming to the surfaces of the pocket 101 . The sarcophagus 106 is configured with a round bottom slot 107 for receiving a sonde 108 . More specifically, the slot 107 is proportioned to receive a standard commercially available sonde of a size which, for example, can be 1¼″ diameter by 19″ long. It is understood that the sarcophagus may be configured with a slot to fit sondes of other standard sizes such as 1″ diameter by 8″ long or a secondary sarcophagus may be provided to increase the effective size of a smaller sonde to that of the larger size. An arcuate cover plate 109 of steel or other suitable material is proportioned to fit into the area of the seat 102 to cover and otherwise protect the sonde 108 from damage during drilling operations. The cover 109 is proportioned, when installed in the seat 102 , to provide an outer cylindrical surface 111 that lies on the same radius as that of the outer cylindrical surface of the housing 41 surrounding the pocket or slot 101 . The cover 109 , is provided with a plurality of longitudinal through slots 112 , to allow passage of electromagnetic signals transmitted from the sonde 108 . The slots 112 are filled with non-metallic material such as epoxy to exclude contaminates from passing into the pocket 101 or otherwise reaching the sonde 108 . Additionally, for purposes of allowing the sonde to transmit signals over a wide angle, the body of the housing 41 is drilled with holes 113 which are filled with epoxy or other non-metallic sealant. A shallow groove 114 is cut in a generally rectangular pattern in the surface 103 around the pocket 101 to receive an O-ring seal 116 .
The round bottom slot or groove 107 in the sarcophagus is dimensioned to provide a friction fit with the sonde 108 . This permits the sonde 108 to be rotated or rolled on its longitudinal axis to “clock” it by registering its angular orientation relative to the plane of the bend in the flex housing 84 as is known in the art.
The cover or plate 109 is retained in position over the sonde 108 by a plurality of screws 117 assembled through holes 118 in the cover and aligned with threaded holes 119 formed in the outer housing 41 . The screw holes 118 , 119 are distributed around the periphery of the cover 109 . The O-ring 116 seals against the inside surface of the cover 109 to exclude contaminates from entering the pocket 101 during drilling operations.
The sarcophagus 106 is proportioned so that it is compressed by the cover 109 around the sonde 108 when the screws 117 draw the cover tight against the seat surface 103 . This compression of the sarcophagus 106 increases its grip on the sonde 108 so that the sonde is locked in its adjusted “clocked” position. The elastomeric property of the sarcophagus 106 , besides enabling it to resiliently grip the sonde when compressed by the cover 109 , can serve to cushion the sonde 108 from excessive shock forces during drilling operation.
Other resilient mounting structures for the sonde 108 are contemplated. For example, the sonde 108 can be retained in the pocket 101 by resilient steel straps arranged to overlie the sonde as it lies in the pocket 101 . The straps can be retained in place by suitable screws or other elements.
When the mud motor 12 is operated, mud or water passing between the stator 88 and rotor 92 travels through the transmission and bearing sections of the mud motor bounded by the flex housing 84 , outer housing 41 , and lower housing 23 and is delivered to the bit 11 . More specifically, the mud flows through the annulus between the flex shaft 71 and an inner bore 120 of the flex housing 84 . From this annulus, the mud enters the central bore 64 of the bearing adapter through the angularly drilled holes 63 . The mud flows from this bore 64 through the axial bore 19 in the bearing mandrel 18 .
From the foregoing description, it can be seen that the disclosed arrangement in which the sonde is received in the wall of a main housing part, namely the outer housing 41 , the sonde can be disposed quite close to the bit 11 with minimal hardware and without complexity. As seen, the flow of mud from the power section 89 to the bit 11 is unrestricted and the diameter of the transmission section is not unnecessarily enlarged beyond that which is already required for the necessary bearings and other componentry. By locating the sonde 108 close to the bit 11 , much greater accuracy in monitoring and tracking the progress of the boring process over that possible with the prior art is achieved.
Operation of the mud motor to steer the pipe string along its desired path will be evident to those skilled in the art. Typically, to adjust the direction of the bore, the drill string is rotated to point the bit in the direction of the needed adjustment. The orientation of the bit is transmitted to a surface receiver by the sonde. The drill string is held against rotation while the mud motor rotates the bit and the drill string is thrust forward to redirect the direction of the bore. The disclosed mud motor provides a unique function that is enabled by the provision of the forward set of thrust bearings 44 . These bearings 44 allow the mud motor to operate to rotate the bit 11 when the drill string is being pulled out of the hole so that during this withdrawal process the hole is conveniently reamed or enlarged with a hole opening device.
FIGS. 5 and 6 illustrate additional embodiments of the invention. Parts like those described in connection with the embodiment of FIGS. 1-4 are designated with the same numerals. In FIG. 5, a tubular cylindrical collar 126 housing the sonde 108 is assembled around a housing 127 that corresponds to the outer housing 41 of the embodiment of FIGS. 1-4. The collar 126 is formed of steel or other suitable material. The collar 126 is fixed longitudinally and angularly relative to the housing 127 by set screws 128 threaded into the wall of the collar 126 and received in blind holes 129 drilled in the wall of the housing 127 . The sonde 108 is received in the sarcophagus 106 and protected by the cover 109 as previously described. Various other techniques, besides the set screws 128 , can be used to fix the collar 126 on the housing 127 . The collar 127 can be threaded onto the housing 127 where the housing, for example, is provided with external threads and a stop shoulder. Another technique is to weld the collar 126 to the housing 127 . If desired or necessary, the sonde 108 can be assembled in a hole aligned with the axis of the collar 126 and open at one end. The opening can be plugged with a suitable closure during use.
FIG. 6 illustrates another embodiment of the invention. A coupler 131 is disposed between the bearing mandrel 18 and the bit 11 . The coupler 131 has external threads mated with the bit box 21 and internal threads receiving the bit 11 . The coupler 131 is formed with the pocket 101 for receiving the sonde 108 . The coupler 131 has a central bore for conveying mud from the bearing mandrel 18 to the bit 11 . If desired, an axially oriented hole can be used instead of the open face pocket 101 to receive the sonde 108 and the hole can be plugged by a suitable closure. Still further, if it is desired to locate the sonde 108 at the center of the coupler 131 , water corsets or passages can be drilled or otherwise formed axially through the coupler and circumferentially spaced about the sonde to allow mud to pass through the coupler.
While the invention has been shown and described with respect to particular embodiments thereof, this is for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiments herein shown and described will be apparent to those skilled in the art all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited in scope and effect to the specific embodiments herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention. | A bottom hole assembly for horizontal directional drilling that improves the accuracy of surveying while boring by enabling the progress of the bore to be monitored and tracked with the aid of a sonde. In one embodiment the sonde is received in the wall of a area of a mud motor surrounding the bearing mandrel, in another embodiment the sonde is carried in the wall of a collar surrounding the bearing mandrel housing, and in an additional embodiment the sonde is carried in an adapter between the bearing mandrel and the bit. | 4 |
PRIORITY
[0001] This Application is a Continuation of U.S. patent application Ser. No. 13/624,315, filed Sep. 21, 2012, which is a of Continuation-in-Part of U.S. patent application Ser. No. 12/580,391, filed Oct. 16, 2009, which claims the benefit of U.S. Provisional Application No. 61/106,186, filed Oct. 17, 2008. The contents of each application are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to stable emulsions containing cinnamaldehyde and diallyl disulfide. Specifically, the stable emulsions utilize Emulsogen® EH and Surfonic® CO 36 to form a superior emulsion stability system.
BACKGROUND OF THE INVENTION
[0003] Emulsions generally refer to heterogeneous systems that comprise two immiscible liquids. In agriculture, emulsions provide formulation vehicles for delivery of herbicides, insecticides, fungicides, bactericides, and fertilizers.
[0004] Mechanical agitation, such as shaking or stirring, or another energy input is required to form an emulsion. Emulsions are inherently unstable, meaning that once they are formed, the immiscible liquids tend to revert or separate. Emulsifying agents, such as surface-active agents, can be used to increase the stability of the emulsions. In the context of emulsions, “stable” or “stability” means that the droplet particles of one liquid are uniformly distributed into another liquid and that this status is maintained for a desirable amount of time.
[0005] Emulsions are especially useful in the field of agriculture wherein numerous lipophilic active ingredients must be dissolved and suspended into water prior to application to the plants. An oil-in-water emulsion (O/W emulsion) is an emulsion wherein liquid oil droplets are finely dispersed in water. Preparing stable O/W emulsions in very difficult and frequently involves extensive experimentation to determine formulations that provide stable concentrated products for end-use diluted emulsions.
[0006] The emulsion system plays an essential role in providing stable emulsions, but identification of a proper system is complex and not easy to identify because of the required optimization of many different formulation characteristics, such as interfacial tension, viscosity, relative density, and temperature.
[0007] In addition, there are hundreds of different emulsifiers and surfactants commercially available with vastly different properties. The available emulsifiers and surfactants could be used in formulations in varying combinations and amounts to produce thousands of different potential formulations, each producing unpredictable stability characteristics. When more than one emulsifier or surfactant are combined in a formulation, they produce an emulsion system.
[0008] Calsogen® EH (available from Clariant) is an emulsifier, specifically, an iso-C12 alkyl benzene sulphonate calcium salt.
[0009] Surfonic® CO 36 (available from Huntsman, Inc.) is a surfactant and it contains polyglycol esters of castor oil.
[0010] Cinnamaldehyde is a naturally occurring organic compound that can be derived from the bark of trees of the genus Cinnamomum. Cinnamaldehyde is a viscous oil that has low solubility in water. Cinnamaldehyde does not present any known risk to humans or the environment and is considered to have a minimal safety risk. For this reason, it is not regulated by the Environmental Protection Agency (“EPA”) because it is exempt from the Federal Insecticide, Fungicide, and Rodenticide Act (“FIFRA”). See 40 C.F.R. §152.25(f).
[0011] Cinnamaldehyde is known to have pesticidal activity. For example, cinnamaldehyde is effective against nematodes. See, for example, U.S. Pat. No. 6,251,951 B1.
[0012] Diallyl disulfide (4,5-dithia-1,7-octadiene) is a naturally occurring organosulfur compound that can be derived from garlic and plants of the genus Allium. Diallyl disulfide is an oil that has low solubility in water. Diallyl disulfide does not present any known risk to humans or the environment and is considered to have a minimal safety risk. For this reason, it is not regulated by the Environmental Protection Agency (“EPA”) because it is exempt from the Federal Insecticide, Fungicide, and Rodenticide Act (“FIFRA”). See 40 C.F.R. §152.25(f).
[0013] There is a need to improve the safety characteristics of pesticides that are applied to plants intended for human and animal consumption. In order to achieve the goal of providing a safer pesticide, users must: (1) use environmentally safe actives, such as essential oils; and (2) if using essential oils, then they must include an environmentally safe emulsion system.
[0014] In prior art formulations, the use of environmentally harmful organic solvents or other components were required to produce stable and effective dilutable emulsions if they contained plant essential oils, such as cinnamaldehyde and dially disulfide. Although organic solvents are very effective in forming emulsions, they are also often flammable, corrosive or toxic to living systems and are of environmental concern. For example, ProGuard® 30% is a commercially available insecticide, miticide and fungicide that contains cinnamaldehyde. However, ProGuard® 30% also contains the undesirable ingredient o-Phenylphenol.
[0015] Therefore, there is a need for environmentally safe pesticidal formulations that contain effective but safe actives.
SUMMARY OF THE INVENTION
[0016] Applicants unexpectedly discovered that an emulsion system comprising Emulsogen® EH and Surfonic® CO 36 provided excellent emulsion stability for cinnamaldehyde and diallyl disulfide formulations.
[0017] In one aspect, the invention is directed to improved and stable formulations containing cinnamaldehyde and diallyl disulfide with the emulsion system of Emulsogen® EH and Surfonic® CO 36.
[0018] In another aspect, the invention is directed to a specific agricultural formulation comprising about 61.0% cinnamaldehyde about 6.0 to about 8.5% diallyl disulfide, from about 13.0 to about 15.5% soybean oil, about 7.0% Calsogen® EH, and about 10.5% Surfonic® CO 36.
[0019] In a further aspect, the invention is directed to methods for suppressing plant damage by plant pathogens comprising applying the formulations of the invention to the locus, soil or seeds of plants in need of said treatment.
[0020] In a final aspect, the invention is directed to agricultural formulations comprising a synergistic amount of cinnamaldehyde and diallyl disulfide.
DETAILED DESCRIPTION
[0021] In one embodiment of the invention, the invention is an agricultural formulation comprising cinnamaldehyde, diallyl disulfide, Surfonic® CO 36, and an iso-C12 alkylbenzene sulphonate calcium salt.
[0022] In another embodiment, the iso-C 12 alkyl benzene sulphonate calcium salt is Calsogen® EH. In a further embodiment, the formulation may contain from about 5 to about 9% by weight of the iso-C 12 alkyl benzene sulphonate calcium salt or Calsogen® EH, preferably from about 6.0 to about 8.0%, and most preferably about 7.0% of the iso-C12 alkyl benzene sulphonate calcium salt or Calsogen® EH.
[0023] In a further embodiment, the formulation may contain a lipophilic solvent. In a preferred embodiment, the lipophilic solvent is soybean oil. The formulation may contain from about 10.0 to about 20.0% by weight, preferably from about 12.0 to 16.0%, and most preferably from about 13.0 to about 15.5% of the lipophilic solvent or soybean oil.
[0024] In yet another embodiment, the formulation may contain from about 50 to about 70% by weight of cinnamaldehyde, preferably from about 58 to about 63% of cinnamaldehyde, and most preferably about 61% cinnamaldehyde.
[0025] In a further embodiment, the formulation may contain from about 5 to about 10% by weight of diallyl disulfide, preferably from about 5.5 to about 9.0%, and most preferably about from about 6.0 to about 8.5% of diallyl disulfide.
[0026] The formulation may contain from about 8 to about 12% of Surfonic® CO 36 by weight in one embodiment. Preferably, the formulation contains from about 9.0 to about 11.0% of Surfonic® CO 36, and more preferably, about 10.5% of Surfonic® CO 36.
[0027] In a preferred embodiment, the invention is directed to an agricultural formulation comprising: from about 59.5 to about 61.5% cinnamaldehyde; from about 6.0 to about 8.5% diallyl disulfide; from about 13.0 to about 15.5% soybean oil; about 7.0% Calsogen® EH; and about 10.5% Surfonic® CO 36. In a more preferred embodiment, the formulation contains about 61.0% cinnamaldehyde.
[0028] An alternative embodiment is directed to methods for suppressing plant damage by plant pathogens comprising applying the formulation of the present invention to the locus, soil or seeds of plants in need of said treatment. In a preferred embodiment, the plant pathogens are nematodes.
[0029] In U.S. patent application Ser. No. 12/580,391, Applicants discussed the synergy between cinnamaldehyde and diallyl disulfide (see Example 3). Specifically, Applicants revealed that when cinnamaldehyde and diallyl disulfide are combined, nematodes are suppressed at bio-control levels far below those needed when the each component is applied alone. Applicants unexpectedly found that this effect was more than merely additive and was synergistic. Accordingly, in an embodiment, this invention is directed to agricultural formulations which contain a synergistic amount of cinnamaldehyde and diallyl disulfide.
[0030] The emulsifying system utilized in formulations of the present invention is a unique combination of two emulsifiers, Calsogen® EH and Surfonic® CO 36. This system can be used in the formulation with a total % weight from about 10 to about 30% of the formulation, preferably from about 15 to about 19% of the formulation, and most preferably at about 17.5% of the formulation.
[0031] As mentioned above, formulations of the present invention may contain lipophilic solvents. The preferred solvent is soybean oil, however, other solvents may be used as long as the solvents are “environmentally safe,” meaning that they are exempt from volatile organic compound (“VOC”) regulation by the EPA. For example, the following solvents may be used: methyl oleate, ethyl lactate, and methyl soyate. The agricultural formulations of the present invention explicitly exclude organic solvents which are considered to have unsatisfactory VOC levels as defined by California Environmental Protection Agency. The agricultural formulations of the present invention explicitly exclude ingredients which are considered by the state of California to cause cancer or reproductive toxicity under the The Safe Drinking Water and Toxic Enforcement Act of 1986 (see Health and Safety Code Section 25249.8(b)).
[0032] Formulations of the present invention contain an iso-C 12 alkyl benzene sulfonate calcium salt. As previously mentioned, Calsogen® EH is preferred. However, other iso-C12 alkyl benzene sulfonate calcium salts known by those of skill in the art may be used in formulations of the invention, such as Phenylsulfonat CA or Phenylsulfonat CA 62 (both available from Clariant).
[0033] The trade names used herein are used to describe a type of component with specific chemistries. When a trade name is used herein, a component with the same of very similar chemistry may be suitable unless indicated otherwise.
[0034] The terms “emulsion concentrate,” “emulsifiable concentrate” and “formulation” are used interchangeably throughout the application.
[0035] The terms “emulsion system” and “emulsifying system” are used interchangeably throughout the application.
[0036] As used herein, all numerical values relating to amounts, weight percentages and the like, are defined as “about” or “approximately” each particular values plus or minus 10% (±10%). For example, the phrase “greater than 0.1%” is to be understood as encompassing values greater than 0.09%. Therefore, amounts within 10% of the claimed values are encompassed by the scope of the invention.
[0037] The percentages of the components in the formulations and comparative formulations are listed by weight percentage.
[0038] It is understood that the foregoing detailed description and accompanying examples are merely illustrative and are not to be taken as limitations upon the scope of the invention, which is defined solely by the appended claims and their equivalents. Various changes and modifications to the disclosed embodiments will be apparent to those skilled in the art. Such changes and modifications, including without limitation those relating to the active agents and excipients of the invention, may be made without departing from the spirit and scope hereof.
[0039] The following examples are offered by way of illustration only, not to limit the scope of this invention, as represented by the claims list attached herein.
EXAMPLES
Example 1
Preparation of a Cinnamaldehyde and Diallyl Disulfide Emulsion Concentrate Formulation
[0040] A cinnamaldehyde and diallyl disulfide emulsion concentrate was prepared. The following components, in the amounts indicated below (in weight % of the component/total weight % of the formulation), were added in the order listed. The formulation was then mixed well with a magnetic stirrer until a homogeneous emulsion was formed.
[0041] 61.0% cinnamaldehyde
[0042] 21.5% diallyl disulfide and soybean oil (about 6 to 8.5% diallyl disulfide and 13.0 to 15.5% soybean oil)
[0043] 7.0% Calsogen® EH
[0044] 10.5% Surfonic® CO 36
[0045] The amount of diallyl disulfide added will vary depending upon the purity of the technical grade diallyl disulfide. Soybean oil may be used in varying amounts to accommodate the strength of the technical grade diallyl disulfide.
Example 2
Stability Study
[0046] The Formulation of Example 1 was compared with 16 other formulations containing the same amount of cinnamaldehyde, diallyl disulfide, and solvent but with different emulsifying systems. The 16 comparative emulsion concentrate formulations were prepared in a manner similar to the manner in which the Formulation of Example 1 was prepared as described above.
[0047] A standard emulsion stability test was utilized. Specifically, 5 mL of each emulsion concentrate formulation was added to 95 mL of water in a 100 mL graduated cylinder. The cylinder was stopped and inverted repeatedly until a homogeneous O/W emulsion was produced. The cylinder was then observed to detect phase separation or other indications of instability.
[0048] The results can be seen below in “Table 1. Emulsion Stability of Cinnamaldehyde and Diallyl Disulfide Formulations.”
[0000]
TABLE 1
Emulsion Stability of Cinnamaldehyde and Diallyl Disulfide Formulation
Emulsifying
Form.
Exp#
System
% in Form.
0 min
2 hr
4 hr
24 hr
Form.
38C
Calsogen ® EH
7
Bloom:
Emulsion: Excellent,
Emulsion:
Emulsion:
of Ex. 1
Surfonic ® CO 36
10.5
Excellent;
uniform, thick;
Excellent, uniform,
Excellent, uniform,
Inversion: 0.5
Separation: None
thick; Separation:
thick; Separation:
None
None
2
38A
Calsogen ® EH
7
Bloom:
Emulsion: Excellent,
Emulsion: Good;
Emulsion: Good;
Emulsogen ® EL
10.5
Excellent;
uniform, thick;
Separation: 2 mL
Separation: 4 mL
360
Inversion: 0.5
Separation: None
clear layer on
clear yellow layer
bottom
on bottom;
Reconstitute: 0.5
inversion
3
38B
Atlox ™ 4838B
7
Bloom:
Emulsion: Excellent,
Emulsion: Good;
Emulsion: Good;
Emulsogen ® EL
10.5
Excellent;
uniform, thick;
Separation: 1 mL
Separation: 3 mL
360
Inversion: 0.5
Separation: None
clear layer on
clear yellow layer
bottom
on bottom;
Reconstitute: 0.5
inversion
4
38D
Atlas ™ G-1086
17.5
Bloom:
Emulsion: Thinned
Emulsion: Thinned
Emulsion: Thinned
Unacceptable;
out; Separation: 8.5 mL
out; Separation: 7 mL
out; Separation: 7 mL
Settling: Settled
white
white
white
at 0 min;
precipitate on
precipitate on
precipitate on
Inversion: 1
bottom.
bottom.
bottom;
Reconstitute: 5
inversions
5
38E
Atlox ™ 4838B
7
Bloom:
Emulsion: Thinned
Emulsion: Thinned
Emulsion: Thinned
Atlas ™ G-1086
10.5
Unacceptable;
out; Separation: 6 mL
out; Separation: 2 mL
out; Separation:
Settling: Settled
white
yellow layer
3.5 mL yellow
at 0 min;
precipitate on
on bottom.
layer on bottom;
Inversion: 1
bottom.
Reconstitute: 0.5
inversion
6
38F
Synperonic ® A20
17.5
Bloom: Poor;
Emulsion: Thinned
Emulsion: None,
Emulsion: None;
Settling: Settled
out; Separation: 5 mL
top 10%
Separation: 5 mL
on bottom at 0 min;
white
clear; Separation:
white precipitate on
Inversion: 5
precipitate on
5 mL white
bottom;
bottom.
precipitate on
Reconstitute: Did
bottom.
not in 5 inversions
7
38G
Atlox ™ 4838B
7
Bloom: None,
Emulsion: Thinned
Emulsion: Thinned
Emulsion: Thinned
Synperonic ® A20
10.5
Unacceptable; Settling:
out; Separation: 5 mL
out; Separation:
out; Separation:
Settled
white on
5 mL white on
6 mL white
on bottom at 0 min;
bottom.
bottom.
precipitate on
Inversion: 5
bottom;
Reconstitute: Did
not in 5 inversions
8
38H
Calsogen ® EH
7
Bloom: None,
Emulsion: Thinned
Emulsion: Thinned
Emulsion: Thinned
Synperonic ® A20
10.5
Unacceptable;
out; Separation: 5 mL
out; Separation: 5 mL
out; Separation: 7 mL
Settling: Settled
white
white
white
on bottom at 0 min;
precipitate on
precipitate on
precipitate on
Inversion: 5
bottom.
bottom.
bottom;
Reconstitute: Did
not in 5 inversions
9
38I
Atlas ™ G-5000
17.5
Bloom:
Emulsion: Thinned
Emulsion: Thinned
Emulsion: Thinned
Acceptable;
out; Separation: 12 mL
out; Separation:
out; Separation: 13 mL
Settling: Milky
white
12 mL white
white
film on walls at
precipitare on
precipitate on
precipitate on
0 min; Inversion: 4
bottom.
bottom.
bottom;
Reconstitute: Did
not in 5 inversions
10
38J
Atlox ™ 4838B
7
Bloom:
Emulsion: Thinned
Emulsion: Thinned
Emulsion: Thinned
Atlas ™ G-5000
10.5
Acceptable;
out; Separation: 10 mL
out; Separation:
out; Separation: 12 mL
Settling: Grit on
white
11 mL white
white
walls at 0 min;
precipitate on
precipitate on
precipitate on
Inversion: 5
bottom, white film
bottom, white film
bottom;
on walls.
on walls
Reconstitute: Did
not in 5 inversions
11
38K
Brij ® S20
17.5
Bloom: None,
Emulsion: Thinned
Emulsion: Thinned
Emulsion: Thinned
Unacceptable; Settling:
out; Separation: 5 mL
out; Separation: 5 mL
out; Separation:
Settled
white
white
5.5 mL white
on bottom at 0 min +
precipitate on
precipitate on
precipitate on
grit;
bottom.
bottom.
bottom;
Inversion: 5, grit
Reconstitute: Did
remains.
not in 5 inversions
12
38L
Atlox ™ 4838B
7
Bloom: None,
Emulsion: Thinned
Emulsion: Thinned
Emulsion: Thinned
Brij ® S20
10.5
Unacceptable;
out; Separation: 5 mL
out; Separation: 5 mL
out; Separation: 6 mL
Settling: Settled
white
white
white
on bottom at 0 min +
precipitate on
precipitate on
precipitate on
grit;
bottom.
bottom.
bottom;
Inversion: 5, grit
Reconstitute: Did
gone.
not in 5 inversions
13
38M
Tween ® 80
17.5
Bloom: None,
Emulsion: Thinned
Emulsion: Thinned
Emulsion: Thinned
Unacceptable; Settling:
out; Separation: 9 mL
out; Separation:
out; Separation: 11 mL
Settled
white
11 mL white
white
on bottom at 0 min;
precipitate on
precipitate on
precipitate on
Inversion: 2
bottom.
bottom.
bottom;
Reconstitute: Did
not in 5 inversions
14
38N
Atlox ™ 4838B
7
Bloom:
Emulsion:
Emulsion:
Emulsion:
Tween ® 80
10.5
Acceptable;
Acceptable;
Acceptable;
Acceptable;
Settling: None at
Separation: 3 mL
Separation: 4 mL
Separation: 5 mL
0 min; Inversion: 1
yellow layer on
yellow layer on
yellow layer on
bottom.
bottom.
bottom;
Reconstitute: 1
inversion
15
38O
Calsogen ® EH
7
Bloom: Very
Emulsion:
Emulsion:
Emulsion:
Tween ® 80
10.5
good; Settling:
Acceptable;
Acceptable;
Acceptable;
None at 0 min;
Separation: 4 mL
Separation: 4 mL
Separation: 4 mL
Inversion: 1
yellow layer on
yellow layer on
yellow layer on
bottom.
bottom.
bottom;
Reconstitute: 1
inversion
16
38P
Tergitol ™ XD
17.5
Bloom: None,
Emulsion: Poor;
Emulsion: None;
Emulsion: None;
roping,
Separation: 9 mL
Separation: 9 mL
Separation: 9 mL
Unacceptable; Settling:
precipitate on
precipitate + 2 mL
precipitate + 3 mL
Settled
bottom.
white layer above
white layer above
on bottom at 0 min;
it, both on bottom.
it, both on bottom;
Inversion: 5
Reconstitute: Did
not in 5 inversions
17
38Q
Calsogen ® EH
7
Bloom: Poor,
Emulsion: Thinned
Emulsion: Thinned
Emulsion: Thinned
Tergitol ™ XD
10.5
Unacceptable; Settling:
out; Separation: 5 mL
out; Separation: 6 mL
out; Separation:
Settled
precipitate on
precipitate on
7.5 mL precipitate
on bottom at 0 min;
bottom.
bottom.
on bottom;
Inversion: 2
Reconstitute: Did
not in 5 inversions
[0049] In Table 1, the experimental properties of the emulsion are defined as follows: (a) “bloom” refers to the spontaneous visible dispersion and emulsification of the Emulsifiable Concentrate phase, when added into the water phase; (b) “inversion” refers to the number of times the cylinder was inverted to achieve an emulsion; (c) “separation” refers to the reversion of immiscible liquids into separate phases; (d) “thinned out” refers to the emulsion appearing thinner; (e) “reconstitute” refers to the number of inversion necessary to form an emulsion; (f) “settling” refers to the component which was deposited on the bottom of the cylinder; (g) “milky film” refers to a thick white film; and (h) “grit” refers to fine particulate-looking appearance.
[0050] Applicants unexpectedly discovered that the Formulation of Example 1 had superior stability, even after 24 hours. The Formulation of Example 1 quickly produced an emulsion. Throughout the observation period, the Formulation of Example 1 remained uniform and thick without separating. All of the other emulsion systems failed to produce satisfactory results. Achieving excellent stability after 24 hours is extremely rare in emulsion concentrate dilutions.
[0051] The unpredictability of the emulsion systems can be seen by comparing the stability of the Formulation of Example 1 with Formulation 2. Both formulations contained Calsogen® EH and the only difference between the formulations was that the Formulation of Example 1 contained Surfonic® CO 36 and Formulation 2 contained Emulsogen® EL 360. Surfonic® CO 36 and Emulsogen® EL 360 are both castor oil ethoxylates (36 EO), however, the Formulation of Example 1 had superior emulsion stability after 24 hours when compared to Formulation 2. Therefore, these formulations illustrate how emulsion systems with very similar chemistries may have different stability properties that cannot be predicted by one skilled in the art.
[0052] Further details regarding the alternative emulsion systems can be found below in “Table 2: Components in Emulsifying Systems.”
[0000]
TABLE 2
Components in Emulsifying Systems
Trade Name
Chemistry
Calsogen ® EH
iso-C12 alkylbenzene sulphonate-calcium salt
Emulsogen ® EL 360
Castor oil ethoxylate (36 EO)
Atlox ™ 4838B
Calcium alkylaryl sulphonate
Surfonic ® CO 36
Castor oil ethoxylate (36 EO)
Atlas ™ G-1086
Polyoxyethylene (40) sorbitol hexaoleate
Synperonic ® A20
Polyoxyethylene (20) C12-C15 alcohol
Atlas ™ G-5000
Polyalklene oxide block (EO/PO) copolymer
Brij ® S20
Polyoxyethylene (20) oleyl ether
Tween ® 20
Polyoxyethylene (20) sorbitan monooleate
Tergitol ™ XD
Alkyl EO/PO copolymer | The present invention relates to agricultural emulsion concentrates which form stable oil-in-water emulsions when diluted with water. More specifically, the invention relates to stable oil-in-water emulsions which include cinnamaldehyde and diallyl disulfide with a Calsogen® EH and Surfonic® CO 36 emulsion system. The increased stability of the emulsion allows for efficient mixing of the emulsion ingredients and effective storage and application of the cinnamaldehyde and diallyl disulfide to areas in need of nematode protection or treatment. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the present invention generally relate to a subsea well. More particularly, embodiments of the invention relate to methods and apparatus for subsea well intervention operations, including retrieval of a wellhead from a subsea well.
2. Description of the Related Art
After the production of a subsea well is finished, the subsea well is closed and abandoned. The subsea well closing process typically includes recovering the wellhead from the subsea well using a conventional wellhead retrieval operation. During the conventional wellhead retrieval operation, a retrieval assembly equipped with a casing cutter is lowered on a work string from a floating rig until the retrieval assembly is positioned over the subsea wellhead. Next, the casing cutter is lowered into the wellbore as the retrieval assembly is lowered onto the wellhead. The casing cutter is actuated to cut the casing by using the work string. The cutter may be powered by rotating the work string from the floating rig. Since the work string is used to manipulate the retrieval assembly and the casing cutter, the floating rig is required at the surface to provide the necessary support and structure for the work string. Even though the subsea wellhead may be removed in this manner, the use of the floating rig and the work string can be costly and time consuming. Therefore, there is a need for an improved method and apparatus for subsea wellhead retrieval.
SUMMARY OF THE INVENTION
The present invention generally relates to methods and apparatus for subsea well intervention operations, including retrieval of a wellhead from a subsea well. In one aspect, a method of performing an operation in a subsea well is provided. The method comprises the step of positioning a tool proximate a subsea wellhead. The tool has at least one grip member and the tool is attached to a downhole assembly. The method also comprises the step of clamping the tool to the subsea wellhead by moving the at least one grip member into engagement with a profile on the subsea wellhead. The method further comprises the step of applying an upward force to the tool thereby enhancing the grip between the grip member and the profile on the subsea wellhead. Additionally, the method comprises the step of performing the operation in the subsea well by utilizing the down hole assembly.
In another aspect, an apparatus for use in a subsea well is provided. The apparatus comprises a grip member movable between an unclamped position and a clamped position, wherein the grip member in the clamped position applies a grip force to a profile on the subsea wellhead. Additionally, the apparatus comprises a lifting assembly configured to generate an upward force which increases the grip force applied by the grip member.
In yet another aspect, a method of performing an operation in a subsea well is provided. The method comprises the step of positioning a tool proximate a subsea wellhead. The tool has at least one grip member and a lock member. The tool is also attached to a downhole assembly. The method further comprises the step of moving the at least one grip member from an unclamped position to a clamped position in which the grip member engages the subsea wellhead. The method also comprises the step of hydraulically activating the lock member such that the lock member engages a portion of the grip member thereby retaining the grip member in the clamped position. Additionally, the method comprises the step of performing the operation in the subsea well by utilizing the downhole assembly.
In a further aspect, an apparatus for use in a subsea well is provided. The apparatus comprises a grip member for engaging a subsea wellhead, wherein the grip member is movable between an unclamped position and a clamped position. The apparatus further comprises a lock member movable between an unlocked position and a locked position upon activation of a hydraulic cylinder, wherein the lock member in the locked position retains the grip member in the clamped position.
In a further aspect, a method of cutting a casing string in a subsea well is provided. The method comprises the step of positioning a tool proximate a subsea wellhead. The tool has at least one grip member and the tool is attached to a cutting assembly. The method further comprises the step of operating the at least one grip member to clamp the tool to the subsea wellhead. The method also comprises the step of cutting the casing string below the subsea wellhead by utilizing the cutting assembly. Additionally, the method comprises the step of applying an upward force to the tool during the cutting of the casing string which is at least equal to an axial reaction force generated from cutting the casing string, wherein at least a portion of the upward force is created by a cylinder member in the tool that acts on the subsea wellhead.
In yet a further aspect, an apparatus for cutting a casing string in a subsea well is provided. The apparatus comprises a cutting assembly configured to cut the casing string. The apparatus also comprises a grip member for engaging a subsea wellhead, the grip member movable between an unclamped position and a clamped position. Additionally, the apparatus comprises a lifting assembly configured to generate an upward force which is at least equal to an axial reaction force generated from cutting the casing string, wherein the lifting assembly comprises a cylinder and piston arrangement that is configured to act upon a portion of the subsea wellhead.
Additionally, a method of gripping a subsea wellhead is provided. The method comprises the step of positioning a tool proximate the subsea wellhead. The tool has at least one grip member. The method further comprises the step of clamping the tool to the subsea wellhead by moving the at least one grip member into engagement with a profile on the subsea wellhead. Additionally, the method comprises the step of applying an upward force to the tool thereby enhancing the grip between the grip member and the profile on the subsea wellhead.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is an isometric view of a subsea wellhead intervention and retrieval tool according to one embodiment of the invention.
FIG. 2 is a view illustrating the placement of the tool on a wellhead.
FIG. 3 is a view illustrating the tool engaging the wellhead.
FIG. 4 is a view illustrating the tool cutting a casing string below the wellhead.
FIGS. 5A and 5B are enlarged views illustrating the components of the tool.
FIG. 6 is a view illustrating the tool after the casing string has been cut.
FIG. 7 is a view illustrating a subsea wellhead intervention and retrieval tool with a perforating tool.
FIG. 8 is a view illustrating a subsea wellhead intervention and retrieval tool with the perforating tool disposed on a wireline.
FIG. 9 is a view illustrating a subsea wellhead intervention and retrieval tool with the perforating tool.
FIG. 10 is a view illustrating a subsea wellhead intervention and retrieval tool with a cutter assembly.
FIG. 11 is a view illustrating a subsea wellhead intervention and retrieval tool with an explosive charge device.
DETAILED DESCRIPTION
Embodiments of the present invention generally relate to methods and apparatus for subsea well intervention operations, including retrieval of a wellhead from a subsea well. To better understand the aspects of the present invention and the methods of use thereof, reference is hereafter made to the accompanying drawings.
FIG. 1 shows a subsea wellhead intervention and retrieval tool 100 according to one embodiment of the invention. As shown, the tool 100 includes a shackle 210 and a mandrel 195 for connection to a conveyance member 202 , such as a cable. The use of cable with the tool 100 allows for greater flexibility because the cable may be deployed from an offshore location that includes a crane rather than using a floating rig with a work string as in the conventional wellhead retrieval operation. In another embodiment, the conveyance member may be an umbilical, coil tubing, wireline or jointed pipe.
The conveyance member 202 is used to lower the tool 100 into the sea to a position adjacent the subsea wellhead. A power source (not shown), such as a hydraulic pump, pneumatic pump or a electrical control source, is attached to the tool 100 via an umbilical cord (not shown) connected to connectors 205 to manipulate and/or monitor the operation of the tool 100 . The power source is attached to a control system 230 of the tool 100 . The control system 230 may include a manifold arrangement that integrates one or more cylinders of the tool 100 . The manifold arrangement may include a filtration system and a plurality of pilot operated check valves which allows the cylinders of the tool to function in a forward direction or a reverse direction. In one embodiment, the manifold arrangement allows the cylinders to operate independently from the other components in the tool 100 . The functionality of the cylinders will be discussed herein. The control system 230 may also include data sensors, such as pressure sensors and temperature sensors that generate data regarding the components of the tool 100 . The data may be used to monitor the operation of the tool 100 and/or control the components of the tool 100 . Further, the data may be used locally by an onboard computer or by the ROV. The data may also be used remotely by sending the data back to the surface via the ROV or via an umbilical attached to the tool.
The power source for controlling the control system 230 of the tool 100 is typically located near the surface. The power source may be configured to pump fluid from the offshore location through the umbilical cord connected to the connectors 205 in order to operate the components of the tool 100 such as arms 125 and wedge blocks 150 as described herein. In another embodiment, the tool 100 may be manipulated using a remotely operated underwater vehicle (ROV). In this embodiment, the ROV may attach to the tool 100 via a stab connector 215 and then control the control system 230 of the tool 100 in a similar manner as described herein. The ROV may also manipulate the position of the tool 100 relative to the wellhead by using handler members 220 .
As illustrated in FIG. 1 , the tool 100 may be attached to a downhole assembly such as a motor 115 and a rotary cutter assembly 105 . The motor 115 may be an electric motor or a hydraulic motor such as a mud motor. The rotary cutter assembly 105 includes a plurality of blades 110 which are used to cut the casing. The blades 110 are movable between a retracted position and an extended position. In another embodiment, the tool 100 may use an abrasive cutting device to cut the casing instead of the rotary cutter assembly 105 . The abrasive cutting device may include a high pressure nozzle configured to output high pressure fluid to cut the casing. The use of abrasive cutting technology allows the tool 100 to cut through the casing with substantially no downward pull or torque transmission to the wellhead which is common with the rotary cutter assembly 105 . In another embodiment, the tool 100 may use a high energy source such as laser, high power light, or plasma to cut the casing. The high energy cutting system may be incorporated into the tool 100 or conveyed to or through the tool 100 via a transmission system. Suitable cutting systems may use well fluids, and/or water to cut through multiple casings, cement and voids. The cutting systems may also reduce downward pull and subsequent reactive torque transmission to the wellhead.
FIG. 2 is a view illustrating the placement of the tool 100 on a wellhead 10 . The tool 100 is lowered via the conveyance member until the tool 100 is positioned proximate the top of the wellhead 10 disposed on a seafloor 20 . As the tool 100 is positioned relative to the wellhead 10 , the motor 115 and the cutter assembly 105 are lowered into the wellhead 10 such that the blades 110 of the cutter assembly 105 are adjacent the casing string 30 attached to the wellhead 10 . Generally, the wellhead 10 includes a profile 50 at an upper end. The profile 50 may have different configurations depending on which company manufactured the wellhead 10 . The arms 125 of the tool 100 include a matching profile 165 to engage the wellhead 10 during the wellhead retrieval operation. It should be noted that the arms 125 or the profile 165 on the arms 125 may be changed (e.g., removed and replaced) with a different profile in order to match the specific profile on the wellhead 10 of interest. The arms 125 are shown in an unclamped position in FIG. 2 and in a clamped position in FIG. 3 .
FIG. 3 illustrates the tool 100 engaging the wellhead 10 . The tool 100 includes an actuating cylinder 135 (e.g. piston and cylinder arrangement) that is attached to the arm 125 . As the cylinder 135 is actuated by the power system, the arms 125 rotate around pivot 130 from the unclamped position to the clamped position in order to engage the wellhead 10 . It must be noted that the arms 125 may be individually activated by a respective cylinder 135 or collectively activated by one or more cylinders. As shown, the profile 165 on the arms 125 mate with the corresponding profile 50 on the wellhead 10 . After the arms 125 have engaged the wellhead 10 , the arms 125 are locked in place by activating a locking cylinder 155 (e.g. piston and cylinder arrangement) which causes a wedge block 150 to slide along a surface of the arm 125 as shown in FIG. 4 . The movement of the wedge block 150 prevents the arms 125 from rotating around the pivot 130 to the clamped position. It must be noted that the wedge blocks 150 may be individually activated by the respective cylinder 155 or collectively activated by one or more cylinders.
FIG. 4 is a view illustrating the tool 100 cutting a casing string 30 below the wellhead 10 . After the arms 125 are locked in place by the wedge block 150 , an optional cylinder 180 (e.g. piston and cylinder arrangement) is activated that causes a shoe 175 to act upon a surface 25 of the wellhead 10 and axially lift the tool 100 relative to the wellhead 10 . The axial movement of the tool 100 relative to the wellhead 10 allows for active clamping of the tool 100 on the wellhead 10 . For instance, as the tool 100 moves relative to the wellhead 10 , the profile 165 on the arms 125 moves into maximum contact with the profile 50 on the wellhead 10 such that the tool 100 is clamped on the wellhead 10 and will not rotate (or spin) relative to the wellhead 10 when the rotary cutter assembly 105 is in operation. In this respect, reactive torque resistance is provided for the mechanical cutting system. After the tool 100 is fully engaged with the wellhead 10 , the motor 115 activates the rotary cutter assembly 105 and the blades 110 move from the retracted position to the extended position as illustrated in FIG. 3 to FIG. 4 . Thereafter, the casing string 30 is cut by the rotary cutter assembly 105 . It should be noted that the cylinders 135 , 155 , 180 may be independently operated by the power source or by the ROV. Additionally, it is contemplated that cylinders 135 , 155 , 180 may include any suitable number of cylinders as necessary to perform the intended function.
FIGS. 5A and 5B are enlarged views illustrating the components of the tool 100 . The conveyance member may be pulled from the surface to enhance the clamping of the tool 100 on the wellhead 10 . The upward force applied to the tool 100 by the conveyance member causes an inner mandrel 170 to move from a first position ( FIG. 5A ) to a second position ( FIG. 5B ). As illustrated in FIGS. 5A and 5B , the inner mandrel 170 includes a key member 190 . It should be noted that the key member 190 may be a separate component attached to the inner mandrel 170 as illustrated or the key member 190 may be formed as part of the mandrel 170 as a single piece. As shown in FIG. 5B , the inner mandrel 170 has moved axially up relative to the wellhead 10 . As a result, the inner mandrel 170 (and/or the key member 190 ) contacts and applies a force to a surface 120 of the arms 125 which increases (or enhances) the gripping force applied by the arms 125 to the profile 50 on the wellhead 10 . In other words, the inner mandrel 170 applies the force to the arms 125 and that force is transferred due to the shape of each arm 125 (i.e. lever) and the pivot 130 into the gripping surface which grips the profile 50 , thereby enhancing the grip on the profile 50 .
The conveyance member connected to the tool 100 may also be pulled from the surface (i.e., offshore location) to create tension in the wellhead 10 and the casing string 30 . As the conveyance member is pulled at the surface, the tool 100 , the wellhead 10 , and the casing string 30 are urged upward relative to the seafloor 20 which creates tension in the wellhead 10 and the casing string 30 . The tension created by pulling on the conveyance member may be useful during the cutting operation because tension in the casing string 30 typically prevents the cutters 110 of the rotary cutter assembly 105 from jamming (or become stuck) as the cutters 110 cut through the casing string 30 . The upward force created by pulling on the conveyance member is preferably at least equal to any downward force generated during the cutting operation. The upward force is typically maintained during the cutting operation. Optionally, the upward force may also be sufficient to counteract the wellhead assembly deadweight.
During the wellhead retrieval operation, the inner mandrel 170 in the tool 100 may move between the first position as shown in FIG. 5A and the second position as shown in FIG. 5B . In the first position, a portion of the inner mandrel 170 (and/or the key member 190 ) is positioned proximate a stop block 185 as shown in FIG. 5A . In this position, the inner mandrel 170 has moved axially down relative to the wellhead 10 which typically occurs when the tension in the conveyance member attached to the tool 100 has been minimized. In the second position, a portion of the inner mandrel 170 is positioned proximate the surface 120 of the arms 125 . In this position, the inner mandrel 170 has moved axially up relative to the wellhead 10 which typically occurs when the tension in the conveyance member attached to the tool 100 has been increased. Further, in the second position, the inner mandrel 170 (and/or the key member 190 ) contacts and applies a force to the surface 120 of the arms 125 which increases (or enhances) the gripping force applied by the arms 125 to the profile 50 on the wellhead 10 . In other words, the inner mandrel 170 applies the force to the arms 125 and that force is transferred due to the shape of each arm 125 (i.e. lever) and the pivot 130 into the gripping surface which grips the profile 50 , thereby enhancing the grip on the profile 50 .
FIG. 6 is a view illustrating the tool 100 after the casing string 30 has been cut. The cutters 110 on the rotary cutter assembly 105 continue to operate until a lower portion of the casing string 30 is disconnected from an upper portion of the casing string 30 . At this point, the rotary cutter assembly 105 is deactivated which causes the cutters 110 to move from the extended position to the retracted position. Next, the tool 100 , the wellhead 10 , and a portion of the casing string 30 are lifted from the seafloor 20 by pulling on the conveyance member attached to the tool 100 until the wellhead 10 is removed from the sea. After the wellhead 10 is located on the offshore location, such as the floating vessel, the cylinders 135 , 155 , 180 may be systematically deactivated to release the tool 100 from the wellhead 10 .
In operation, the tool 100 is lowered into the sea via the conveyance member until the tool 100 is positioned proximate the top of the wellhead 10 disposed on the seafloor 20 . Next, the cylinder 135 is actuated to cause the arms 125 to rotate around pivot 130 to engage the wellhead 10 . Subsequently, the arms 125 are locked in place by actuating the cylinder 155 which causes the wedge block 150 to slide along the surface of the arms 125 to prevent the arms 125 from rotating around the pivot 130 to the unclamped position. Thereafter, the cylinder 180 is activated which causes the shoe 175 to act upon the surface 25 of the wellhead 10 and axially lift the tool 100 relative to the wellhead 10 . The axial movement of the tool 100 relative to the wellhead 10 allows for active clamping of the tool 100 on the wellhead 10 . This sequential function is automatically controlled by the onboard manifold or can be manually sequenced as required by the operator or via a ROV. Next, the conveyance member connected to the tool 100 is pulled from the surface (i.e. offshore location) to create tension on the wellhead assembly 10 and the casing string 30 . The motor 115 activates the rotary cutter assembly 105 and the blades 110 move from the retracted position to the extended position to cut through the casing string or multiple casing strings 30 . The wellhead assembly deadweight is born mechanically to leverage the load for increased clamping force on the external wellhead profile to maximize reactive torque resistance capability for high torque cutting. Axial load cylinder 180 function to stabilize and preload grip arms during cutting operation. After the casing string 30 is cut, the tool 100 , the wellhead 10 and a portion of the casing string 30 is lifted from the seafloor 20 by pulling on the conveyance member attached to the tool 100 . When the wellhead 10 is safely located on the offshore location, such as the floating vessel, the cylinders 135 , 155 , 180 may be systematically deactivated to release the tool 100 from the wellhead 10 . At any time during operation, the cylinder function sets 135 , 155 , 180 may be independently controlled and shut down or reversed for function testing, unsuccessful wellhead release, or maintenance as required through surface controls or remotely using a ROV in case of umbilical failure.
FIG. 7 is a view illustrating a subsea wellhead intervention and retrieval tool 200 attached to a perforating tool 215 . For convenience, the components of the tool 200 that are similar to the components of the tool 100 will be labeled with the same reference indicator. As shown in FIG. 7 , the tool 200 has engaged the wellhead 10 in a similar manner as described herein.
The tool 200 may be attached to an optional packer member 205 that is configured to seal an annulus formed between a tubular member 220 and the casing string 30 attached to the wellhead 10 . The packer member 205 may be any type of packer known in art, such as a hydraulic packer or a mechanical packer. The packer member 205 may be used for isolation or well control. Upon activation of the packer member 205 , the packer member 205 moves from a first diameter and a second larger diameter. Upon deactivation, the packer member 205 moves from the second larger diameter to the first diameter. The packer member 205 may be activated and deactivated multiple times.
The tool 200 may be attached to an optional ported sub 210 and the perforating tool 215 mounted on a pipe 225 . It is to be noted that the pipe 225 , the ported sub 210 and the perforating tool 215 may be an integral part of the tool 200 or a separate component that is lowered through the tool 200 via a conveyance member, such as pipe, coiled tubing or an umbilical. Generally, the ported sub 210 may be used in conjunction with the packer member 205 to monitor, control pressure or bleed-off pressure, gas or liquid. The ported sub 210 may also be used to pump cement into the wellbore. In one embodiment, the ported sub 210 is selectively movable between an open position and a closed position multiple times.
The perforating tool 215 is generally a device used to perforate (or punch) the casing string 30 or multiple casing strings, such as casing strings 30 , 40 . Typically, the perforating tool 215 includes several shaped explosive charges that are selectively activated to perforate the casing string. It is to be noted that the perforating tool 215 may also be used to sever or cut the casing string 30 so that the wellhead 10 may be removed in a similar manner as described herein.
In operation, the tool 200 is lowered into the sea via the conveyance member and attached to the wellhead 10 disposed on the seafloor 20 in a similar manner as set forth herein. Next, the optional packer 205 may be activated. The ported sub 210 may also be activated and used as set forth herein. Additionally, the perforating tool 215 may be used to perforate (or cut) the casing string. The tool 200 may further be used to remove the wellhead 10 in a similar manner as described herein.
FIG. 8 is a view illustrating a subsea wellhead intervention and retrieval tool 250 with the perforating tool 215 disposed on a wireline 255 . For convenience, the components of the tool 250 that are similar to the components of the tools 100 , 200 will be labeled with the same reference indicator. As shown in FIG. 8 , the tool 250 has engaged the wellhead 10 in a similar manner as described herein. As also shown in FIG. 8 , the perforating tool 215 has been positioned in the casing string 30 by utilizing the wireline 255 . This arrangement may be useful if multiple areas are to be perforated by the perforating tool 215 . Further, the use of wireline 255 allows the capability of running the perforating tool 215 in and out of the wellbore multiple times (or runs). Additionally, the tubular member 220 is open ended thereby allowing fluid flow to be pumped through the tubular member 220 .
In operation, the tool 250 is lowered into the sea via the conveyance member and attached to the wellhead 10 disposed on the seafloor 20 in a similar manner as set forth herein. Next, the optional packer 205 may be activated to create a seal between the tubular member 220 and the casing string 30 . Thereafter, the perforating tool 215 may be positioned in the casing string 30 by utilizing the wireline 255 and then activated to perforate (or cut) the casing string. The tool 250 may further be used to remove the wellhead 10 in a similar manner as described herein.
FIG. 9 is a view illustrating a subsea wellhead intervention and retrieval tool 300 with the perforating tool 215 . For convenience, the components of the tool 300 that are similar to the components of tools 100 , 200 will be labeled with the same reference indicator. As shown in FIG. 9 , the tool 300 has engaged the wellhead 10 in a similar manner as described herein. The tool 300 includes the ported sub 210 and the perforating tool 215 . As set forth herein, the perforating tool 215 may be used to perforate (or sever) the casing string 30 or any number of casing strings, such as casing strings 30 , 60 . Additionally, the ported sub 210 may be used in a pressure test and/or to distribute cement 55 which is pumped from the surface.
In operation, the tool 300 is lowered into the sea via the conveyance member and attached to the wellhead 10 disposed on the seafloor 20 in a similar manner as set forth herein. Next, the optional packer 205 may be activated and the ported sub 210 may used as set forth herein. Additionally, the perforating tool 215 may be operated to perforate (or cut) the casing string. The tool 300 may further be used to remove the wellhead 10 in a similar manner as described herein.
FIG. 10 is a view illustrating a subsea wellhead intervention and retrieval tool 350 attached to a cutter assembly 360 . For convenience, the components of the tool 350 that are similar to the components of the tool 100 will be labeled with the same reference indicator. As shown in FIG. 10 , the tool 350 has engaged the wellhead 10 in a similar manner as described herein.
The cutter assembly 360 uses a cutting stream 365 to cut the casing string 30 . In one embodiment, the cutter assembly 360 is a laser cutter. In this embodiment, the laser cutter would be connected to the surface via a fiber optic bundle (not shown). The fiber optic bundle would be used to transmit light energy to the cutter assembly 360 from lasers on the surface. The cutter assembly 360 would direct the light energy by using a series of lenses (not shown) in the cutter assembly 360 toward the casing string 30 . The light energy (i.e. cutting stream 365 ) would be used to cut the casing string 30 or perforate a hole in the casing string 30 .
In another embodiment, the cutter assembly 360 is a plasma cutter. In this embodiment, the plasma cutter would be connected to the surface via a conduit line (not shown). The conduit line would be used to transmit pressurized gas to the cutter assembly 360 . The gas is blown out of a nozzle in the cutter assembly 360 at a high speed, at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal of the casing string 30 . The plasma (i.e. cutting stream 365 ) would be used to cut the casing string 30 or perforate a hole in the casing string 30 .
In a further embodiment, the cutter assembly 360 is an abrasive cutter. In this embodiment, the abrasive cutter would be connected to the surface via a fluid conduit (not shown). The fluid conduit would be used to transmit pressurized fluid having abrasives to the cutter assembly 360 . The pressurized fluid (with abrasives) is blown out of a nozzle in the cutter assembly 360 . The pressurized fluid (i.e. cutting stream 365 ) would be used to cut the casing string 30 or perforate a hole in the casing string 30 . In another embodiment, a chemical or a high energy media may be used with the cutter assembly 360 to cut (or perforate) the casing string 30 .
The tool 350 includes an optional rotating device 355 configured to rotate the cutter assembly 360 . The rotating device 355 may be controlled at the surface or downhole. The rotating device 355 may be powered by electric power or hydraulic power. Generally the rotating device 355 will rotate the cutter assembly 360 in a 360 degree rotation in order to cut the casing string 30 . The speed, direction and the timing of the rotation will also be controlled by the rotating device 355 in order to allow the cutting stream 365 to sever (or perforate) the casing string 30 .
The tool 350 may be attached to an optional anchor device 370 to anchor the tool 350 to the casing string 30 . The anchor device 370 may include radially extendable members that grip the casing string 30 upon activation of the anchor device 370 . Generally, the anchor device 370 is used to stabilize (or centralize) the cutter assembly 360 in the casing string 30 .
In operation, the tool 350 is lowered into the sea via the conveyance member and attached to the wellhead 10 disposed on the seafloor 20 in a similar manner as set forth herein. Next, the optional anchoring device 370 may be used to stabilize (or centralize) the cutter assembly 360 in the casing string 30 . Thereafter, the cutter assembly 360 may be activated to perforate (or cut) the casing string and the cutter assembly may be rotated by using the rotating device 355 . The tool 350 may further be used to remove the wellhead 10 in a similar manner as described herein.
FIG. 11 is a view illustrating a subsea wellhead intervention and retrieval tool 400 with an explosive charge device 405 . For convenience, the components of the tool 400 that are similar to the components of tools 100 , 200 will be labeled with the same reference indicator. As shown in FIG. 11 , the tool 400 has engaged the wellhead 10 in a similar manner as described herein.
The tool 400 includes the explosive charge device 405 for cutting (or perforating) the casing string 30 or any number of casing strings. Generally, the explosive charge device 405 includes several shaped explosive charges that are selectively activated to cut (or perforate) the casing string 30 . The explosive charge device 405 may also include a single massive explosive charge. If the casing string 30 is to be cut, the explosive charge device 405 may include a 360 degree charge which will cut (or sever) the casing string 30 upon activation. In the embodiment illustrated in FIG. 11 , the explosive charge device 405 is part of the tool 400 . It is to be noted, however, that the explosive charge device 405 could be a separate device that is lowered through the tool 405 via a wireline or another type of conveyance member, such as coil tubing, jointed pipe or an umbilical.
In operation, the tool 400 is lowered into the sea via the conveyance member and attached to the wellhead 10 disposed on the seafloor 20 in a similar manner as set forth herein. Next, the explosive charge device 405 may activated to perforate (or cut) the casing string. The tool 400 may also be used to remove the wellhead 10 in a similar manner as described herein.
The subsea tool described herein may be used for subsea well intervention operations, including retrieval of a wellhead from a subsea well. In one embodiment, one or more systems or subsystems of the subsea tool may be controlled, monitored or diagnosed via Radio Frequency Identification Device (RFID) or a radio antenna array. In another embodiment, the components of the subsea tool may be activated by using a RFID electronics package with a passive RFID tag or an active RFID tag. In this embodiment, one or more components in the subsea tool, such as cylinders or an attached downhole assembly such as a cutter assembly, perforating tool, ported sub, anchoring device, etc., may include the electronics package that activates the component when the active (or passive) RFID tag is positioned proximate a suitable sensor. For instance, the subsea tool having a component with the electronics package is lowered into the sea via the conveyance member and positioned proximate the wellhead disposed on the seafloor in a similar manner as set forth herein. Thereafter, the active (or passive) RFID tag is pumped through an umbilical connected to the tool or lowered into the sea. When the active (or passive) RFID tag is detected, the relevant component may be activated. For example, the electronics package in the tool may sense the active (or passive) RFID tag then send a control signal to actuate the gripping arm. The same electronics package may sense another active (or passive) RFID tag and then send another control signal to actuate the wedge block assembly. The same electronics package may sense a further active (or passive) RFID tag and then send a further control signal to actuate the lifting cylinders. In this manner, the tool may be controlled by using the electronics package with the active (or passive) RFID tags. In a similar manner, an electronics package with the active (or passive) RFID tags may be used to activate and control a downhole assembly attached to the tool.
The embodiments describe herein relate to a single subsea wellhead intervention and retrieval tool. However, it is contemplated that multiple subsea wellhead intervention and retrieval tools may be used together in a system. Each subsea wellhead intervention and retrieval tool may be independently powered or linked to a primary subsea power source for simultaneous onsite multiple unit operation.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | The present invention generally relates to methods and apparatus for subsea well intervention operations, including retrieval of a wellhead from a subsea well. In one aspect, a method of performing an operation in a subsea well is provided. The method comprising the step of positioning a tool proximate a subsea wellhead. The tool has at least one grip member and the tool is attached to a downhole assembly. The method also comprising the step of clamping the tool to the subsea wellhead by moving the at least one grip member into engagement with a profile on the subsea wellhead. The method further comprising the step of applying an upward force to the tool thereby enhancing the grip between the grip member and the profile on the subsea wellhead. Additionally, the method comprising the step of performing the operation in the subsea well by utilizing the downhole assembly. | 4 |
This application is the national phase under 35 U.S.C. § 371 of PCT International Application No. PCT/CN01/00127 which has an International filing date of Feb. 16, 2001, which designated the United States of America.
SUMMARY OF THE INVENTION
The invention relates to a cell line specifically expressing mutated human tissue-type plasminogen activator (TNK-TPA), the construction strategy for said cell line and application of the cell line in manufacturing recombinant human tissue-type plasminogen activator
BACKGROUND OF THE INVENTION
Human tissue-type plasminogen activator (t-PA) can dissolve local thrombi in blood vessels and recanalize a blocked vessel by activating plasminogen. At present, Genentech (USA) is the only entity that can produce recombinant human t-PA(rt-PA) at a large scale by means of genetic engineering technology and has developed successfully a rt-PA medicine. The first generation of rt-PA made in this company has become the treatment of choice for thrombotic diseases, but it has some shortcomings First, its price is rather high at $1375 per vial on the international market. Second, its function has some weak points: 1)short half-life, just 3 to 5 minutes; 2)low specific affinity with fibrin; 3) activity and efficacy should be further improved. A much higher dose should be given because of the short half-life. Low specificity and activity give rise to two results. On one hand, there is still 10-20% patient's thrombi that cannot be completely dissolved by rt-PA. On the other hand, it results in fibrinolysis over all the body and affects the normal blood clotting mechanism so as to cause severe complications such as bleeding, especially in the skull and digestive tract.
For the above reasons, some other companies have developed the second generation of rt-PA since the rt-PA was used in the clinical. They modified the rt-PA gene in order to eliminate or improve upon the above weak points. TNK-TPA is a kind of mutated form of rt-PA which is universally researched. For example, Keyt BA, Paoni NF, Refino rt CJ, et al proclaimed “a Faster-acting And More Potent Form of Tissue Plasminogen Activator” ((Proc Natl Acad Sci USA) 1997 Apr. 26; 91(9): 3670-4). It was constructed on the basis of three sites of the t-PA gene by site-directed mutation. Two sites are located in the Kringle function domain, T103N and Q117N; one site is located in the protease domain, “KHRR296-299AAAA” (K296A, H297A, R298A, R299A). T103N adds a glycosylation site which increases specificity of complexing of TNK-tPA and fibrin and decreases its cleanup rate; Q117N destroys combination of K1 region and mannose and the action domain of Kupffer cells in liver, and prolongs half-life; KHRR296-299AAAA destroys the functional region of PAI-1 and prolongs its half-life, too. As for the production of TNK-TPA, it is universal to adopt an ordinary eukaryotic gene expression vector, using CHO cells as the host cell. TNK-TPA integrates randomly into the expression system of the host cell genome. For example, Wu Benchuan, et al, announced the above expression system and preparation method of expressed protein in the article “Purification and identification of recombinant tissue-type plasminogen activator” published in <Development of Biochemistry and Biophysics> (1997, 24 (1):71-75).
DETAILED DESCRIPTION OF THE INVENTION
The inventor discovered two families carrying an extra bi-satellite microchromosome (BM) in these two families with 2 and 3 generations, the BM does no harm to human body. The families show a normal phenotype. Seventeen similar families are reported in the world, and nobody conceived of assembling human gene vector using the small chromosome elements. The applicant put forward the structure Using the FISH technique, it was found that the bi-satellite microchromosomes come from the short arms of human group D or G chromosomes 13, 14, 15, 21 and 22. The short arms of human group D or G chromosomes are nucleolus organizing regions abundant in ribosomal DNA (rDNA). Different polymorphisms with different length exist in these regions in human chromosomes, and the genes in these regions can be actively transcribed in the cell metaphase. Thus it was inferred that specific DNA fragments can be used as a targeting sequence if they were isolated from BM, and the gene of interest can be transferred into the nucleolus organizing region in the short arms of human group D or G chromosomes. There the gene should be relatively highly, stably and harmlessly expressed The following example can prove this strongly.
The inventor at first constructed a specific pUC19 library of the microchromosomes by a micro-dissection method and obtained a single copy fragment by screening the library The fragment was proved by the FISH technique to come from the short arms of human group D or group G chromosomes and the single copy was used as probe to screen a human PAC genomic library. Then, a 120 kb DNA fragment which comes from BM and short arms of human group D or group G chromosomes was confirmed by the FISH technique ( FIG. 1 ). No gene concerned with important physiological function is found by analyzing sequence of this BM specific fragment (BMSF), so it is safe to take it as a target The applicant further used a small fragment from the BMSF as a targeting sequence to construct a gene vector.
Based on above evidence, a gene vector using a DNA sequence without vital physiological function-related gene or a DNA sequence with identity to short arms of human group D or G chromosomes as a targeting sequence can site-directly introduce a desired gene into the short arms of human group D or group G chromosomes and so the cell line according to the invention can then be obtained.
Different vectors can be constructed on the basis of the targeting sequence according to the present technique, and then one can obtain a recombinant vector-TNK-TPA by ligating a TNK-TPA gene into the constructed vector The methods used for constructing the targeting vector and the TNK-TPA vector are common in the art. Using the recombinant above, the desired gene TNK-TPA can be also transferred into a host cell by routine method.
The example of the invention gives in detail the identification of the 120 kb specific DNA sequence from short arms of human group D or group G chromosomes, and the construction of the vector using a 3.8 kb fragment from the 120 kb BMSF as a targeting ing sequence. The full sequence of the vector is given in SEQ ID NO: 1. Then a TNK-TPA gene as a desired gene is ligated into the vector and the recombinant vector-TNK-TPA is achieved. The inserting site of TNK-TPA gene is at nucleotide 5910 of the vector. The bacterial strain containing the recombinant vector-TNK-TPA is preserved in the China Typical Culture Collection Center (Wuhan University, China. Wuhan 430072) on Sep. 29, 2000. The collection number is CCTCCM200032. The depositor names it Escherichia coli JM109/JH-5/pNS-TPA.
According to the above methods, a novel cell line with the desired gene TNK-TPA integrated in the short arms of human group D or group G chromosomes of an E. coli HT1080 cell. The cell line was accepted by China Typical Culture Collection Center (Wuhan University, China. Wuhan 430072) on Aug. 18, 2000. The collection number is CCTCC C200006. The cell line is a human fibrosarcoma cell line, which is human gene-transformed cell. The depositor names it human fibrosarcoma cell line /JH-2/TPA. The preserved cell line is a pure cultivative cell line. The cells may be cultured in 10% calf serum in DMEM, pH 7.0-7.4, at 37° C.
The above cell line can substitute for transformed CHO transformed cells to prepare TNK-TPA.
The purified protein expressed by the cell line of the invention has been confirmed to be the desired protein by Western blotting and amino acid sequence analysis.
The invention provides a novel cell line by site-directedly transferring a recombinant human-source gene vector/TNK-TPA cDNA into D group and/or G group chromosomes of a human HT1080 cell and so provides a method to produce TNK-TPA Compared with the existing technology, the invention dramatically decreases cost of TNK-TPA because of its efficient and stable expression.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows FISH mapping of 120 kb BMSF fragment cloned in PAC.
FIG. 2 is a circular map of the gene vector described in the invention (length of gene vector sequence: 1162 bp); pGEM-7 (8267-11162): vector replication component and prokaryote screening system; TK(1-2840): eukaryote negative screen gene, using TK promoter and TK polyA signal; Neo(4342—5910): eukaryote positive screen gene, using sv40 promoter and sv40 polyA signal; GLS (2841—4341,5911—8267): leading sequence for gene targeting; Cloning site (5910): insert-site of desired gene
FIG. 3 is FISH mapping of targeted TNK-TPA gene in positively a transformed cell colony. This revealed that the TNK-TPA gene has been site-directedly transferred into the short arms of human group D or group G chromosomes by the vector.
FIG. 4 is Western blotting result of purified TNK-TPA protein, 1˜4 are purified TNK-TPA protein, “−” denotes negative control.
EXAMPLE 1
Preparation of a Gene Targeting Sequence of the Invention
1 Isolation of PAC Clone with Gene Targeting Sequence
1.1 Construct BM specific pUC19 library through micro-dissection, PCR, microcloning (Deng H-X, Yoshirua K, Dirks R W, et al. Hum Genet 1992,89:13.) 1.2 Identification of BM Specific Single Copy DNA
(1) preparation of colony matrix membrane: draw 14×12 square wells on two nylon membranes, labeled as A and B, and put into two plates with solid LB, respectively, then pick white clones randomly from library plates and inoculate to the 14×12 square wells of two membranes with same coordinate, add 100 ng single copy DNA to the 13th line as positive control, and then add 100 ng gDNA to 14th line as negative control. Two plates are incubated for 10˜12 hours at 37° C., and membrane B is stored at 4° C. Remove membrane A from plate, and treat on a filter paper soaked by following solution: 10% SDS, 5 minutes, 0.5N NaOH/1.5M NaCl, 3 minutes, 1.5M NaCl/0.5M Tris.HCl, 3 minutes, 2×SSC/0.2M Tris.HCl, 10 minutes, 80° C. vacuum dry 2 hours, keep for use.
(2)Preparation of gDNA Probe
Sample 50˜75 ng gDNA, add sterile water to 11 ml, boil and denature at 100° C. for 10 minutes. The following system is used as a random primer labeling reaction:
2 mM dNTP(dATP − ) 3 μl primer mixture 2 μl Klenow enzyme 1 μl α- 32 p-dATP 3 μl
vortex and mix up thoroughly, incubate 30 minutes at 37° C. Add 8 μl stop mixture, pass through G-50 column to purify probe, withdraw 1/10 of the mixture to conduct liquid scintillation.
(3) Hybridization: colony matrix membrane is immersed in 2×SSC 10 minutes, lightly wipe off colony fragments from the membrane surface. Pre-hybridize at 65° C. in 5 ml hybridization solution over 30 minutes. Sample probe solution to boil and denature 10 minutes at 100° C. according to the concentration of 1.2×10 6 cpm/ml and measure liquid scintillation value, add 5 ml fresh hybridization solution, hybridize with colony lattice membrane over 12 hours at 65° C., and wash membrane according to following conditions: 2×SSC/0.1% SDS, 10 minutes at room temperature, 2×SSC/0.1% SDS, 10 minutes at 65° C., 0.1% ×SSC/0.1% SDS, 10 minutes at 65° C., −70° C., autoradiograph. No or a weak hybridization signal is primarily regarded as single copy.
(4) Sequence analysis, Southern blotting: pick a clone from the corresponding position of membrane B, culture it in one small scale, sequence plasmid DNA extracted. The sequence of single copy DNA shows no similarity compared with the database of GenBank. At last, digest the plasmid by EcoRI enzyme and isolate the insert DNA by random primer method, label the insert by α- 32 p-dATP and hybridize with gDNA digested by EcoRI on a piece of nylon membrane, those showing 1 or 2 hybridization bands are single copy DNA clones.
1.3 Identification of PAC Clone with BM Specific Sequence and Short Arms of Human Group D or Group G Chromosomes
(1) Screen Human PAC gDNA and Acquire Positive Clone
(2) Label 260 bp single copy probe P8-7 with α- 32 p-dATP by random primer method→purify probe by G-50 column (medium granularity)→ready for use 4° C. →immerse 7 PAC membranes in 2×SSC 10 minutes→pre-hybridize 3 hours, 55° C. →denature probe 10 minutes, 100° C. →add to 50 ml hybridization solution purchased commercially to a final concentration of 4.6×10 5 cpm/ml and hybridize with PAC membrane 1 hour 65° C. →wash membrane: 2×SSC, once a time 10 minutes at room temperature, 2×SSC/0.1% SDS, 10 minutes at 65° C. twice→apply to X-ray film, autoradiograph at 70° C. 12 hours→develop X-ray film→read the positive clones.
(3) Randomly pick positive clones and number from five different plates, purchase PAC clone.
1.4 Hybridization of the DNA fragment in PAC clone with metaphase cells confirms that the insert DNA in positive PAC clone originates from short arms of human group D or group G chromosomes through FISH, as the FIG. 1 shows.
The above experimental methods refer to the Molecular Cloning written by J Sambrook et al., second Edition, Cold Spring Harbor laboratory Press, 1989.
2. Isolation of the targeting sequence. Main material: β-agarase(Bio-Labs), Not I Agarose
(1) Digest the plasmid PAC169 by Not I enzyme
(2) Isolate an around 120 kb insert DNA through PFGE.
Pulse electrophoresis conditions electrophoresis buffer: 0.5×TBE High strength Analytical
Grade Agarose: (Bio-Rad, low Melting point agarose LMP) 1%,
Switch time: from two to fifteen second, electrophoresis time: 18 h. voltage: 6v/cm, angle: 120°, temperature: 14° C.
(3) After electrophoresis, stain the gel with EB (0.2 ug/ml) thirty minutes. According to the Marker display, cut that 120 kb DNA band with sterile knife.
(4) Treat the gel cut out by β-agarase and precipitate with enthanol.
EXAMPLE 2
Preparation of Gene Vector of the Invention
1. The Construction of Gene Vector and Induction of Target Gene
1.1 Construct Gene Vector
1.1.1 Nsi I and Stu I (blunt enzyme) digest PAC DNA, run the sample on a common agarose gel, recover the 3.8 kb DNA and purify the DNA by electric elution.
1.1.2 pGEM-TK vector DNA is digested with Hind III, and then digested with Klenow further to generate the blunt ends.
1.1.3 The blunt ends of pGEM-TK/Hind III is further digested with Nsi I.
1.1.4 The purified 3.8 kb/Nsi I+Stu I digested DNA and the Nsi I digested pGEM-TK are ligated for 17 hours at 16° C.
1.1.5 The ligated product is transformed into JM109 competent bacteria, culture 19 hours at 37° C. in an ampicillin plate.
1.1.6 Randomly pick single clones and identify the positive clones with Nsi I and Nhe I double digestion.
1.1.7 The plasmid pCDN-GPR is digested with Xba I and Nhe I to acquire the XbaI+NheI digested Neo gene.
1.1.8 Construct pNS2 gene vector by ligating the XbaI+NheI digested Neo gene with the pGEM-TK-3.8 kb/Nhe I fragment.
2.1 Induction of TNK-TPA Gene
2.1.1 Clone TNK-TPA (CDS) into pcDNA 3.1(-).
2.1.2 Design the primers TPCF and TPCR to amplify TNK-TPA gene and expression element (CMV promoter and BGH polyA signal), Avr II restrictive sites are added to the two ends of the primers.
Primer Sequence:
(SEQ ID NO:2)
TPCF:
ATGCAT CCTAGG GGAGGTCGCTGAGTAGTG
AvrII
(SEQ ID NO:3)
TPCR:
TGCATG CCTAGG TACCCCCTAGAGCCCAG
AvrII
2.1.3 Digest TNK-TPA gene and expression element (CMV promoter and BGH polyA signal) with AvrII, ligate it to the pNS2 vector digested with Nhe I.
2.1.4 Transform the ligated product into recombinant JM109 E. coli to obtain a bacterial strain containing the vector-TNK-TPA (collection number is CCTCC M200032).
The above experimental methods refer to the Molecular Cloning written by J Sambrook et al., second edition, Cold Spring Harbor laboratory Press. 1989.
3 The Gene Vector Extraction
3.1 Material
3.1.1 QIAGEN Plasmid Maxi Kit
3.1.2 Culture Medium: Liquid LB
Trypton
5
g
Yeast extract
2.5
g
NaCl
2.5
g
Add H 2 O to
500
ml
Sterilize by autoclaving
3.1.3 Ampicillin: 100 mg/ml (1000×)
3.2 Method
1) Pick positive single clones and inoculate them in 3 ml LB (Amp+), incubate for 1 h at 37° C., 250 rpm. 2) Inoculate 100 ul of primary culture in 100 ml LB (Amp+), incubate for 16 h at 37° C., 250 rpm. 3) Harvest the bacteria by centrifugation at 6000×g for 15 minutes at 4° C. 4) Resuspend the bacterial pellet in 10 ml of buffer P1. 5) Add 10 ml of buffer P2, mix gently but thoroughly 6 times, and incubate at room temperature for 5 minutes. 6) Add 10 ml of chilled buffer P3, mix gently by inverting 6 times, and incubate on ice for 20 minutes. 7) Centrifuge at 2000×g for 30 min at 4° C. 8) Transfer supernatant containing plasmid DNA promptly into a 40 ml high-speed centrifuge tube and centrifuge at 2000×g for 15 min at 4° C. 9) Equilibrate a QIAGEN tip 500 by applying 10 ml buffer QBT. 10) Transfer the supernatant to the QIAGEN-tip 500 and allow it to pass through this column. 11) Wash the QIAGEN-tip with 30 ml buffer QC. 12) Elute DNA with 15 ml QF and collect elution. 13) Precipitate DNA by adding 10.7 ml (0.7 volumes) isopropylalcohol to the elution, mix up. 14) Centrifuge immediately at 15000×g for 30 min at 4° C. 15) Remove the supernatant, wash DNA pellet with 5 ml of 70% ethanol and centrifuge at 15000×g for 10 min. 16) Remove the 70% ethanol, air-dry the pellet for 10 min, and dissolve the DNA in TE solution.
EXAMPLE 3
Transfer the recombinant vector-TNK-TPK acquired in the example 2 into host cell HT1080, obtain the required cell lines after screening, and express in vitro, confirms site-directed integration and high efficiency expression.
1 Material
1.1 Cell: HT1080
Culture Medium: High Sugar DMEM+10% FBS(HT1080) EMEM+10% FBS
1.2 Electroporation apparatus: purchased from Bio-Rad Company.
2. Methods
1) Culture the cells in a 75 cm 2 culture bottle to 70%˜80% confluence. 2) Harvest the cells and wash with HeBs Buffer for two times, then account the cells. 3) Centrifuge at 15000 rpm at 4° C. for 10 min. 4) Resuspend the cells with a reasonable volume of HeBS Buffer to make the cell density to 10 6 ˜10 7 /ml. 5) Add 0.8 ml suspension (about 10 μg DNA vector) to an 0.4 cm electroporation cuvette 6) Electroporate the suspension, parameters: 260V, 550 uF for 11˜13 ms. 7) Transfer the shocked cells to a 75 cm 2 culture flask, add 14 ml culture medium with ampicillin/streptomycin, then culture in 37° C., 5% CO 2 for 24˜48 hrs. 8) Screen the cell with G418 (final concentration of 300 μg/ml), change medium every 2-3 days, in parallel, normal cells are used as a control. 9) Calculate the survival clone number in transfected cells after normal cells completely die in 7-10 days, and then add G418 (150 μg/ml) to maintain surviving clones. 10) Continue to screen the transfected cells with GCV (the ultimate concentration of 500 ng/ml) 11) Most cells die in 7-10 days, add GCV 250 μg/ml to remaining living cells or withdraw GCV, culture the cell up to 70%˜80% confluence, and determine the expression activity of the transfected gene.
3 Results
The TNK-TPA gene with the vector were transferred into HT1080 cells by electroporation and the positive cell lines were obtained after positive and negative screening (Collection NO. CCTCC: C200006), and confirmed to be site-directed insertion by FISH ( FIG. 3 ). The results of assay of TNK-TPA activity are shown in Table 1.
Expression activities are: negative control HT1080 cells is 0 U/106 cells/24 hrs, the positive HT1080 cells is 408 U/106/24 hrs after transfer and 407 U/106 cells/24 hrs after 95 days. The expression of TNK-TPA is highly stable. In addition, the expressed protein of TNK-TPA is proved by Western Blotting and amino acid sequencing ( FIG. 4 ).
TABLE 1
The results of activity assay of TNK-TPA for positive
HT1080 cells(ug/10 6 cells/24 hrs)
The days
The days
of transfer
T1*
of transfer
T15*
33
408
54
188
37
396
58
204
60
411
95
114
68
430
74
430
88
441
90
440.9
95
407
*T1, T15 are two positive cell lines expressing TNK-TPA
4 The Technology of TNK-TPA Protein Preparation
1) Culture TNK-TPA/HT1080 cell line with DMEM medium till 80% confluence, and continue to culture them with serum-free, collect the supernatant after 24 hrs which containing expressed TNK-TPA; 2) Filtrate the supernatant with 0.22 μm filter membrane. 3) Concentrate the filtrate 7 times with 10 KD ultrafiltration membrane. 4) Pass through PROSEP-LYSINEII chromatography media column. 5) Wash out the nonspecific protein absorbed on the column with 5× column volume of 0.05M PB buffer (pH 7.0). 6) Elute TNK-TPA protein bound to the column with 0.2M Arginine/0.05M PB (PH7.5); 7) Desalt protein solution with 3 KD ultrafiltration membrane, lyophilize it into powder dosage. | The invention involves a cell line which can express human mutated tissue-type plasminogen activator (TNK-TPA), and its preparation methods. The collection number of cell lines in this invention is CCTCC C200006. We first used a DNA fragment from the short arms of human group D or group G chromosomes or its homolog to construct a recombinant human source gene vector-TNK-TPA (collection number is CCTC m200032); TNK-TPA gene is then incorporated into the target site in the nucleolus organizing region (NOR) of human group D or G chromosomes in host cell line HT1080; of which the recombinant cell line is attained after screening. The recombinant cell line can be used for manufacturing protein. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of and claims the priority benefit of U.S. patent application Ser. No. 13/205,433, filed Aug. 8, 2011, and titled, “Low Interconnect Resistance Integrated Switches,” which claims priority benefit of U.S. provisional application No. 61/372,513, filed Aug. 11, 2010, and titled “Field Effect Transistor and Method of Making Same.” The above-referenced applications are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to compound semiconductor devices and, more particularly to field effect transistors.
BACKGROUND
“Performance per watt” is a key differentiator for smart phones, tablets, notebook PCs and other portable electronic systems. These systems require more computing performance and functionality, lower power consumption for longer battery life and smaller, thinner form factors. Such systems use multiple DC-DC voltage converters to reduce the 3-20 Volts supplied by one or more batteries to the 0.5-1 Volts required by processors, memories, displays, and other components.
Today's inefficient voltage converters waste power when they generate heat which often must be managed, shortens battery life, and limits system performance. The switches used in voltage converters may be a key determinant of the converters' efficiency and performance. Given the preponderance of portable electronic systems throughout the world, reducing the amount of energy wasted in voltage converters may significantly contribute to global energy conservation.
SUMMARY OF THE INVENTION
The present invention relates to field effect transistors (FETs) and methods of making them include using three-dimensional interconnect technology, namely, the Sarda design and compound semiconductor substrate material. FETs accordingly to embodiments of the present invention comprise compound semiconductor materials, for example Gallium Arsenide (GaAs) and Gallium Nitride (GaN). In embodiments of the present invention, methods for manufacturing FET devices include metal posts created on each source and drain finger in a pattern, and are embedded in an oxide layer covering the entire surface of the device; a corresponding wafer with interconnect patterns and metal posts may be chemically treated and aligned with the oxide layer, creating strong oxide-oxide bonds. A patterned metal layer may be separated by a dielectric material created using a copper damascene process. Structures according to the present invention may provide narrowed source and drain fingers, and alternating with others that are wide enough to support the Sarda design.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings, as they support the claimed invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a starting material according to a typical process.
FIG. 2 illustrates starting materials for fabricating field effect transistors (FETs) according to embodiments of the present invention.
FIG. 3 depicts a seed metal deposition step according to embodiments of the present invention.
FIG. 4 illustrates a photoresist patterning step according to embodiments of the present invention.
FIG. 5 shows a metallization and lift-off followed by a seed metal etching step according to embodiments of the present invention.
FIG. 6 depicts an oxide deposition step according to embodiments of the present invention.
FIG. 7 illustrates a chemical mechanical planarization (CMP) process step according to embodiments of the present invention.
FIG. 8 shows singulation and die bonding steps according to embodiments of the present invention.
FIG. 9 shows an optional bonded die thinning step according to embodiments of the present invention.
FIG. 10 shows a contact pad via etching step according to embodiments of the present invention.
FIG. 11 shows a cross-sectional image of a FET according to embodiments of the present invention.
FIG. 12 depicts a typical monolithic microwave integrated circuit (MMIC).
FIG. 13 illustrates a MMIC application of the FET according to embodiments of the present invention.
FIG. 14 illustrates a multi-chip assembly flow diagram according to embodiments of the present invention.
FIG. 15 shows a typical power FET.
FIG. 16 illustrates a post pattern on a device wafer according to embodiments of the present invention.
FIG. 17 illustrates a post pattern on an interconnect substrate according to embodiments of the present invention.
FIG. 18 illustrates a bonded structure for a FET according to embodiments of the present invention.
FIG. 19 shows a cutaway view of copper vias between first and last metal layers according to embodiments of the present invention.
FIG. 20 illustrates a cross-sectional view of the bonded structure illustrated in FIG. 19 .
FIG. 21 shows a cutaway view of a first metal layer illustrated in FIG. 20 .
FIG. 22 illustrates a power FET according to embodiments of the present invention.
FIG. 23 illustrates a comparison between a typical power FET and a power FET according to embodiments of the present invention.
FIG. 24 is a schematic diagram of a push-pull amplifier including a typical balanced pair of power FET devices.
FIG. 25 is a schematic diagram of a balanced amplifier including a typical balanced pair of power FET devices.
FIG. 26 illustrates post connections between first and last level metal according to embodiments of the present invention.
FIG. 27 depicts a balanced power FET first level metal view according to embodiments of the present invention.
FIG. 28 illustrates a typical power amplifier circuit board.
FIG. 29 shows post connections between first and last level metal according to embodiments of the present invention.
FIG. 30 shows a multi-port power FET first level metal view according to embodiments of the present invention.
FIG. 31 illustrates a comparison between the power device on the circuit board of FIG. 28 and the multi-port power FET according to embodiments of the present invention.
FIG. 32 is a schematic diagram of a typical buck converter.
FIG. 33 illustrates the source, drain and gate metal pattern for a gFET™ device according to embodiments of the present invention.
FIG. 34 shows a post pattern on the gFET™ device according to embodiments of the present invention.
FIG. 35 depicts a post pattern on the interconnect substrate according to embodiments of the present invention.
FIG. 36 illustrates the bonded structure of combined FIGS. 33 and 34 according to embodiments of the present invention.
FIG. 37 is a cut-away view of copper vias between first and last metal layers according to embodiments of the present invention.
FIG. 38 shows a cross-sectional view of the bonded structure of FIG. 37 .
FIG. 39 is a cut-away view of the first metal layer of FIG. 38 .
FIG. 40 illustrates a gFET™ device according to embodiments of the present invention.
FIG. 41 is a schematic diagram with the gFET™ device illustrated in FIG. 32 in a converter according to embodiments of the present invention.
FIG. 42 is a schematic diagram of a dual gFET™ switch fabric according to embodiments of the present invention.
FIG. 43 is a schematic diagram of a variable resistance ratio gFET™ switch fabric according to embodiments of the present invention.
FIG. 44 illustrates a layout for the source, drain and gate metal pattern for a gFET™ device according to various embodiments of the present invention.
FIG. 45 illustrates a layout for the source, drain and gate metal pattern for a gFET™ device according to further embodiments of the present invention.
FIG. 46 is a table providing a comparison of compound-semiconductor switch devices fabricated with a typical layout and three layouts according to embodiments of the present invention.
FIG. 47 is a comparison between a compound semiconductor switch and a gFET™ switch according to embodiments of the present invention.
FIG. 48 is a tabular comparison between a MOSFET and a gFET™ device according to embodiments of the present invention.
FIG. 49 is a graph depicting performance characteristics of a typical Gallium Nitride (GaN) switch devices and a projected gFET™ device according to embodiments of the present invention.
FIG. 50 is a graph illustrating a comparison between 30V Trench and Lateral Power MOSFETs devices, and a gFET™ device according to embodiments of the present invention.
FIG. 51 is a graph illustrating a comparison of the measured efficiency of a Buck Converter using the GaNpowIR Gen 1.1 compound semiconductor switch device shown in FIG. 49 compared to typical MOSFET-based Buck Converters.
FIG. 52 illustrates a post pattern on a Cascode FET according to embodiments of the present invention.
FIG. 53 is a schematic diagram of a Cascode device according to embodiments of the present invention.
FIG. 54 illustrates a post pattern on interconnect substrate for the embodiment of FIG. 52 .
FIG. 55 illustrates a bonded structure.
FIG. 56 is a cut-away view of copper vias between first and last metal layers of FIG. 55 .
FIG. 57 shows a cutaway view of a first metal layer according to embodiments of the present invention.
FIG. 58 illustrates a Cascode FET according to embodiments of the present invention.
DETAILED DESCRIPTION
FETs, particularly those fabricated from wide band gap compound semiconductors (CS) are usefully applied in switch applications, as they include a combination of high blocking, or off-state, resistance with a low on-state resistance, and fast switching speed. These devices typically have an on-state resistivity of approximately 1 Ohm-mm. In order to achieve on-state resistances in the milli-Ohm range, very large FETs with gate peripheries in the range of many millimeters are required. Typical power FET device layouts usually have large footprints, which require a lot of expensive wafer surface for each die. In contrast, a gFET™ switch device according to embodiments of the present invention is more surface area efficient. Since the cost of a FET device chip is inversely related to its area, because the cost of processing a given wafer is fixed, minimizing the size of the device chip means more die will be obtained from a given wafer and thus each die will be less expensive to manufacture. Therefore embodiments of the present invention, for example the gFET™ device, may be significantly less expensive to manufacture than a comparable switch device using a typical CS power device structure, thereby addressing the problems with typical CS FETs and methods of manufacturing them.
In a layout for a typical FET, having a drain metal, source metal, and gate metal, the source and drain fingers may be about 30 microns each in width and the channel in which the gate may be positioned may be 5 microns in length, which are typical for a CS power FET device. As used herein, the corresponding short dimension of the gate structure is referred to as its length and accordingly the other dimension is its width. It may be possible with a basic layout for a typical FET to have some reduced source and drain finger widths, which may be helpful for compacting the device to a some degree. For example, considering representative dimensions for typical FETs, if the source and drain finger widths were 7 microns each then the same symmetrical unit cell (now illustrated as 72×100 microns in dimension) encompasses three (3) times the gate width at 600 microns (an increase in the gate width to area ratio by 2.9 times). However, the channel length would not be shrunk proportionately because of the various device performance restrictions, such as breakdown voltage. Also, the ability to shrink the source and drain finger widths in particular may be limited in typical power FET layouts, because of lithography constraints associated with the typical interconnect technology as well as thermal and current density considerations. If the source fingers are interconnected using air bridge technology, there may be a minimum width to ensure compatibility with the lithography demands of that process step. While there are other methods for creating an air bridge, for example, over a gate busbar, that may change requirements, there continue to be constraints associated with typical devices that include the essentially two dimensional die layout. Tradeoffs include efficient use of the area, complexity of the process, and thermal issues and electrical considerations, such as DC resistive losses, RF losses, and RF phase variations.
For interconnecting multiple source, gate and drain fingers to one or several points, there may be some crossing via air bridge, such as source crossing each gate-drain gate combination, to get to the next source or a pad for connection. Since the connections may be made in three dimensions from a two dimensional surface, these connections may be made up, over, or under the device. Given all these constraints, typical power FET devices typically require source and drain fingers that are at least about 20-30 microns in width.
To address and resolve issues, the Sarda design provides for size-minimized field effect transistors (FETs) and devices made therefrom, and methods of making them using three-dimensional interconnect technology. The FET structure further includes a patterned metal layer, constructed and configured for providing a conductive path to form interconnects between the source and the drain, the metal layer being separated by a dielectric material created, for example, using a copper damascene process. Structures according to the present invention may provide narrowed source and drain fingers, alternating with others that are wide enough to support the Sarda design. FETs accordingly to embodiments of the present invention comprise compound semiconductor materials, for example Gallium Arsenide (GaAs) and Gallium Nitride (GaN). Advantageously, the size of the power FET according to construction, configuration and methods of making according to the present invention provides for substantially reduced, or eliminated, out-board bonding pad areas and other regions that would normally be needed with typical devices that use other interconnect techniques.
Other elements, in addition to the compaction solution provided by embodiments of the present invention, may include: 1) novel device layouts only possible with the FET design of the present invention; and 2) the fact that device layouts and designs of the present invention provide that the gate fingers are fed from both ends, thereby improving yield.
Referring now to the drawings generally, illustrations are for the purpose of describing various embodiments of the invention and are not intended to limit the invention thereto. The figures are provided to demonstrate several illustrations of embodiments constructed and configured according to embodiments of the present invention.
FIG. 1 illustrates a starting material according to a typical process.
FIG. 2 shows a step according to embodiments of the present invention.
FIG. 3 shows a seed metal deposition step according to embodiments of the present invention.
FIG. 4 shows a photoresist patterning step according to embodiments of the present invention.
FIG. 5 shows a seed metal etch step according to embodiments of the present invention.
FIG. 6 shows an oxide deposition step according to embodiments of the present invention.
FIG. 7 shows a chemical mechanical planarization (CMP) process step according to embodiments of the present invention.
FIG. 8 shows singulation and die bonding steps according to embodiments of the present invention.
FIG. 9 shows an optional bonded die thinning step according to embodiments of the present invention.
FIG. 10 shows a contact pad via etching step according to embodiments of the present invention.
FIG. 11 shows a cross-sectional image of a FET according to embodiments of the present invention.
FIG. 12 illustrates a typical monolithic microwave lintegrated circuit (MMIC), including a photograph of a power amplifier. Its area and size extends to include about 10 pads around the periphery for connecting the chip to the circuit. This area for the pads may increase the overall size of a typical MMIC, when compared with the smaller MMIC application of the FET according to embodiments of the present invention, which may essentially eliminate any area associated with pads (i.e., outboard area), since they are positioned above the active area of the chip rather than outboard from it.
FIG. 13 illustrates an MMIC application of the FET according to embodiments of the present invention. The embodiments of the present invention may omit wire bonds and associated pads for connecting the device. Instead, embodiments may advantageously include posts, that functionally replace the wire bonds, and which are very small. For example, on a scale as illustrated in the FIG. 13 , the posts are shown to be approximately thirty (30) times their actual size. Thus, FIG. 13 illustrates that the peripheral area may be significantly reduced. In this example, which may be representative of a typical number, the die area may be reduced by about 40%, due only to the elimination of the pad area required by typical devices.
In embodiments of the present invention, the MMIC device may be bonded to the interconnect substrate, with the posts included within that area (not outside in pad area), for making the connections to the circuit from the device via the posts. This illustrates how the devices may be made smaller and therefore cheaper. Other advantages may include that the board, carrier, or interconnect substrate area is correspondingly reduced, because the connections to the MMIC are positioned underneath the chip by at least about the same amount as for the MMIC illustrated in FIG. 13 . The size savings is advantageous, because the MMICs on their corresponding interconnect substrates are often used in smaller devices like mobile phones, where reduction in size of the final electronic device may be commercially important and valuable. The wire bonds themselves may often be a source of failure because if the bonds are not connected properly, they fail, which in turn causes device failure. Since the wire bonds are inductive, they also parasitically degrade the device performance. Such wire bonds may be omitted in the FET devices and their applications according to embodiments of the present invention. In embodiments of the present invention, the elements of the device may be encapsulated in silicon dioxide. In embodiments of the present invention, an external package may be not needed, which saves size and cost. While not depicted in FIG. 13 , the present invention may provide a FET and applications where it is possible to make connections anywhere on the die surface, rather than just the edges of the chips. This may further advantageously allow for manufacturers of devices to simplify their design, which includes many benefits. Examples include lower material cost associated with the die and board; higher yield, due to elimination of assembly failures; better performance, due to the elimination of connection parasitics; more reproducible performance because of the elimination of connection variations; better reliability; and the advantage of multi-chip on-wafer assembly.
FIG. 14 illustrates a multi-chip assembly flow diagram. Various devices are shown which may be individually bonded onto the interconnect wafer (identified as a motherboard in the figure) to create a multi-component that may be tested on wafer. Furthermore, it may be assembled into packaging. This may save space, cost, and component count while at the same time improving performance by reducing interconnection parasitics.
FIG. 15 is a diagram of a typical power FET, illustrating components such as drain bonding pad, gate bonding pad, source metal, drain metal, air bridge source interconnect, and gate fingers. There may be problems associated with the typical power FET layout, including the following:
1) regarding air-bridge interconnect, air-bridge interconnect may be a complicated multi-mask process, which drives the width of the source fingers to be greater than would otherwise be necessary (and the gold plating used may be expensive); 2) regarding bonding pads, the drain and gate pads outboard from the active device, which increases the overall chip area; and the outboard source pads necessary for bonding or via-holes also increase chip size; 3) the drain fingers may be too wide (˜30 μm) to handle high current flow along their length; 4) the gate fingers are fed from one side, which increases the gate finger resistance and reduces the yield.
FIG. 16 illustrates a post pattern on a device wafer according to embodiments of the present invention.
FIG. 17 illustrates a post pattern on an interconnect substrate according to embodiments of the present invention. The layout may enable manufacturing of embodiments including a post-to-post bonding design. If die-to-wafer bonding is not required, then there may be no need to use the post-to-post bonding. Rather, the interconnect structures described as being on the interconnect wafer can, instead, be simple metal layers fabricated directly on top of and above the posts on the device wafer. Nevertheless, the device structure and layout according to embodiments of the present invention have further advantages, as discussed herein.
FIG. 18 illustrates a bonded structure for a FET according to embodiments of the present invention.
FIG. 19 shows a cutaway view of copper vias between first and last metal layers according to embodiments of the present invention.
FIG. 20 illustrates a cross-sectional view of the bonded structure illustrated in FIG. 19 .
FIG. 21 shows a cutaway view of a first metal layer according to embodiments of the present invention in FIG. 20 .
FIG. 22 illustrates a power FET which may be surface mounted according to embodiments of the present invention.
FIG. 23 provides a comparison between a typical FET and a Sarda design power FET according to embodiments of the present invention and includes Table 1.
Power amplifiers may comprise a pair of power FET devices according to embodiments of the present invention in a push-pull amplifier configuration incorporating balun combiners as shown in FIG. 24 , or in a balanced configuration typically using quadrature couplers such as a Lange coupler as shown in FIG. 25 . In either case, the two devices should be as closely identical (e.g., electrically) as possible in power, gain, and linearity at high frequency to yield optimum amplifier performance. However these parameters cannot be measured in individual chips on a wafer, so matched pairs of devices cannot be preselected. Variations in the electrical characteristics of devices across the wafer are due to process and/or mechanical variations, but these are not abrupt. Thus, adjacent devices will typically be better matched electrically than, for example, pairs selected at random. Even devices that are adjacent on the wafer will not be perfectly matched as they are spread out, and not nearly as compact as with embodiments of the present invention. If a process step includes cutting the die with two devices on each die, and one device may be bad, then both are lost, which produces yield losses. In contrast, embodiments of the present invention and the gates thereof may not have this problem, so there may not be substantial yield impact.
FIG. 26 illustrates post connections between first and last level metal on embodiments of the present invention. The interconnection scheme may be shown, with the vertical lines providing a configuration as close as possible to a common ground. This may contribute to stability (i.e., if the chips are physically apart, and there may be a slight difference in the ground path, it may cause oscillation and instability in the amplifier). Accordingly, this balanced power FET may be identical to two single FETs, with two inputs, two outputs, and a common ground as shown.
FIG. 27 illustrates a balanced power FET first level metal view according to embodiments of the present invention. The advantages may include the same advantages of the power FET embodiments of the present invention, which may provide a chip for balanced or push-pull amplifier applications, wherein the devices are physically right next to each other on the wafer, so they may be a high probability of them having identical characteristics, which may be ideal for matching; a true common source on the chip minimizes possible oscillations that would otherwise exist; wire bond inductance may be eliminated with the present invention, which further minimizes oscillations; and the Lange couplers or baluns may be integrated into the interconnection substrate, thereby eliminating separate components.
For a typical power FET, the more gate periphery it has the more power it can generate, but the lower its output impedance will be (a few Ohms or even less). The impedance level of the device may be matched to 50 Ohms. The bigger the difference between the device output impedance and 50 Ohms, the more difficult the matching and the greater the loss of device performance will be. Overcoming a large initial mismatch may include multiple stages of matching, further degrading performance. As a result, large power devices are normally a collection of smaller cells, with individually higher output impedances, connected using a branching tree matching network. FIG. 28 provides an example illustration of a circuit board including a typical Power FET. The chip may be especially long in the vertical direction because there may be a ground point between each of the cells providing the space needed for the via holes in the chip that are used to reach the electrical ground which may be on the back side. Branching of cells may be common in power devices.
FIG. 29 shows post connections between first and last level metal according to embodiments of the present invention. There may be two separate inputs (or one strapped together) and 2 times n outputs, where n could be from 1 to 8 (or more).
FIG. 30 shows a multi-port power FET first level metal view showing two inputs and four outputs according to embodiments of the present invention.
FIG. 31 illustrates a comparison between the device in FIG. 31 and the multi-port power FET according embodiments of the present invention. In this case, the same amount of gate periphery may be in each one of the output connections as in each initial node of a typical device output branching network, but in a much smaller size die. Thus, the goal of increasing the impedance of each of the sections of the device may still be achieved, but with an area-efficient layout. For example, the die may be eight times smaller. The aspect ratio of a typical device may be 11:1, making this chip (which may be typically only 0.1 mm thick) extremely difficult to handle without breaking it. In the present invention, handling may be easier because the die may be nearly square when compared with a typical rectangular geometry, shown in the Figure. In addition to easier handling, there are 24 wire bonds to connect with a typical device on the left side of the figure. In contrast, the present invention may not have wire bonds, so there are advantages with respect to matching. Regarding electrical performance along the length, there may be variation, so the more spread out the device is, the more dephasing that will exist along the long dimension. Thus, the combined effect with these improvements may produce an amplifier with better performance.
Nearly every piece of contemporary electronics includes at least one DC-to-DC converter. A DC-to-DC converter may take a supply voltage and steps it down to the voltage(s) required by other components in the system. Regardless of which voltage(s) is provided, a different voltage may be needed within the electronic equipment (e.g., in a computer there are components including the processor, memory chips, DVD drive, etc. all of which may need different voltages). The conversion efficiency of the circuit (the DC-DC converter) that supplies those voltages may be substantially determined by the switches it uses and the number of phases it has (each phase requiring two switches). For example, portable computers and servers may commonly use six-phase converters.
FIG. 32 is a schematic diagram of a typical buck converter according to embodiments of the present invention, which would be one phase of such a six-phase DC-DC converter. It may consist of two devices: a control FET and a synchronization (sync) FET. The on-resistance of the sync FET may be an important factor in converter efficiency. The lower the target on-resistance, the bigger (in terms of gate periphery) this switch FET may be. In addition, both devices may switch as quickly as possible for best efficiency. This characteristic may be driven by the amount of charge under the gate and the mobility of those charges, since that determines how quickly those charges can be swept out from under the gate turning the switch off. Compound semiconductors have inherently lower on-resistance, lower gate charge, and higher mobility (˜5×) compared with typical MOSFET switches. Embodiments according to the present invention may be manufactured at low cost, and it may have commercial advantages over, for example, MOSFET products. Thus, the present invention may provide a performance advantage at nearly equivalent costs.
FIG. 33 illustrates the compact source/drain/gate metallization pattern enabled by the Sarda design. FIG. 34 shows a post pattern on the gFET™ device fabricated with that pattern; FIG. 35 shows a post pattern on the interconnect substrate; and FIG. 36 illustrates the bonded structure of the combined FIGS. 33 and 34 , all according to embodiments of the present invention. FIG. 37 is a cut-away view of copper vias between first and last metal layers according to embodiments of the present invention. FIG. 38 shows a cross-sectional view of the bonded structure of FIG. 37 . FIG. 39 depicts a cut-away view of the first metal layer of FIG. 38 . FIG. 40 illustrates a gFET™ device which may be surface mounted.
FIG. 41 shows a schematic diagram with the gFET™ device illustrated in FIG. 32 in a converter. All electrical terminals are on one surface facilitating easy bumping and flip die attach. The Vo terminal connects directly to the ohmic metal fingers that are common between the two devices.
Through selection of different interconnect structures, a wide variety of different switch fabric designs can be made from this same basic structure. For example, FIG. 42 shows a dual gFET™ device switch fabric (quad switch device) configured as two separate control/sync pairs with a common input and separate outputs. In this example, the top pair might consist of larger devices (e.g., having lower resistance, higher current handling capability, etc.) and the lower pair could be much smaller devices (e.g., having higher resistance, lower current handling capability, etc.). This latter pair would be suitable for a “baby phase” used when the load is only requiring a small amount of current (such as in standby mode). In embodiments of the present invention, the top pair may be turned off and the overall efficiency of the converter maximized. If the load required high current, on the other hand, both pairs may be on operating in parallel to deliver the maximum amount of energy at an optimal efficiency point. Further embodiments of the present invention may include pairs with identical ratios to support two identical, but separate, phases on the same die (to save space, for example). As would be appreciated by one of ordinary skill in the art, other applications are possible.
Different interconnect structures may yield different configurations, for example, a variable resistance ratio FET switch fabric as shown in FIG. 43 . The control and sync FETs are segmented, but the entire device is a single control/sync pair with one input and one output. Since each of the segments is separately controlled, the resistance ratio between the control and sync FETs can be dynamically adjusted by turning on one or the other or both segments independently in the two FETs. Through choice of resistor values (relative segment sizes) nine different resistance ratios may be possible.
FIG. 44 illustrates a layout for a gFET™ device according to further embodiments of the present invention. And FIG. 45 illustrates a layout for a gFET™ device according to various embodiments of the present invention.
FIG. 46 is a table comparing a typical FET with a typical power FET geometry and three embodiments of the gFET™ device geometry according to the present invention.
With reference to FIG. 37 , a break anywhere in the gate renders a typical device useless. In embodiments according to the present invention, a break may not be fatal because there are feeds from both ends of each gate finger, so the voltage that gets to the break from both directions still can pinch off the channel (turn-off the switch) assuming the break is reasonably small, as may typically be the case. Embodiments of the present invention include a better yield. Coupled with the inherently smaller size of embodiments of the present invention there may be twelve times more good die per wafer using the present invention process and configuration.
48 provides a table comparing a typical MOSFET switch FET and a gFET™ device according to embodiments of the present invention. The on-resistance of typical MOSFET switches for this type of application may be 1.25 milli-Ohms, comparable to the gFET™ device shown in the table. However, the typical MOSFET requires significantly more carriers to achieve such a low on-resistance. This necessarily means more carriers (charge) under the gate (Q g ) and a much higher (worse) FOM (5×) than the gFET™ device. However, the projected size of the gFET™ device may be essentially identical to the packaged MOSFET switch.
FIG. 48 is a typical Gallium Nitride (GaN) switch device and a projected gFET™ device according to embodiments of the present invention. The IR device that has been released (Gen1.1) has a FOM of 30. It is not projected to reach a FOM of 5, a value comparable to what embodiments of the present invention may be expected to achieve, until 2013.
FIG. 50 is a graph illustrating a comparison between 30V Trench and Lateral Power MOSFETs, and a gFET™ device of according to embodiments of the present invention. The right hand line may be roughly a FOM of 140-150. Certain advanced MOSFET devices are on a line with about a FOM of 50-60. The present invention at the time of this application may be expected to achieve a FOM of 5.
FIG. 48 is a graph illustrating the measured efficiency of a Buck Converter using an GaNpowIR Gen 1.1 compound semiconductor switch device shown in FIG. 49 compared to Buck Converters using typical MOSFET devices. The converter efficiency improvement may be 4 percentage points. Considering a converter may be 89% efficient, its loss may be about 11%. If the loss is reduced to 7% (a 4 percentage point improvement), then that corresponds to nearly a 40% reduction in loss. Since the FOM of embodiments of the present invention may be significantly better than that of the GaNpowIR Gen 1.1 device, it may be reasonable to assume that the efficiency improvement of a DC-DC converter using the present invention would be at least as good as that of one using the IR device shown in the Figure.
The average server computer uses about 150 watts. The energy required for cooling and power distribution may be about 2.5× that of the energy consumed by the server itself. So each server requires about 525 watts to operate and cool it. Assuming that electricity costs about 8 cents per kilowatt-hour, the electricity to run each server costs about $1 per day. If the converter efficiency improves by 4%, then the electricity savings per server may be 4 cents per day. Assuming that a gFET™ switch can be sold for a price comparable to a present art MOSFET switch (about $2) then a six-phase DC-DC converter will have $12 worth of gFET™ switches in it. At 4 cents per day electricity savings, those switches pay for themselves in less than one year. That savings doesn't take into account the fact that because the gFET™ switches can operate at higher frequency, the size, and thus the cost, of the converter will be less because the other components in it (inductors, capacitors, etc.) are smaller (and cheaper) for higher frequency operation.
FIG. 52 illustrates a post pattern on Cascode FET according to embodiments of the present invention.
FIG. 52 provides a schematic diagram of a cascode device according to embodiments of the present invention. For a Cascode FET the drain of the smaller (input) device may have a direct connection to the source of the larger (output) device. The gate of the output device may be connected to ground with a capacitor, which may effectively ground the gate at high frequency. Such a cascode configuration creates a two-stage amplifier with high gain but also high output-to-input isolation, which helps prevent the amplifier from oscillating.
FIG. 54 illustrates a post pattern on interconnect substrate for the embodiment of FIG. 52 .
FIG. 55 illustrates a bonded structure.
FIG. 56 may be a cut-away view of copper vias between first and last metal layers for FIG. 55 .
FIG. 57 shows a cutaway view of the first metal layer of the embodiment of the present invention according to embodiments of the present invention.
FIG. 58 illustrates a Cascode FET which may be surface mounted according to embodiments of the present invention. Embodiments of the present invention may incorporate a direct connection between the input device drain and the output device source that may be virtually lossless, because it is integrated directly into the device, which may be a great advantage with the present invention. Also, the large C-shaped section of the ground pad (first level metal) may be separated from the underlying output device gate last level metal by silicon dioxide creating the output gate bypass capacitor, thus also integrated directly into the device.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. Applications of the devices and methods according to the present invention include Power FETs, MMICs, gFET™ devices, push-pull amplifier, and the like, and applications thereof, by way of example but not limitation, servers, personal computers, electric cars, media players, mobile communications devices, portable computing devices, etc. In the example of MMICs, the wire bonds of a typical device may be omitted and instead posts may be used as set forth in the foregoing description, and the die size may be advantageously reduced by more than about 40%. In the example of push-pull amplifiers, which include an input 0-180 degrees power splitter driving two identical devices in anti-phase and a 0-180 degrees output power combiner adding the output power of the two devices in the amplifier load, advantages of the methods and devices according to the present invention provide push-pull power FET for a push-pull amplifier with four (4) times higher device impedance compared to a single-ended device with the same output power, a virtual ground that can be used for more compact and simpler matching structures, and cancellation of even products and harmonics for better efficiency and linearity; these are illustrated in FIG. 24 for a push-pull amplifier schematic and virtual ground and FIG. 25 for a balanced amplifier schematic.
The above-mentioned examples are provided to serve the purpose of clarifying the aspects of the invention and it will be apparent to one skilled in the art that they do not serve to limit the scope of the invention. The foregoing described illustrative embodiments of the present invention are examples of specific implementations in accordance with the inventive principles. It is to be understood that numerous and varied other modifications will occur to those skilled in the art in accordance with these inventive principles. In such cases, the invention is only restricted by the following claims wherein it is defined. | Circuits and systems comprising one or more switches are provided. A circuit includes a first switch formed on a substrate; and a second switch formed on the substrate, the second switch including a first terminal coupled to a third terminal of the first switch. A system includes a supply; a first switch formed on a substrate, the first switch coupled to the supply; a second switch formed on the substrate, the second switch coupled to the first switch; a third switch formed on the substrate, the third switch coupled to the supply; a fourth switch formed on the substrate, the fourth switch coupled to the third switch; and a driver coupled to respective second terminals of the first, second, third, and fourth switches. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority of European Patent Office application No. 08007726.6 EP filed Apr. 21, 2008, which is incorporated by reference herein in its entirety.
FIELD OF INVENTION
The present invention relates to a crack detection system for detecting cracks in a loaded engineering structure. The loaded engineering structures can be, e.g., a wind turbine rotor blade, an airplane wing, a propeller, a helicopter rotor, a structural car part, a concrete building, a concrete water dam, etc.
BACKGROUND OF INVENTION
Cracks and failures in such loaded engineering structures can have severe consequences. Early warning of a propagating crack can save lives and property.
SUMMARY OF INVENTION
A method and a device by which it is possible to detect cracks in a wind turbine rotor blade is disclosed in WO2006/012827A1. A device for monitoring the state of rotor blades on wind power installations measures the structure-borne noise by at least one displacement sensor arranged on the rotor blade. A frequency spectrum is determined from the sensor signals and compared to reference spectra corresponding to defined states of damage and other particular states. From comparing the determined spectrum with the reference spectra the state of the rotor blade can be determined.
Another way of detecting cracks in wind turbine rotor blades is described in Niels Preben Immerkaer and Ivan Mortesen, LM Glasfiber A/S Lunderskov, November 2004. The authors describe to provide three optical fibres running in parallel to the trailing edge of a wind turbine rotor blade. The distances of the optical fibres from the trailing edge are 2 cm, 4 cm, and 6 cm, respectively. A crack developing from the trailing edge will break the optical fibres beginning with the outermost optical fibre, i.e. the optical fibre that is the closest to the trailing edge. From the number of optical fibres of the crack detection system which are broken the urgency state with respect to the crack can be determined. The optical fibres which are used are part of a fibre Bragg grating system (FBG). Such systems utilise a single fibre of a diameter of about 120 μm.
Outgoing from this state of the art it is a first objective of the present invention to provide an advantageous crack detecting system for detecting cracks in loaded engineering structures which can, in particular, be used for crack detection in wind turbine rotor blades.
It is a second objective of the present invention to provide an advantageous method for detecting cracks in an engineering structure.
The first objective is solved by a crack detection system for detecting cracks in a loaded engineering structure and the second objective is solved by a method for detecting cracks. The depending claims contain further developments of the invention.
An inventive crack detecting system for detecting cracks in a loaded engineering structure comprises a light source, optical fibres that are led through the structure, and a means for coupling the light of the light source into the optical fibres. The optical fibres which are used in the inventive crack detection system have diameters below 75 μm.
The fibres used in fibre Bragg grating systems have, as already mentioned, a diameter of about 120 μm. Moreover, these fibres are extremely fragile. Compared to these fibres, the fibres with a diameter below 75 μm are less fragile and their dimensions are comparable with the dimensions of the fibres in a typical glass fibre laminate. Hence, the fibres with diameters below 75 μm are more robust than those fibres used in fibre Bragg grating system and are in particular useful for use in a fibre reinforced laminated structure such as, e.g., a shell of a wind turbine rotor blade.
In order to increase their capacity of transmitting light the fibres can be led through the structure in form of fibre bundles. Such bundles can consist of up to several hundred single fibres which makes the system even more robust as a higher number of fibres gives redundancy to the system and making it, therefore, less vulnerable.
A further advantage of bundling fibres is that in case of an emerging crack not all fibres of a bundle do necessarily brake at the same time. When more and more fibres of the bundle brake, the transmission of light through the fibre bundle decreases. This is a simple and robust way to measure degradation of the engineering structure, which is, in particular useful if the degradation comes slowly. However, even if a crack develops rapidly a determination of the sequence of breaking of the fibres in a bundle can give hints on the development of the crack which may be useful in evaluating the crack.
As single fibres with diameters below 75 μm, e.g., with diameters of about 50 μm, are used, the bundle is compatible with the surrounding fibres if the engineering structure is made from a fibre reinforced laminated structure. Moreover, bundling the optical fibres increases the capacity of transmitting light which enables cracks to be detected by light emerging from broken fibre bundles with the naked eye, in particular by night. Hence, visually finding cracks during an inspection of the engineering structure by visually detecting light which escapes from fibre bundles that are broken due to a crack in the structure becomes possible.
To ensure proper wetting by glue or matrix material in a laminated structure the fibre bundle can be enclosed in a permeable hose, e.g., a braided hose of plastic fibres (typically thermoplastic polyester) or glass fibres. Alternatively, one or more threads could be wound around the fibre bundles to form an enclosure. The thread or threads wound around the fibre bundles, or the permeable hose could be strongly coloured in order to make the fibre bundles easy to locate. This measure can prevent damage of the optical fibres in case of later repair or maintenance work at the composite laminate structure.
A bundle of fibres that is optionally enclosed in a permeable hose or surrounded by one or more threads can be embedded in the laminate structure when the laminate structure is manufactured, or can be embedded in an existing structure like, for example, a wind turbine rotor blade, by cutting a longitudinal groove into the surface, and afterwards gluing the fibre bundle into this groove. Alternatively, fibre bundles can be glued to the outside or the inside of the structure without cutting a groove. If they are glued to the outside of the structure they will not be covered by paint in order to simplify visual detection of escaping light.
If not only a visible detection should be possible, the optical fibres or the fibre bundles can be connected to light detectors. In addition, a modulation unit connected to the first source for modulating it's light and a time gate unit is connected to the detectors for receiving the detector signals could be present. In this case, the signal from the detector could be passed through the time gate to suppress noise and any other unwanted signal, and hence increase the sensitivity. Moreover, the time gate could be delayed relative to the modulation light from the light source and the time delay could be varied. The time delay resulting in the largest registered signal could be used to estimate the distance of the light source from the cut in the optical fibre or the optical fibre bundle which corresponds to the distance of the crack from the light source.
Alternatively or additionally, light detectors could be located at the ends of the optical fibres or the fibre bundles which are opposite to the ends where the light is coupled into the fibres or the fibre bundles. Then, a transmission coefficient determination unit which determines and monitors the transmission coefficients of the optical fibres or the fibre bundles, in particular their individual transmission coefficients, could be used to detect sudden decreases in the transmission coefficient which would indicate a crack that has opened in the blade.
If a crack is positioned, e.g., in a wind turbine rotor blade in such a way that it opens and closes due to gravitational forces as the rotor rotates, the transmission coefficient as determined would vary cyclically with a frequency corresponding to the rotation frequency of the rotor. Thus, the Fourier coefficient of a time series of transmission coefficients which corresponds to this frequency would give an indication of the severity of the damage. Alternatively, the relative difference between the 10% and the 90% quantities of the time series could be monitored.
To allow performing the mentioned method, a frequency detection unit can be present in the crack detection system which is connected to the transmission coefficient determination unit for receiving transmission coefficient signals representing the transmission coefficients of the optical fibres or the fibre bundles and which is designed to determine frequency components in the transmission signals.
In a further alternative, the light source may be a pulsed light source which emits light pulses with pulse lengths in the range below 500 ns. Moreover, a time delay determination unit would be present which determines the time delay between sending a pulse by the light source and receiving the respective pulse by the detector. Then, the intensity of the light scattered back towards the light source from a cut in the fibres representing a crack of the structure could be monitored. A sudden increase in backscattered intensity can be taken as an indication that a crack has opened. The time delay from the emission of the pulse by the light source to the detection of the reflected light could be used to determine the distance of the cut in the fibres from the light source and, hence, the location of the crack in the blade. The short pulse will make sure that the reflected pulse can be separated from the original pulse.
The light source used in the inventive crack detection system could be any of a light-emitting diode (LED), a laser diode, or any other suitable light source. The light detector could be a light sensitive resistor, a photo diode, or any other suitable light detector. As optical fibres glass fibres or plastic fibres, for example, PMMA-fibres, could be used.
In case cracks, i.e. cuts in optical fibres or fibre bundles, are detected by visual inspection, the light source could be switched off between inspections to ensure a longer lifetime of the light source. If, on the other hand, a continuous monitoring is performed, the light source could be switched off intermittently to prolong the lifetime of the light source.
The inventive crack detection system can be used for performing the inventive method for detecting cracks in an engineering structure. In this method the transmission or reflection of light emitted into the optical fibres or the fibre bundles is monitored and a crack is detected by a sudden change of the transmission or the reflection. In particular, if light detectors are located at the same end of the optical fibres or fibre bundles at which also the light source or light sources is/are located, the reflection would be monitored. On the other hand, if the detectors are located at the far end of the fibres or the fibre bundles with respect to the end at which the light source is located, the transmission would be monitored. A sudden change in transmission or reflection would be a reliable indication of a crack in the engineering structure.
When the light is emitted into the optical fibres or fibre bundles in form of light pulses, a time delay of a reflected light pulse with respect to the emitted light pulse can be determined in order to estimate the distance of the crack from the light source.
The severity of a crack can be estimated if a time series of transmission coefficients or reflection coefficients is established and a Fourier analysis of the time series is performed. This is, in particular, advantageous if the engineering structure is a wind turbine rotor blade. If a crack is positioned such in the rotor blade that it opens and closes due to gravitational forces as the rotor rotates, the transmission coefficient or reflection coefficient would vary cyclically with a frequency corresponding to the rotation frequency of the rotor. Thus, the Fourier coefficient corresponding to this frequency would give an indication of the severity of the damage. The higher the Fourier coefficient is, the higher would be the estimated damage.
Alternatively, instead of performing a Fourier analysis of the time series it would be possible to monitor the difference between the 10% quantile and the 90% quantile of the time series. In other words, the full range of transmission coefficient values or reflection coefficient values would be divided into 10 equal intervals where the quantiles would represent the boundaries between these intervals. If the difference between the number of data points below the 10% quantile on the one hand and below the 90% quantile on the other hand is relatively large, this would mean that the distribution is rather narrow. A narrow distribution, however, means a relatively constant transmission coefficient or reflection coefficient. If a crack is opening and closing due to gravitational forces the distribution of transmission coefficient values or reflection coefficient values would spread so that the difference between the number of data points below the 10% quantile and the number of data points below the 90% quantile would be reduced. A crack would be estimated to be more severe if the reduction is high.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features, properties and advantages of the present invention will become clear from the following description of embodiments of the invention in conjunction with the accompanying drawings.
FIG. 1 shows an inventive crack detection system in the context of a wind turbine rotor blade.
FIG. 2 shows a first alternative of arranging the optical fibres or optical fibre bundles of the crack detection system.
FIG. 3 shows a second alternative of arranging the optical fibres or fibre bundles of a crack detection system.
FIG. 4 shows a third alternative of arranging the optical fibres or fibre bundles of a crack detection system.
FIG. 5 shows an optical fibre bundle enclosed by a hose.
FIG. 6 shows an optical fibre bundle enclosed by a threat wound around the fibre bundle.
FIG. 7 shows a detail of the crack detection system shown in FIG. 1 .
FIG. 8 shows a second embodiment of the inventive crack detection system in the context of a wind turbine rotor blade.
FIG. 9 shows a detail of the second embodiment of the crack detection system.
DETAILED DESCRIPTION OF INVENTION
FIG. 1 shows a first embodiment of an inventive crack detection system in a wind turbine rotor blade. Note that the wind turbine rotor blade is only an example for an engineering structure in which the crack detection system can be used.
The wind turbine rotor blade 1 shown in FIG. 1 comprises a root section 3 , a shoulder 5 which adjoins the root section in outward direction of the blade, and an airfoil section 7 which extends from the shoulder 5 to the blade's tip 9 . Furthermore, the blade 1 comprises a leading edge 11 and a trailing edge 13 .
The blade shown in FIG. 1 is equipped with an inventive crack detection system. The crack detection system comprises a plurality of optical fibre bundles 15 in which the single fibres have diameters below 75 μm, a light source 17 which is, in the present embodiment, located in the root section of the blade 1 , and a means 19 for coupling the light of the light source into the fibre bundles 15 . The means for coupling the light into the fibre bundles 15 is indicated in the figure as block 19 . Suitable means for coupling light into optical fibres or fibre bundles are known to those skilled in the art and will therefore not be described here. The light source can be at least one incandescent lamp, one or more super luminescent light emitting diodes, or at least one laser or laser diode.
Although fibre bundles 15 which may contain up to several hundred single optical fibres are used in the present embodiment, the use of fibre bundles is not mandatory. Instead, single optical fibres of diameters below 75 μm could, in principle, be used as well. Whether fibre bundles or single optical fibres which extend through the blade are used depends on the amount of light which shall be transferred through the fibre bundles or optical fibres respectively.
The inventive crack detection system of the first embodiment further comprises a number of light detectors 21 for detecting light reflected back towards the light source, one light detector 21 for each of the optical fibre bundles 15 , in the present embodiment. However, it is also conceivable to use a light detector 21 for a subset of the optical fibre bundles 15 , i.e. to connect more than one fibre bundle to a light detector.
Although the light source 17 , the means 19 for coupling the light into the fibre bundles and the light detectors 21 are shown to be located in the root section in FIG. 1 they could as well be located in a different location, for example, in the rotor hub to which the rotor blade is connected. This would offer the advantage that a single arrangement of a light source, means for coupling light into fibre bundles and light detectors would be sufficient for all rotor blades of the rotor.
FIGS. 2 to 4 show three different options to arrange the optical fibre bundles 15 , or single optical fibres, in the blade 1 . The figures show cross sections through the blade 1 from the leading edge 11 to the trailing edge 13 .
In FIG. 2 the optical fibre bundles 15 are located at the outside of the blade's shell 23 . They could be fixed to the shell 23 by gluing them to the shell's outer surface. In order to minimise the impact of the optical fibre bundles 15 on the aerodynamics of the blade 1 the diameters of the fibre bundles should be as low as possible, i.e. the fibre bundles should consist only of a few single fibres. Gluing at the outside of the blade's shell 23 is, in particular, suitable if single optical fibres are used instead of fibre bundles 15 since their diameters below 75 μm prevents the single optical fibres from having a large impact on the aerodynamics of the blade 1 .
A further option of arranging the fibre bundles 15 , or single optical fibres, is shown in FIG. 3 . Like in FIG. 2 , the fibre bundles 15 are glued to the shell 23 of the wind turbine rotor blade. However, in difference to the option depicted in FIG. 2 the fibre bundles of FIG. 3 are glued to the inner surface of the shell 23 so that they do not have any impact on the aerodynamics of the blade 1 . For the rest, that what has been said with respect to the fibre bundles 15 or optical fibres, respectively, shown in FIG. 2 is also valid for the fibre bundles or fibres shown in FIG. 3 .
A third option of arranging the fibre bundles 15 , or single optical fibres, is depicted in FIG. 4 . In this arrangement, the optical fibre bundles 15 are integrated into the shell 23 of the rotor blade 1 , which is usually a fibre reinforced laminated structure. This means that the optical fibres or optical fibre bundles 15 can be easily integrated into the shell when the shell's laminated structure is formed. The diameter of the single optical fibres, which is below 75 μm and, in particular, in the range of about 50 μm, makes them compatible with the surrounding fibres of a typical fibreglass laminate used for making wind turbine rotor blade shells.
In order to ensure proper wetting of the fibre bundles or fibres by glue or a liquid polymer used in forming the shell 23 , the fibres or fibre bundles can be enclosed in a permeable hose 25 such as a braided hose of plastic fibres, typically thermoplastic polyester, or glass fibres. An optical fibre bundle 15 consisting of a plurality of optical fibres 6 surrounded by a hose 25 is shown in FIG. 5 in a sectional view. Alternatively the fibres 6 of the fibre bundle 15 can be enclosed by one or more threads wound around an optical fibre or an optical fibre bundle, as it is shown in FIG. 6 . Such a hose or thread can be strongly coloured in order to enable easy location of the fibre or the fibre bundle to prevent damage of the fibre or fibre bundle if the shell 23 needs to be revised or repaired.
The way of detecting the crack by use of the crack detection system shown in FIG. 1 will now be described with respect to FIG. 7 . FIG. 7 shows in more detail the light source 17 , the optical fibre bundles 15 , and the light detectors 21 . The means for coupling the light into the optical fibres 15 is omitted in the figure to keep the figure more simple. The crack detection system comprises a modulation unit in form of a pulse generator 29 for generating light pulses which are to be coupled into the optical fibres 15 . The pulse generator 29 can act on the light after this has been emitted by the light source 17 . Such a pulse generator could be realised, for example, in form of a chopping mechanism like a shutter, a chopping wheel, et cetera. Alternatively the pulse generator 29 can act on the light source 17 itself so as to operate the light source 17 in a pulsed mode, i.e. such that the light source 17 itself emits the light in form of light pulses. In the embodiment shown in FIG. 7 , the pulse generator 29 is connected to the light source 17 in order to provide control signals for operating the light source 17 in a pulsed mode with pulse lengths in the range below 500 ns.
The pulse generator 29 is connected to a window generator 31 in a time gate unit 32 which is connected to the light detectors 21 for receiving signals representing detected light. The time gate 32 passes signals to the analyser 33 if they arrive within the time window defined by the window generator 31 . Otherwise the signals from the light detectors 21 would not be passed to the analyser 33 . The window generator 31 is adjustable such that the length of the time window can be adjusted and that the time difference between sending a light pulse and the centre of the time window can be shifted. Hence, the time gate unit 32 is operated as time delay determining unit.
In use of the crack detection system the time window 31 is initially large enough to allow every signal from a light detector to pass towards the analyser. If the blade does not show any cracks the light pulses from the light source 17 will pass the fibre bundles 15 and leave them at the tip ends 35 of the fibre bundles so that the light detectors 21 do not detect any light. However, in case of a crack a cut in the fibre bundle or a part of a fibre bundle could occur which would lead to reflections so that light is reflected back from the crack to at least one light detector 21 . In order to achieve this, the fibre bundles are sufficiently close to each other that a crack which exceeds a given critical dimension would in any case cut a fibre bundle.
Once reflected light is detected by the analyzer 33 the time window is decreased such that its length is sufficiently less than the time between two light pulses. Then the offset of the window's centre with respect to the time of emitting the light pulse is shifted and the intensity received by the light detector 21 is monitored. From the time difference between sending the light pulse and the centre of the time window when the detected light shows a maximum the distance of the cut in the fibre bundle 15 from the detector 21 can be estimated. Hence, the inventive crack detection system not only indicates the presence of a crack but also gives a hint on the location of the crack in the blade. However, if only the presence of a crack is needed to be detected, the time gate 32 and the pulse generator 29 can be omitted since in this case no pulsed emission of light is necessary.
Optical fibre bundles 15 with up to several hundred single optical fibres 6 , e.g. 400 fibres, can be used so as to transmit a large amount of light. In case of a crack a fraction of this light would be reflected to a light detector. The remaining light would leave the fibre bundle and the rotor blade 1 through the cut and the crack, respectively. In such a case one could locate the crack by optical inspection with the naked eye, in particular by night. The light detector would then only be used for triggering an alarm which initiates such an inspection. Moreover, if inspections are performed on a routinely basis the light detectors 21 could be omitted at all since with the use of large optical fibre bundles the crack detection could be fully based on visual inspection with the naked eye by night.
If, on the other hand, the crack detection system as it is shown in FIG. 7 is used, there may be no need to use optical fibre bundles of several hundred fibres, or even no need to use fibre bundles at all, if the sensitivity of light detectors is large enough to detect light which is reflected in few optical fibres or a single optical fibre with a diameter below 75 μm. Then, whether the crack detection system is kept simple with relatively large optical fibre bundles or more complex with small optical fibre bundles or single optical fibres could be made dependent on whether an automated crack detection or a crack detection by regular visual inspections is desired.
However, not only the large amount of light transmitted through a fibre bundle with up to several hundred fibre bundles is an advantage of the bundles but also that incremental breakage of the fibres, one by one, tells a story—in quantity—about the rising damage in the area where the bundle is located. When more and more fibres break, an increase of the intensity of reflected light would be detected at the location of the light source—or a decrease in transmission if the light detectors are located at the far ends of the fibre bundles with respect to the light source. This is a simple and robust way to measure degradation. When the individual broken fibre crack opens and closes during a rotor revolution, the signal is modulated (sinusoidal). A single fibre, however, would only allow to detect a binary signal, like reflection off-reflection on (or transmission on-transmission off).
A second embodiment of the inventive crack detection system is shown in FIGS. 8 and 9 . The second embodiment differs from the first embodiment in the location of the light detectors 21 . Unlike in the first embodiment the light detectors 21 are located at the far ends of the optical fibre bundles 15 rather than at the light source ends. This means that in case of a crack which cuts a fibre bundle 15 the light detectors 21 would not detect an increase of light but a decrease since the transmission is decreased by the crack. Such a crack detection system can be equipped with a transmission coefficient determination unit 37 (see FIG. 9 ) which determines the transmission coefficient through an optical fibre bundle 15 on the basis of the intensity detected by the respective light detector 21 and the known intensity of the light source 17 . A time series generator 38 is connected to the transmission coefficient determination unit 37 for receiving the transmission coefficients and forming the time series of transmission coefficients. Moreover, a frequency detection unit 39 is connected to the time series generator 38 for receiving the generated time series. The frequency detection unit 39 performs a Fourier analysis of the time series and finds the Fourier coefficient of the time series which corresponds to the rotation frequency of the rotor. This transmission coefficient is then output to an analysing unit 41 which is connected to the frequency detection unit 39 and which performs an estimate of the severity of the crack based on the Fourier coefficient. This is possible if the crack opens and closes due to gravitational forces acting on the blade during a rotation cycle since the transmission coefficient of the respective fibre bundle would vary between a maximum value (when the crack is closed) to a minimum value (when the crack is open) with a periodicity which corresponds to the rotational frequency of the rotor.
A large Fourier coefficient would indicate a large impact of the crack on the transmission coefficient which would allow the crack to be estimated as being severe.
A possible alternative to Fourier analysing of the time series would be to monitor the difference between the 10% quantile and the 90% quantile of the transmission coefficient values of the time series. The 10% quantile would represent all values the probability of which to occur would be less than 10%. On the other hand, the 90% quantile would be all values the probability of which to occur would be 90%. If the ratio of the 10% quantile to the 90% quantile would change this would indicate a crack. The degree of change would give an indication of the crack's severity. The reason is that due to the already mentioned gravitational forces the number of high transmission coefficients and the number of low transmission coefficients would increase so that the ratio of the 10% quantile to the 90% quantile would increase as well. A slight increase of the ratio would then mean that only few transmission coefficient values would be detected which lie below the average. In case of a large crack much more transmission coefficient values would be detected which lie well below the average value during a rotational cycle. In this way a large crack would lead to a bigger ratio of the 10% quantile to the 90% quantile as compared to a small crack.
The optical fibres or optical fibre bundles in the inventive crack detection system can be evenly distributed over the blade's cross section they could be unevenly distributed. In particular, the number of optical fibres or optical fibre bundles could be increased in areas of the blade which are more prone to cracks than others. An example is shown in FIG. 4 where the density of fibre bundles in the trailing edge 13 of the blade is increased with respect to the rest of the blade.
The described crack detection system not only allows for detecting cracks in engineering structures like, in particular, wind turbine rotor blades, but allows also for a location and an estimate of the severity of the damage. In case the system should be kept as simple as possible, it can also be designed such that a crack detection with the naked eye is possible, in particular by night. | A crack detection system and a method for detecting cracks in a loaded engineering structure are provided. The system and method include a light source coupled and optical fibers that are led through the structure. The optical fibers have diameters below 75 μm. The light source is coupled to the optical fibers. | 5 |
BACKGROUND OF THE INVENTION
Technical Field
The present invention relates to a variable capacitance device and an antenna device that utilizes the variable capacitance device.
Background Art
In NFC (near field communication) modules used for mobile FeliCa, a phenomenon has been known to occur in which reception sensitivity decreases as a result of the resonant frequency shifting away from 13.56 MHz due to variations in the antenna coil, for example. To correct these shifts in the resonant frequency, frequency adjustment circuits that include capacitors are placed inside the modules, all parts are inspected before the modules are shipped, and the capacitance of the capacitors is minutely adjusted.
Conventionally, switched capacitors, in which FET (field effect transistor) switches are connected in series in a fixed capacitance element, have been used. Switchover settings are then written onto a control IC (integrated circuit) during the pre-shipping inspection, and when NFC is being used, the module switches over to the FET mode and minutely adjusts the capacitance of the capacitor.
However, general-purpose ceramic capacitors, which have become cheaper than FET switches in recent years and which can handle high voltages, have been considered as a possible replacement for FET switches. Ceramic capacitor materials have a property that has been actively utilized: the capacitance decreases as a DC bias voltage is applied.
The capacitance of ceramic capacitors changes over time when bias voltage is applied, however, which is a problem. This has led to consideration of using variable capacitance devices that utilize a plurality of variable capacitance elements that are connected in series and that include a dielectric layer formed via a thin film instead of by sintering.
When creating such a variable capacitance device, it is preferable that variable capacitance elements and resistors be formed upon the same substrate. As part of this process, an insulating moisture-resistant film and a conductive adhesive film are formed on the variable capacitance element portion of the device in order to keep the device moisture resistant. There have been mechanical reliability issues and current leakage problems in such devices, however, depending on certain factors. These factors include the relationship between the insulating moisture-resistant film and an interlayer insulation layer formed on the insulating moisture-resistant film, as well as the properties of the conductive adhesive film.
RELATED ART DOCUMENTS
Patent Documents
Patent Document 1: Japanese Patent Application Laid-Open Publication No. 2011-119482
Patent Document 2: Japanese Patent Application Laid-Open Publication No. 2008-66682
Patent Document 3: Japanese Patent Application Laid-Open Publication No. 2004-207630
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a variable capacitance device and antenna device that substantially obviate one or more of the problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a relatively simple and effective way and structure to prevent current leakage in and increase the mechanical reliability of a variable capacitance device.
Additional or separate features and advantages of the invention will be set forth in the descriptions that follow and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims thereof as well as the appended drawings.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, in one aspect, the present disclosure provides a variable capacitance device, including: a supporting substrate having a plurality of variable capacitance elements formed thereon, the plurality of variable capacitance elements being connected in series, wherein each of the plurality of variable capacitance elements includes: a lower electrode formed over the supporting substrate; a dielectric formed on the lower electrode; and an upper electrode formed on the dielectric, wherein each of the plurality of variable capacitance elements has a separate lower electrode, or at least some of the plurality of variable capacitance elements share a lower electrode, thereby forming a plural set of the lower electrodes that serves as the lower electrodes of the respective variable capacitance elements, wherein the variable capacitance device further includes an insulating moisture-resistant film and a conductive adhesive film that are formed after the upper electrodes for the respective variable capacitance elements have been formed, whereby the insulating moisture-resistant film and the conductive adhesive film are in layers that are positioned at a level higher than a layer in which the upper electrodes are formed, and wherein the conductive adhesive film and the insulating moisture-resistant film have a gap in a plan view between at least some of regions where the plural set of the lower electrodes are respectively formed so as to avoid electrical leakage between said at least some of regions through the conductive adhesive film.
Using a variable capacitance device with such a configuration prevents current leakage from occurring between lower electrode regions.
In addition, the variable capacitance device described above may be configured so as to further include an insulating layer formed on the insulating moisture-resistant film, and the insulating layer may contact a top surface of the supporting substrate at the gap of the conductive adhesive film and the insulating moisture-resistant film.
The above-described variable capacitance device may be used in an antenna device. This would allow for the creation of a higher quality antenna device.
A detailed explanation of the configuration mentioned above will be made in the following embodiments, but the invention itself is not limited to the embodiments.
According to at least some aspects of the present invention, problems related to a moisture-resistant film, which is formed at the same time that variable capacitance elements connected in series are formed in a film, can be resolved.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an example of a circuit configuration of a variable capacitance device according to an embodiment of the present invention.
FIG. 2 is a transparent top view of a basic configuration of a variable capacitance device according to the embodiment of the present invention shown in FIG. 2 .
FIG. 3 shows an equivalent circuit of a variable capacitance device in which leaks occur.
FIG. 4 is a cross-section of the variable capacitance device of FIG. 2 , taken along the line A-A′ of FIG. 2 .
FIG. 5 is another cross-section of the variable capacitance device of FIG. 2 , taken along the line B-B′ of FIG. 2 .
FIG. 6 is a graph for showing the effects of the embodiment.
FIG. 7 illustrates an example of an antenna device according to one aspect of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
FIG. 1 shows an example of a circuit formed in a variable capacitance device according to an embodiment of the present invention. In the variable capacitance device shown in FIG. 1 , a variable capacitance array containing variable capacitance elements C 1 to C 4 is connected in series from a high frequency signal input terminal (Signal(in)) to a high frequency signal output terminal (Signal(out)). In addition, for each of the variable capacitance elements C 1 to C 4 in the variable capacitance array, one end is connected to a ground terminal DC 1 via resistors R 1 to R 3 , and the other end is connected to a control voltage application terminal DC 2 via resistors R 4 and R 5 . The capacitance of the variable capacitance elements C 1 to C 4 in the variable capacitance array changes in accordance with voltage applied between the terminals DC 2 and DC 1 .
FIG. 2 is a transparent top view showing a basic configuration of the variable capacitance device of FIG. 1 in the case that the device is formed of thin films. FIG. 4 is a cross-section of the variable capacitance device of FIG. 2 , taken along the line A-A′ of FIG. 2 . FIG. 5 is another cross-section of the variable capacitance device of FIG. 2 , taken along the line B-B′ of FIG. 2 .
On a supporting substrate ( 1 in FIG. 4 ), lower electrode layers 10 , 11 are formed for two variable capacitance elements, respectively. The variable capacitance elements C 4 and C 3 are created by forming a dielectric layer ( 9 a in FIG. 4 ) and an upper electrode layer 21 , and a dielectric layer ( 9 b in FIG. 4 ) and an upper electrode layer 22 , on the lower electrode layer 10 . In a similar manner, the variable capacitance elements C 2 and C 1 are created by forming a dielectric layer ( 9 c in FIG. 4 ) and an upper electrode layer 23 , and a dielectric layer ( 9 d in FIG. 4 ) and an upper electrode layer 24 , on the lower electrode layer 11 . Resistance layers 15 to 19 , which correspond to resistors R 1 to R 5 in FIG. 1 , are formed on an insulating moisture-resistant film ( 4 in FIG. 4 ) and a conductive adhesive film ( 3 in FIG. 4 ), both of which will be discussed later.
A conductive layer 31 corresponding to a wiring layer is formed on the upper electrode layer 21 . A conductive layer 57 that corresponds to a wiring layer is formed on the conductive layer 31 at an opening in an interlayer insulation layer ( 72 in FIG. 4 ). The conductive layer 57 is connected to a terminal electrode 41 that corresponds to a high frequency signal output terminal. A conductive layer 32 that corresponds to a wiring layer is formed on the upper electrode layer 22 and the upper electrode layer 23 . A conductive layer 33 corresponding to a wiring layer is formed on the upper electrode layer 24 . A conductive layer 58 that corresponds to a wiring layer is formed on the conductive layer 33 at an opening in the interlayer insulation layer ( 72 in FIG. 4 ). The conductive layer 58 is connected to a terminal electrode 44 that corresponds to a high frequency signal input terminal.
Conductive layers 51 , 52 that correspond to wiring layers are formed on the resistance layer 15 at an opening in an interlayer insulation layer ( 5 in FIG. 4 ). The resistance layer 15 is connected to the conductive layer 31 and a conductive layer 34 that corresponds to a wiring layer. In a similar manner, conductive layers 54 , 53 that correspond to wiring layers are formed on the resistance layer 16 at an opening in the interlayer insulation layer ( 5 in FIG. 4 ). The resistance layer 16 is connected to the conductive layer 32 and the conductive layer 34 . Conductive layers 56 , 55 that correspond to wiring layers are formed on the resistance layer 17 at an opening in the interlayer insulation layer ( 5 in FIG. 4 ). The resistance layer 17 is connected to the conductive layers 33 , 34 . A conductive layer 59 that corresponds to a wiring layer is formed on the conductive layer 34 at an opening in the interlayer insulation layer ( 72 in FIG. 4 ). The conductive layer 59 is connected to a terminal electrode 42 that corresponds to the terminal DC 1 that is connected to the ground.
A conductive layer 66 that corresponds to a wiring layer is formed on the lower electrode layer 10 at an opening in the interlayer insulation layer ( 5 in FIG. 4 ), and a conductive layer 36 that corresponds to a wiring layer is formed on the conductive layer 66 . Meanwhile, a conductive layer 60 that corresponds to a wiring layer is formed on the resistance layer 18 at an opening in the interlayer insulation layer ( 5 in FIG. 4 ), and the conductive layer 36 is formed on the conductive layer 60 .
In a similar manner, a conductive layer 65 that corresponds to a wiring layer is formed on the lower electrode layer 11 at an opening in the interlayer insulation layer ( 5 in FIG. 4 ), and a conductive layer 37 that corresponds to a wiring layer is formed on the conductive layer 65 . Meanwhile, a conductive layer 64 that corresponds to a wiring layer is formed on a resistance layer 19 at an opening in the interlayer insulation layer ( 5 in FIG. 4 ), and the conductive layer 37 is formed on the conductive layer 64 .
Furthermore, a conductive layer 61 that corresponds to a wiring layer is formed on the resistance layer 18 at an opening in the interlayer insulation layer ( 5 in FIG. 4 ), and a conductive layer 35 that corresponds to a wiring layer is formed on the conductive layer 61 . A conductive layer 63 that corresponds to a wiring layer is formed on the resistance layer 19 at an opening in the interlayer insulation layer ( 5 in FIG. 4 ), and a conductive layer 35 is formed on the conductive layer 63 . A conductive layer 62 that corresponds to a wiring layer is formed on the conductive layer 35 , and the conductive layer 62 is connected to a terminal electrode 43 that corresponds to the control voltage application terminal DC 2 .
In this embodiment, in order to increase the moisture-resistance of the variable capacitance elements formed via the lower electrode layers, the dielectric layers, and the upper electrode layers, a conductive adhesive film ( 3 in FIG. 4 ) and an insulating moisture-resistant film ( 4 in FIG. 4 ) are provided. To form these patterned films, layers for forming these films are successively deposited on the entire surface of the supporting substrate after the upper electrode layers 21 to 24 are formed. Then, portions of the deposited layers that should be opened to allow the upper electrode layers 21 to 24 to be connected to conductive layers which are to be formed on the upper electrode layers, respectively, are removed via plasma etching or the like.
With this configuration, the mechanical reliability of the device may decrease since there is poor adhesion between the insulating moisture-resistant film 4 and the interlayer insulation layer 5 , which is to be formed after the formation of the conductive adhesive film 3 and the insulating moisture-resistant film 4 , and which functions as a protective layer for the variable capacitance elements. In addition, the conductivity of the conductive adhesive film 3 , which increases the adhesion of the insulating moisture-resistant film 4 with respect to the variable capacitance elements and the substrate, may cause leaks to occur between the lower electrode layer 10 and the lower electrode layer 11 , which would lead to a decrease in the Q factor. In terms of a circuit, as shown in FIG. 3 , this means that there exists a resistor Rb that connects the terminal on the input terminal side of the capacitor C 2 with the terminal on the output terminal side of the capacitor C 3 , which is undesirable.
Thus, in one aspect of the present embodiment, a slit 71 , as shown in FIG. 2 , is formed by removing respective portions of the insulating moisture-resistant film 4 and the conductive adhesive film 3 that are located between the lower electrode layer 10 and the lower electrode layer 11 . This removal is performed by plasma etching or the like. The slit 71 separates the conductive adhesive film 3 into two regions: a first region (left-hand side) that contacts the lower electrode layer 10 and a second region (right-hand side) that contacts the lower electrode layer 11 . The slit 71 also separates the insulating moisture-resistant film 4 into two regions: a first region (left-hand side) that is formed on the first region of the conductive adhesive film 3 and a second region (right-hand side) that is formed on the second region of the conductive adhesive film 3 . Moreover, the slit 71 extends to an area on the supporting substrate where the resistance layer 16 is formed in order to further prevent leaks. A shown in FIG. 2 , in the area where the resistance layer 16 is formed, the slit 71 separates the insulating moisture-resistant film 4 and the conductive adhesive film 3 into respective first regions and second regions. A slit of any shape can be used as the slit 71 as long as the slit is able to electrically separate the lower electrode layer 10 and the lower electrode layer 11 .
With the above-described configuration, leaks between the lower electrode layer 10 and the lower electrode layer 11 through the conductive adhesive film are prevented from occurring. Further, the interlayer insulation layer 5 to be formed on the insulating moisture-resistant film 4 contacts the supporting substrate at the slit. Therefore, adhesion of the interlayer insulation layer 5 to the substrate is improved.
Next, the cross section A-A′ in FIG. 2 will be explained in more detail using FIG. 4 .
A thermal oxide film 2 that is made of SiO 2 is formed on a surface of the supporting substrate 1 , which may be made of silicon, for example. The supporting substrate 1 may also be a conductive substrate (preferably a high-resistance substrate) with an insulating layer film thereon or an insulating substrate made of quartz, alumina, sapphire, glass, or the like, instead of the silicon substrate. The silicon substrate 1 has a thickness of 400 μm, for example, and the SiO 2 film 2 has a thickness of 1 μm, for example.
The lower electrode layers 10 , 11 are formed on the thermal oxide film 2 (this may be done via an adhesive layer (made of Ti or TiO 2 , for example)). The lower electrode layers 10 , 11 are made of a noble metal such as Pt, Ir, or Ru, or a conductive oxide such as SrRuO 3 , RuO 2 , or IrO 2 , for example. The thickness of the lower electrode layers 10 , 11 is 250 nm, for example.
The dielectric layers 9 a, 9 b are formed on the lower electrode layer 10 , and the dielectric layers 9 c, 9 d are formed on the lower electrode layer 11 . The dielectric layers 9 a to 9 d are made of BST (BaSrTiO 3 ), PZT (PbZrTiO 3 ), another oxide with a perovskite structure, or the like, to which a trace amount of Mn has been added, for example. The thickness of the dielectric layers 9 a to 9 d is 100 nm, for example.
Furthermore, the upper electrode layer 21 is formed on the dielectric layer 9 a, the upper electrode layer 22 is formed on the dielectric layer 9 b, the upper electrode layer 23 is formed on the dielectric layer 9 c, and the upper electrode layer 24 is formed on the dielectric layer 9 d. The upper electrode layers 21 to 24 are, similar to the lower electrode layers 10 , 11 , made of a noble metal such as Pt, Ir, or Ru, or a conductive oxide such as SrRuO 3 , RuO 2 , or IrO 2 . The thickness of the upper electrode layers 21 to 24 is 250 nm, for example.
After the upper electrode layers 21 to 24 are formed, layers for forming the conductive adhesive film 3 and the insulating moisture-resistant film 4 , respectively, are formed on the entire surface of the upper electrode layers 21 to 24 . The layer for the conductive adhesive film 3 is formed of TiO x (x being a value smaller than 2), for example. The thickness of the layer for the conductive adhesive film 3 is between 5 and 10 nm, for example. The layer for the insulating moisture-resistant film 4 is a single layer made of Al 2 O 3 , SiN, Ta 2 O 5 , SrTiO 3 , or the like, or any combination thereof, for example.
Portions of these layers for the conductive adhesive film 3 and the insulating moisture-resistant film 4 on top of the upper electrode layers 21 to 24 are removed via plasma etching or the like, thereby forming the patterned conductive adhesive film 3 and the patterned insulating moisture-resistance film 4 so as to allow the upper electrode layers 21 to 24 to be connected to the to-be-formed conductive layers 31 to 33 . At the same time, the slit 71 is formed so that the patterned conductive adhesive film 3 and the insulating moisture-resistant film 4 have two separate regions contacting the lower electrode layer 10 and the lower electrode layer 11 , respectively. This structure prevents leaks from occurring between the lower electrode layers 10 and 11 .
After the conductive adhesive film 3 and the insulating moisture-resistant film 4 are formed, the interlayer insulation layer 5 that is a protective layer is formed. The interlayer insulation layer 5 is made of a polyimide, for example. The thickness of the interlayer insulation layer 5 is 3 μm, for example. As a result of the slit 71 being formed, the interlayer insulation layer 5 is connected to the thermal oxide film 2 , adhesion is increased, and mechanical reliability is improved.
Then, respective portions of the interlayer insulation layer 5 above the upper electrode layers 21 to 24 are removed via plasma etching so as to allow the upper electrode layers 21 to 24 to be connected to the to-be-formed conductive layers 31 to 33 . Before the conductive layers 31 to 33 are formed, however, a seed layer/conductive moisture-resistant film 81 is formed. The seed layer/conductive moisture-resistant film 81 is made of TaN (40 nm)/Ta (30 nm)/Cu (100 nm), for example. Instead of TaN/Ta, TiN, TiSiN, TaSiN, or other nitrides, SrRuO 3 , IrO 2 , or other oxides, or the like, may be used.
After the seed layer/conductive moisture-resistant film 81 is formed, a conductive layer for forming the conductive layers 31 to 33 is deposited. Various conductive materials such as Cu, Al, or the like, for example, can be used for the layer for the conductive layers 31 to 33 . The thickness of the conductive layers 31 to 33 is 3 μm, for example.
After the layer for the conductive layers 31 to 33 is deposited, portions of the layer are removed via plasma etching or the like to define the patterned conductive layers 31 to 33 having respective desired shapes. Thereafter, an interlayer insulation layer 72 is formed. Similar to the interlayer insulation layer 5 , the interlayer insulation layer 72 may be made of a polyimide, for example.
In order to form the terminal electrodes 41 , 44 , a portion of the interlayer insulation layer 72 is removed via plasma etching or the like, a seed layer/conductive moisture-resistant film 82 similar to the seed layer/conductive moisture-resistant film 81 is formed, and the conductive layers 57 , 58 are formed. The conductive layers 57 , 58 are formed via a conductive material such as Cu, for example, and have a thickness of 3 μm, for example.
The terminal electrodes 41 , 44 are then formed on the conductive layers 57 , 58 . The terminal electrodes 41 , 44 are made of Ni/Sn, for example, but may also be made of SnAg, Au, or a solder material. The terminal electrodes 41 , 44 are made of Ni 2 μm/Sn 5 μm, for example.
Next, the cross section B-B′ in FIG. 2 will be explained in more detail using FIG. 5 .
The thermal oxide film 2 is formed on the supporting substrate 1 , and the conductive adhesive film 3 and the insulating moisture-resistant film 4 are formed on the thermal oxide film 2 . Resistance layers 15 to 17 are then formed on the insulating moisture-resistant film 4 . The resistance layers 15 to 17 are made of a high resistance film such as a TaSiN, a NiCr alloy, a FeCrAl alloy, or the like, for example. The thickness of the resistance layers 15 to 17 is 100 nm, for example.
By plasma etching or the like, slits 71 a and 71 b are then formed in the conductive adhesive film 3 and the insulating moisture-resistant film 4 .
As shown in this cross section, the conductive adhesive film 3 and the insulating moisture-resistant film 4 are separated into a left-hand side region and a right-hand side region via the slits 71 a and 71 b. Thus, the resistance layer 16 does not come into contact with the conductive adhesive film 3 or the insulating moisture-resistant film 4 .
The interlayer insulation layer 5 is then formed, and the portion of the interlayer insulation layer 5 above the resistance layers 15 to 17 is removed via plasma etching or the like.
Next, the seed layer/conductive moisture-resistant film 81 is formed, and then the conductive layers 52 , 53 , 55 , and 34 are formed. The conductive layers 52 , 53 , 55 , and 34 are formed from the same material at the same time as the conductive layers 31 to 33 and have the same thickness as the conductive layers 31 to 33 .
After the conductive layers 52 , 53 , 55 , and 34 are formed, the interlayer insulation layer 72 is formed. The portion of the interlayer insulation layer 72 that is above the conductive layer 53 is removed via plasma etching or the like. Next, the seed layer/conductive moisture-resistant film 82 is formed, after which the conductive layer 59 is formed. The conductive layer 59 is formed of the same material at the same time as the conductive layers 57 , 58 and has the same thickness as the conductive layers 57 , 58 . The terminal electrode 42 is formed on the conductive layer 59 . The terminal electrode 42 is formed of the same material at the same time as the terminal electrodes 41 , 44 and has the same thickness as the terminal electrodes 41 , 44 .
The fact that using a variable capacitance device with such a structure improves the Q factor will be explained using FIG. 6 . The horizontal axis of FIG. 6 represents the Q factor, and the vertical axis represents rate of occurrence (in %). Here, a prescribed number of variable capacitance devices having a configuration without slits 71 (comparison examples) were formed on a single wafer, and a prescribed number of variable capacitance devices according to the present embodiment that have slits 71 were formed on another wafer.
For the comparison examples, which did not have slits 71 , variable capacitance devices with Q factors between 45 and 50 had the highest frequency of occurrence. While few in number, variable capacitance devices with high Q factors were also obtained.
On the other hand, for the variable capacitance devices according to the present embodiment that had slits 71 , it can be seen that all such devices had Q factors of 60 or above and, as a whole, had higher Q factors than the comparison examples.
As mentioned above, according to the present embodiment, the Q factor can be increased, and mechanical reliability is increased as a result of improved adhesion between the interlayer insulation layer 5 and the supporting substrate 1 .
In the example mentioned above, a variable capacitance device with four variable capacitance elements was used. However, the present invention is not limited to this; the number of variable capacitance elements included in a variable capacitance device may be a number other than four. In such cases, more than two lower electrode layers may be formed. Also, in the above-mentioned embodiment, two variable capacitance elements shared one lower electrode layer. However, the present invention is not limited to this; for each of the variable capacitance elements, a single lower electrode layer may be provided, depending on the design needs.
In such cases, slits 71 may be provided to isolate respective regions where the lower electrode layers are formed so as to separate the conductive adhesive film 3 and the insulating moisture-resistant film 4 into a plurality of regions. Thus, more than one slit may be appropriately provided. As also mentioned above, since such a configuration prevents leaks between the lower electrode layers and improves adhesion between the interlayer insulation layer 5 and the supporting substrate 1 , the shape of the slits 71 may be modified in accordance with the shape of the lower electrode layer regions or the like.
An antenna device that utilizes a variable capacitance device according to an embodiment of the present invention has a configuration shown in FIG. 7 , for example. The antenna device has: a signal processing and control circuit 200 , a capacitor C DCcut for cutting the DC, the variable capacitance device 100 according to an embodiment of the present invention, and a coil L used as an antenna. The signal processing and control circuit 200 is configured to apply the appropriate voltage to the variable capacitance device 100 so as to properly demodulate signals received by the coil L.
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 invention. Thus, it is intended that the present invention cover modifications and variations that come within the scope of the appended claims and their equivalents. In particular, it is explicitly contemplated that any part or whole of any two or more of the embodiments and their modifications described above can be combined and regarded within the scope of the present invention. | A variable capacitance device includes: a supporting substrate having a plurality of variable capacitance elements formed thereon, the plurality of variable capacitance elements being connected in series, wherein each of the plurality of variable capacitance elements has a separate lower electrode, or at least some of the plurality of variable capacitance elements share a lower electrode, thereby forming a plural set of the lower electrodes that serves as the lower electrodes of the respective variable capacitance elements, wherein the variable capacitance device further includes an insulating moisture-resistant film and a conductive adhesive film, and wherein the conductive adhesive film and the insulating moisture-resistant film have a gap in a plan view between at least some of regions where the plural set of the lower electrodes are respectively formed so as to avoid electrical leakage between said at least some of regions through the conductive adhesive film. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of U.S. application Ser. No. 12/772,102 filed Apr. 30, 2010, which is a divisional of U.S. application Ser. No. 11/876,706, filed Oct. 22, 2007, now U.S. Pat. No. 7,722,351, both of which are incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] This invention is relates to an injection molding apparatus, and more particularly, an injection molding apparatus having a valve pin.
Related Art
[0003] Injection molding apparatuses, such as hot halves and hot runners, commonly use valve pins to control flow of molding material.
[0004] When a cavity, valve pin, heater, mold gate, or other related component wears or fails, the molded product may have defects and the injection molding apparatus may have to be shut down for maintenance or repair. Such downtime eats into production time, which is nearly always sought to be maximized.
SUMMARY OF THE INVENTION
[0005] A method for taking a nozzle of a valve gated runner includes the steps of releasably attaching a valve pin to a movable part of an actuator for moving the valve pin between an open position and a closed position and detaching the valve pin from the actuator by moving the movable part of the actuator towards the open position when the valve pin is immobilized. The valve pin and the movable part valve pin may be releasably attached by a magnetic force. The step of detaching the valve pin from the actuator may be accomplished by overcoming the magnetic force. A valve pin plate can be provided for a plurality of valve pins to be releasably attached to the actuator.
BRIEF DESCRIPTION OF THE FIGURES
[0006] Embodiments of the present invention will now be described more fully with reference to the accompanying drawings, where like reference numbers indicate similar structure.
[0007] FIG. 1 is a cross-sectional view of an injection molding apparatus according to an embodiment of the present invention.
[0008] FIG. 2 is a cross-sectional view of one of the magnetic couplings of FIG. 1 .
[0009] FIG. 3 is a cross-sectional view of the injection molding apparatus of FIG. 1 showing the valve pins in their opened positions.
[0010] FIG. 4 is a cross-sectional view showing one of the valve pins of FIG. 1 immovable.
[0011] FIGS. 5 a and 5 b are cross-sectional views of one of the magnetic couplings of FIG. 1 shown in various positions.
[0012] FIGS. 6 a and 6 b are cross-sectional views of a magnetic coupling according to another embodiment of the present invention.
[0013] FIGS. 7 a and 7 b are cross-sectional views of a magnetic coupling according to another embodiment of the present invention.
[0014] FIGS. 8 a and 8 b are cross-sectional views of a magnetic coupling according to another embodiment of the present invention.
[0015] FIG. 9 is a cross-sectional view of a magnetic coupling according to another embodiment of the present invention.
[0016] FIGS. 10 a and 10 b are cross-sectional views of a magnetic coupling according to another embodiment of the present invention.
[0017] FIG. 11 is a cross-sectional view of an injection molding apparatus according to another embodiment of the present invention.
[0018] FIG. 12 is a cross-sectional view of the injection molding apparatus of FIG. 11 showing the valve pins in their opened positions.
[0019] FIG. 13 is a cross-sectional view showing one of the valve pins of FIG. 11 immovable.
[0020] FIG. 14 is a cross-sectional view of an injection molding apparatus according to another embodiment of the present invention.
[0021] FIG. 15 is a cross-sectional view of part of an injection molding apparatus according to another embodiment of the present invention.
[0022] FIG. 16 is a cross-sectional view of a portion of a valve pin according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] FIG. 1 shows an injection molding apparatus 100 according to an embodiment of the present invention. The features and aspects described for the other embodiments can be used accordingly with the present embodiment.
[0024] The injection molding apparatus includes an actuator plate 102 , actuators 104 , a valve pin plate 106 , a back plate 108 , a manifold 110 , nozzles 112 , a mold plate 114 , a cavity plate 116 , cores 118 , valve pins 120 , valve pin bushings 122 , and magnetic couplings 124 . The injection molding apparatus 100 can include any number of manifolds and nozzles, in any configuration. In this embodiment, one manifold is shown for simplicity. The injection molding apparatus 100 can include additional components, such as mold plates, alignment dowels, mold gate inserts, and cooling channels, among others.
[0025] The actuator plate 102 has openings for accommodating the actuators 104 .
[0026] If the actuators 104 depend on a working fluid for operation (i.e., pneumatic or hydraulic types), fluid conduits can be provided in the actuator plate 102 . Should the actuators 104 be electric or magnetic or of some other design, electrical conduits can be provided.
[0027] The actuators 104 are disposed in the actuator plate 102 and can be pneumatic, hydraulic, electric, magnetic, or of some other design. The actuators 104 can translate the valve pin plate 106 by linear motion (e.g., a pneumatic piston) or rotary motion (e.g., an electric screw drive). To accomplish this, each actuator 104 has a stationary part (e.g., a housing or cylinder) connected to the actuator plate 102 and has a movable part 125 (e.g., a piston) connected to the valve pin plate 106 . The number of actuators is a design choice, and in other embodiments more or fewer actuators can be used. Any style of actuator is suitable, provided that it can move the valve pin plate 106 .
[0028] The valve pin plate 106 is connected to the movable part 125 of each actuator 104 . The valve pin plate 106 has a plurality of threaded openings for receiving the magnetic couplings 124 . The valve pin plate 106 can move up and down in response to the actuation of the actuators 104 . The valve pin plate 106 need not be a plate as such, but can be any rigid member capable of connecting one or more actuators to a plurality of magnetic couplings. In other embodiments, the valve pin plate 106 is an assembly of stacked plates.
[0029] The back plate 108 is disposed between the valve pin plate 106 and the valve pin bushings 122 and serves to secure the valve pin bushings 122 in the manifold 110 . The back plate 108 has several bores through which the valve pins 120 extend.
[0030] The manifold 110 defines a manifold channel 126 and includes a manifold heater. The manifold channel 126 receives molding material (e.g., plastic melt) from an inlet (not shown) or an upstream manifold (not shown). The manifold heater can be of any design, such as the insulated resistance wire illustrated. It should also be mentioned that, because of the plate interconnections (not shown), the manifold 110 is stationary relative to the stationary parts of the actuators 104 .
[0031] The nozzles 112 are connected to the manifold 110 and each nozzle 112 defines one of a plurality of nozzle channels 128 in communication with the manifold channel 126 . In this embodiment, each nozzle 112 includes a nozzle body, a nozzle flange, a nozzle heater embedded in the nozzle body, a thermocouple, a terminal end for connecting the heater to a power source, a nozzle tip, and a tip retainer. The nozzles 112 in combination with the manifold 110 define a hot runner.
[0032] The mold plate 114 has wells to accommodate and support the nozzles 112 . The wells are sized to thermally insulate the nozzles 112 from the surrounding material.
[0033] The cavity plate 116 and the cores 118 define cavities 130 , and the cavity plate 116 defines mold gates leading to the cavities 130 . The cavity plate 116 and cores 118 are separable from the mold plate 114 along a parting line to allow ejection of molded products from the cavities 130 . In other embodiments, a single cavity can be fed molding material by several nozzles 112 .
[0034] Each of the valve pins 120 extends from one of the magnetic couplings 124 to one of the nozzles 112 for controlling flow of molding material through the mold gates and into the cavities 130 .
[0035] Each valve pin bushing 122 is held to the manifold 110 by the back plate 108 . Each valve pin bushing 122 includes a disc-shaped main body and a cylindrical bushing portion connected to and extending from the main body and into the manifold 110 . Each valve pin bushing 122 has a valve pin bore, which creates a seal with the valve pin 120 while still allowing the valve pin 120 to slide.
[0036] Each magnetic coupling 124 couples a respective valve pin 120 to the valve pin plate 106 . Each magnetic coupling 124 directly transmits actuator closing force to the respective valve pin 120 when the valve pins 120 are being closed (i.e., moved down). Each magnetic coupling 124 also applies a magnetic force to move the respective valve pin 120 when the valve pins 120 are being opened (i.e., moved up). During normal operation, the magnetic force is sufficient to keep the valve pins 120 coupled to the valve pin plate 106 when the valve pins 120 are opened and closed. If one of the valve pins becomes immovable, the respective magnetic force is overcome by an actuator opening force so that the valve pin plate 106 and remaining valve pins 120 move (i.e., up) with respect to the immovable valve pin. The magnetic couplings 124 are described in more detail below. It should be noted that the directions indicated above are reversed if the valve pins 120 are designed to open flow of molding material when moved down and to close flow when moved up.
[0037] FIG. 2 is a cross-sectional view of one of the magnetic couplings 124 . The magnetic coupling 124 includes a housing 202 , a first magnetic part 204 , and a second magnetic part 206 .
[0038] The housing 202 connects the first magnetic part 204 to the valve pin plate 106 . The housing 202 is threaded into a threaded bore of the valve pin plate 106 . A bore 208 , which can also be threaded, is provided through the back end of the housing 202 .
[0039] The first magnetic part 204 is connected to the valve pin plate 106 via the housing 202 and thus moves with the valve pin plate 106 . The first magnetic part is 204 is inserted into the housing 202 and fixed to the housing 202 by way of magnetic attraction when the housing 202 is made of a magnetically responsive material such as steel. If the housing 202 is not made of a magnetically responsive material or if additional fixing force is required, an adhesive or a tight friction fit can be used, for example. A tool can be inserted into the bore 208 of the housing 202 to push the first magnetic part 204 free from the housing 202 .
[0040] The second magnetic part 206 is positioned below the first magnetic part 204 and close enough to establish a magnetic force with the first magnetic part 204 . In this embodiment, the second magnetic part 206 is attractively aligned with the first magnetic part 204 and the resulting the magnetic force is an attractive magnetic force. The second magnetic part 206 is slidable in the housing 202 and is thus moveable with respect to the first magnetic part 204 . The second magnetic part 206 has a T-shaped slot for receiving the head of the valve pin 120 , so that the second magnetic part 206 and the valve pin 120 are connected and can move together. By way of its location, the first magnetic part 204 defines a stopped position of the second magnetic part 206 relative to the first magnetic part 204 (and thus to the valve pin plate 106 ), and the attractive magnetic force tends to force the second magnetic part 206 into the stopped position. When the second magnetic part 206 is pulled away from the first magnetic part 204 , the attractive magnetic force tends to pull the second magnetic part 206 back towards the first magnetic part 204 and into the stopped position.
[0041] In this embodiment, the first magnetic part 204 is a permanent magnet, such as a neodymium magnet or a samarium-cobalt magnet, and the second magnetic part 206 includes magnetically responsive material, such as steel, iron, or similar. The choice between a neodymium magnet, a samarium-cobalt magnet, and a magnet of some other material should be made addressing concerns such as temperature exposure and impact during operation. Magnetically responsive material can be ferromagnetic, ferrous material, or any other kind of material that experiences a significant force in the presence of a magnetic field. In this embodiment, the second magnetic part 206 is made of steel. In other embodiments, the first magnetic part 204 can be of a magnetically responsive material and the second magnetic part 206 can be a permanent magnet, or both parts 204 , 206 can be some combination of permanent magnets and electromagnets.
[0042] In FIG. 1 the valve pins 120 are in their closed positions, such that molding material is prevented from flowing through the mold gates and into the cavities 130 . FIG. 3 , on the other hand, shows the valve pins 120 in their opened positions, such that molding material can flow through the mold gates and into the cavities 130 . As can be seen in FIG. 3 , the actuators 104 have moved the valve pin plate 106 up thereby moving the magnetic couplings 124 , which, by way of attractive magnetic forces, pull the valve pins 120 up. When the valve pins 120 are to be returned to their closed positions ( FIG. 1 ), the valve pin plate 106 moves down, which causes the magnetic couplings 124 to rigidly (i.e., independently of magnetic forces) push the valve pins 120 down.
[0043] FIG. 4 is a cross-sectional view showing one of the valve pins 120 that has become immovable, held in the closed position by an immobilizing force. As can be seen, three of the valve pins 120 are open, as pulled by the valve pin plate 106 via the magnetic couplings 124 ; while one valve pin 120 is closed (at 400 ), despite the pull of the valve pin plate 106 . As shown, the magnetic coupling 124 connected to the closed valve pin 120 has reacted to the immobilizing force and has extended to compensate for the movement of the valve pin plate 106 . In one example, the immobilizing force is provided by solidified molding material resulting from the nozzle heater being shut down. That is, when a nozzle is to be taken out of service because of a worn valve pin or leaking cavity, the nozzle's heater can be shut down to stop molding material from flowing. Solidified molding material can also occur if a nozzle heater fails. When the magnetic couplings 124 are designed to have a magnetic force less than the expected immobilizing force, then the magnetic couplings 124 will allow for continued operation of valve pins when one or more nozzles are taken out of service.
[0044] In this embodiment, a selected nozzle 112 can be taken out of service by closing the valve pins 120 , shutting down the selected nozzle's heater, and then waiting until molding material in the selected nozzle's channel has solidified or sufficiently cooled to provide a strong enough immobilizing force. Afterwards, the injection molding apparatus 100 can be restarted as usual, and the valve pin 120 of the immobilized nozzle will remain stationary by virtue of the magnetic coupling 124 . The magnetic coupling 124 is also amenable to use with other methods of taking a nozzle out of service.
[0045] FIGS. 5 a and 5 b show a magnetic coupling 124 associated with an immobilized valve pin 120 . FIG. 5 a shows the valve pin plate 106 down and the valve pin 120 closed, while FIG. 5 b shows the valve pin plate 106 up and the valve pin 120 still closed. As indicated at 502 , the valve pin 120 stays in the closed position even though the valve pin plate 106 has moved upwards by a distance 504 (which, in this embodiment, is equivalent to the valve pin travel). The first magnetic part 204 has moved upwards relative to the second magnetic part 206 , which has remained stationary with the fixedly connected valve pin 120 . Viewed with the valve pin plate taken as a reference, the second magnetic part 206 has slid within the housing 202 away from the first magnetic part 204 . As such, a gap 506 (which, in this embodiment, is also equivalent to the valve pin travel) separates the first and second magnetic parts 204 , 206 . The attractive magnetic force can be viewed as acting within the gap 506 to tend to bring the first and second magnetic parts 204 , 206 closer together.
[0046] FIGS. 6 a and 6 b show a magnetic coupling 600 according to another embodiment of the present invention. The magnetic coupling 600 can be used to couple a valve pin (e.g., the valve pin 120 of FIG. 1 ) to a valve pin plate (e.g., the valve pin plate 106 of FIG. 1 ). FIG. 6 a shows the valve pin plate 106 down and the valve pin 120 closed, while FIG. 6 b shows the valve pin plate 106 up and the valve pin 120 still closed, as in the case of an immobilized valve pin. The features and aspects described for the other embodiments can be used accordingly with the present embodiment.
[0047] The magnetic coupling 600 includes a housing 602 , a first magnetic part 604 , and a second magnetic part 606 . The housing 602 connects the first magnetic part 604 to the valve pin plate 106 , and thus the first magnetic part 604 moves with the valve pin plate 106 . The magnetic coupling 600 is similar to the magnetic coupling 124 and only differences are described in detail below.
[0048] The second magnetic part 606 is positioned below the first magnetic part 604 and close enough to establish an attractive magnetic force with the first magnetic part 604 . The second magnetic part 606 includes a magnet holder 608 , a permanent magnet 610 , and a valve pin holder 612 . The magnet 610 is inserted into the magnet holder 608 and secured in place by the valve pin holder 612 , which threads into the magnet holder 608 . The valve pin holder 612 has a T-shaped slot for receiving the head of the valve pin 120 . The magnet 606 is attractively aligned with the first magnetic part 604 and the resulting the magnetic force is an attractive magnetic force that tends to pull the second magnetic part 606 back towards the first magnetic part 604 and into the stopped position.
[0049] In this embodiment, the first magnetic part 604 is a permanent magnet, but an electromagnet could also be used. The magnet 610 could also be an electromagnet.
[0050] FIGS. 7 a and 7 b show a magnetic coupling 700 according to another embodiment of the present invention. The magnetic coupling 700 can be used to couple a valve pin (e.g., the valve pin 120 of FIG. 1 ) to a valve pin plate (e.g., the valve pin plate 106 of FIG. 1 ). FIG. 7 a shows the valve pin plate 106 down and the valve pin 120 closed, while FIG. 7 b shows the valve pin plate 106 up and the valve pin 120 still closed, as in the case of an immobilized valve pin. The features and aspects described for the other embodiments can be used accordingly with the present embodiment.
[0051] The magnetic coupling 700 includes a housing 702 , a first magnetic part 704 , and a second magnetic part 706 . The housing 702 connects the first magnetic part 704 to the valve pin plate 106 , and thus the first magnetic part 704 moves with the valve pin plate 106 . The magnetic coupling 700 is similar to the magnetic coupling 124 and only differences are described in detail below.
[0052] The housing 702 connects the first magnetic part 704 to the valve pin plate 106 . The housing includes a threaded cylindrical body 708 and a threaded stopper 710 . The cylindrical body 708 is threaded into a threaded bore of the valve pin plate 106 . The stopper 710 is threaded into the cylindrical body 708 . The lower portion of the cylindrical body 708 has a lip 711 .
[0053] The first magnetic part 704 is a magnet that is connected to the valve pin plate 106 via the housing 702 and thus moves with the valve pin plate 106 . The first magnetic part is 704 is inserted into the cylindrical body 708 of the housing 702 and rests on the lip 711 . If the housing 702 is made of a magnetically responsive material the first magnetic part may be attracted to the lip 711 . The first magnetic part 704 need not fit tightly in the cylindrical body 708 . The first magnetic part 704 has a bore 712 to accommodate the valve pin 120 .
[0054] The second magnetic part includes a valve pin holder 714 and a magnet 716 . The second magnetic part 706 is positioned above the first magnetic part 704 and close enough to establish a magnetic force with the first magnetic part 704 . In this embodiment, the second magnetic part 706 is repulsively aligned with the first magnetic part 704 and the resulting the magnetic force is a repulsive magnetic force. To achieve this, the magnet 716 is repulsively aligned with the first magnetic part 704 . The second magnetic part 706 is slidable in the housing 702 and is thus moveable with respect to the first magnetic part 704 . The valve pin holder 714 has a T-shaped slot for receiving the head of the valve pin 120 , so that the valve pin holder 714 and the valve pin 120 are connected and can move together. If the valve pin holder 714 is made of a magnetically responsive material, then the valve pin holder 714 is attractively connected to the magnet 716 , but this is not necessary. By way of its location, the stopper 710 defines a stopped position of the second magnetic part 706 relative to the first magnetic part 704 (and thus to the valve pin plate 106 ). The repulsive magnetic force tends to force the second magnetic part 706 into the stopped position and tends to force the first magnetic part 704 against the lip 711 . When the second magnetic part 706 is pushed towards the first magnetic part 704 , the repulsive magnetic force tends to push the second magnetic part 706 back towards the stopper 710 and into the stopped position.
[0055] In normal operation, while the valve pin plate 106 moves up and down, the components of the magnetic coupling 700 stay in the relative positions shown in FIG. 7 a. The stopper 710 rigidly (i.e., independently of magnetic forces) pushes the valve pin holder 714 , and thus the valve pin 120 , down when the valve pin plate 106 moves down; while the repulsive magnetic force is strong enough to push the magnet 716 , and thus the valve pin holder 714 and the valve pin 120 , up when the valve pin plate 106 moves up. However, when the valve pin 120 is immobilized in the closed position, the immobilizing force overcomes the repulsive magnetic force so that the second magnetic part 706 is held stationary while the first magnetic part 704 moves towards it against the repulsive magnetic force. As a result, the valve pin 120 can be immobilized while the remaining valve pins connected to the valve pin plate 106 can be kept in service.
[0056] In this embodiment, the first magnetic part 704 is a permanent magnet, but an electromagnet could also be used. The magnet 716 could also be an electromagnet. However, neither the first magnetic part 704 nor the magnet 716 could be replaced by magnetically responsive material, as a repulsive magnetic force would not be generated.
[0057] FIGS. 8 a and 8 b show a magnetic coupling 800 according to another embodiment of the present invention. The magnetic coupling 800 can be used to couple a valve pin (e.g., the valve pin 120 of FIG. 1 ) to a valve pin plate (e.g., the valve pin plate 106 of FIG. 1 ). FIG. 8 a shows the valve pin plate 106 down and the valve pin 120 closed, while FIG. 8 b shows the valve pin plate 106 up and the valve pin 120 still closed, as in the case of an immobilized valve pin. The features and aspects described for the other embodiments can be used accordingly with the present embodiment.
[0058] The magnetic coupling 800 includes a plug 802 , a first magnetic part 804 , and a second magnetic part 806 . The magnetic coupling 800 is similar to the magnetic coupling 124 and only differences are described in detail below.
[0059] The plug 802 is threaded into a threaded bore of the valve pin plate 106 .
[0060] The plug 802 is made of magnetically attractive material and is connected (via magnetic attraction) to the first magnetic part 804 , so that the first magnetic part 804 is connected to the valve pin plate 106 . In other embodiments, the plug 802 is not made of magnetically responsive material and is connected to the first magnetic part 804 by an adhesive or other connective means. A lock nut 808 is also provided and is threaded to the plug 802 . The lock nut 808 can be used to lock the position of the plug 802 and the first magnetic part 804 , so that the normal position of the second magnetic part 806 is adjustable.
[0061] The first magnetic part is 804 is inserted into an unthreaded portion of the bore of the valve pin plate 106 . The first magnetic part 804 moves with the valve pin plate 106 via its magnetic attraction to the plug 802 secured to the valve pin plate 106 . In this embodiment, the first magnetic part 804 is a permanent magnet.
[0062] The second magnetic part 806 is positioned below the first magnetic part 804 and close enough to establish a magnetic force with the first magnetic part 804 . In this embodiment, the second magnetic part 806 is made of magnetically responsive material and is thus attractively aligned with the first magnetic part 804 to establish an attractive magnetic force. The second magnetic part 806 is slidable in the unthreaded portion of the bore of the valve pin plate 106 and is thus moveable with respect to the first magnetic part 804 . The second magnetic part 806 has a T-shaped slot for receiving the head of the valve pin 120 , so that the second magnetic part 806 and the valve pin 120 are connected and can move together. By way of its location, the first magnetic part 804 defines a stopped position of the second magnetic part 806 . When the second magnetic part 806 is pulled away from the first magnetic part 804 , the attractive magnetic force tends to pull the second magnetic part 806 back towards the first magnetic part 804 and into the stopped position.
[0063] To adjust the normal operational position of the second magnetic part 806 and thus the valve pin 120 , the lock nut 808 is first loosened, the plug 802 is then rotated in the required direction, and then the lock nut 808 is tightened again.
[0064] In this embodiment, the first magnetic part 804 is a permanent magnet, but an electromagnet could also be used. In addition, the second magnetic part 806 could include a permanent magnet or an electromagnet.
[0065] In another embodiment, the plug is made of magnetically attractive material and is considered the first magnetic part, while the second magnetic part includes a magnet that moves with a valve pin holder made of magnetically attractive material. Such embodiment is similar to that of FIG. 8 in all respects, except that the magnet is more attracted to the valve pin holder than to the plug.
[0066] FIG. 9 shows a magnetic coupling 900 according to another embodiment of the present invention. The magnetic coupling 900 can be used to couple a valve pin (e.g., the valve pin 120 of FIG. 1 ) to a valve pin plate (e.g., the valve pin plate 106 of FIG. 1 ). The features and aspects described for the other embodiments can be used accordingly with the present embodiment.
[0067] The magnetic coupling 900 includes a plug 902 , a first magnetic part 904 , a second magnetic part 906 , and a lock nut 908 . The magnetic coupling 900 is similar to the magnetic coupling 800 and only differences are described in detail below.
[0068] The first magnetic part is 904 is an electromagnet having a coil of wire 910 wrapped around or embedded within a core 912 . Wire leads 914 extend out of the magnetic coupling 900 through a bore 916 in the plug 902 that acts as an electrical conduit. The wire leads 914 can be connected to a control circuit (not shown). The second magnetic part 906 is made of magnetically responsive material.
[0069] In other embodiments, where one or more electromagnets are used, electrical conduits for wire leads can be formed in any convenient component. For example, if the second magnetic part 906 is provided with an electromagnet, an electrical conduit can be provided in the valve pin plate 106 . Design of such an electrical conduit can take into account movement of the second magnetic part 906 relative to the valve pin plate 106 should the valve pin 120 become immobilized.
[0070] FIGS. 10 a and 10 b show a magnetic coupling 1000 according to another embodiment of the present invention. The magnetic coupling 1000 can be used to couple a valve pin (e.g., the valve pin 120 of FIG. 1 ) to a valve pin plate (e.g., the valve pin plate 106 of FIG. 1 ). FIG. 10 a shows the valve pin plate 106 down and the valve pin 120 closed, while FIG. 10 b shows the valve pin plate 106 up and the valve pin 120 still closed, as in the case of an immobilized valve pin. The features and aspects described for the other embodiments can be used accordingly with the present embodiment.
[0071] The magnetic coupling 1000 includes a positioning mechanism 1002 , a first magnetic part 1004 , and a second magnetic part 1006 . The positioning mechanism 1002 connects the first magnetic part 1004 to the valve pin plate 106 , and thus the first magnetic part 1004 moves with the valve pin plate 106 . The magnetic coupling 1000 is similar to the magnetic coupling 124 and only differences are described in detail below.
[0072] The positioning mechanism 1002 connects the first magnetic part 1004 to the valve pin plate 106 . The positioning mechanism 1002 includes a base plate 1008 , a positioning bolt 1010 , a lock plate 1012 , and a lock bolt 1014 . The base plate 1008 is bolted or otherwise fixed to the valve pin plate 106 and has a threaded bore for receiving the positioning bolt 1010 . The positioning bolt 1010 threads into the base plate 1008 and the lock plate 1012 and has a head that connects to the first magnetic part 1004 . The lock plate 1012 is located near the base plate 1008 and has threaded bores for the positioning bolt 1010 and the lock bolt 1014 . The lock bolt 1014 threads into the lock plate 1012 and can be tightened to butt against the base plate 1008 . When the normal position of the valve pin 120 is to be adjusted, the position of the first magnetic part 1004 is adjusted by first turning the lock bolt 1014 until the lock plate 1012 is parallel with the base plate 1008 , turning the positioning bolt 1010 until the valve pin 120 is in the required position, and then turning the lock bolt 1014 again to tilt the lock plate 1012 with respect to the base plate 1008 to effectively jam the thread of the positioning bolt 1010 in the threaded bore of the base plate 1008 . The jamming of the positioning bolt 1010 is nonpermanent and simply serves to inhibit rotation of the positioning bolt 1010 and thereby lock the position of the first magnetic part 1004 and thus the normal position of the valve pin 120 .
[0073] The first magnetic part 1004 has a non-circular cross-section to fit in a like-shaped opening of the valve pin plate 106 . This prevents rotation of the first magnetic part 1004 when the positioning bolt 1010 is rotated for adjustment. The first magnetic part 1004 includes an open-ended T-shaped slot 1016 for removably holding the head of the positioning bolt 1010 , as well as a bore 1018 through which a tool can be inserted to push the second magnetic part 1006 free from the first magnetic part 1004 . In this embodiment, the first magnetic part 1004 is made of magnetically responsive material.
[0074] The second magnetic part 1006 is positioned below the first magnetic part 1004 and close enough to establish a magnetic force with the first magnetic part 1004 . In this embodiment, the second magnetic part 1006 is attractively aligned with the first magnetic part 1004 and the resulting the magnetic force is an attractive magnetic force. The second magnetic part 1006 includes a permanent magnet 1020 that establishes the attractive magnetic force and a valve pin holder 1022 . The magnet 1020 is fixed inside a recess of the valve pin holder 1022 using a friction fit, an adhesive, or the like. O-rings 1023 or similar seals are provided between the valve pin holder 1022 and the valve pin plate 106 . The valve pin holder 1022 has a T-shaped slot for receiving the head of the valve pin 120 , so that the second magnetic part 1006 and the valve pin 120 are connected and can move together. By way of its location, the first magnetic part 1004 defines a stopped position of the second magnetic part 1006 relative to the first magnetic part 1004 , and the attractive magnetic force tends to pull the second magnetic part 1006 towards the first magnetic part 1004 and into the stopped position.
[0075] In another embodiment, the first magnetic part 1004 could include a permanent magnet or an electromagnet. The magnet 1020 could also be an electromagnet or could be made from magnetically responsive material.
[0076] FIG. 11 shows an injection molding apparatus 1100 according to an embodiment of the present invention. The features and aspects described for the other embodiments can be used accordingly with the present embodiment.
[0077] The injection molding apparatus 1100 includes an actuator plate 1102 , an actuator 1104 , a valve pin plate 1106 , a back plate 1108 , a manifold 1110 , a nozzle 1112 , a mold plate 1114 , a cavity plate 1116 , a core 1118 , valve pins 1120 , a valve pin bushing 1122 , and magnetic couplings 1124 . The injection molding apparatus 1100 can include any number of manifolds and nozzles, in any configuration. In this embodiment, one manifold is shown for simplicity. The injection molding apparatus 1100 can include additional components, such as mold plates, alignment dowels, mold gate inserts, and cooling channels, among others.
[0078] The actuator plate 1102 has an opening for accommodating the actuator 1104 . If the actuator 1104 depends on a working fluid for operation, fluid conduits can be provided in the actuator plate 1102 . Should the actuator 1104 be electric or magnetic or of some other design, electrical conduits can be provided.
[0079] The actuator 1104 is disposed in the actuator plate 1102 and can be pneumatic, hydraulic, electric, magnetic, or of some other design. The actuator 1104 can translate the valve pin plate 1106 by linear motion (e.g., a pneumatic piston) or rotary motion (e.g., an electric screw drive). To accomplish this, the actuator 1104 has a stationary part connected to the actuator plate 1102 and has a movable part 1125 connected to the valve pin plate 1106 . The number of actuators is a design choice, and in other embodiments more actuators can be used. Any style of actuator is suitable, provided that it can move the valve pin plate 1106 .
[0080] The valve pin plate 1106 is connected to the movable part 1125 of the actuator 1104 and can move up and down in response to the actuation of the actuator 1104 . The valve pin plate 1106 need not be a plate as such, but can be any rigid member capable of connecting one or more actuators to a plurality of magnetic couplings. In another embodiment, the valve pin plate 1106 is an assembly of stacked plates.
[0081] The back plate 1108 is disposed between the valve pin plate 1106 and the valve in bushing 1122 and serves to secure the valve pin bushing 1122 in the manifold 1110 . The back plate 1108 has several bores through which the valve pins 1120 extend.
[0082] The manifold 1110 defines a manifold channel 1126 and includes a manifold heater. The manifold channel 1126 receives molding material (e.g., plastic melt) from an inlet (not shown) or an upstream manifold (not shown). The manifold heater can be of any design, such as the insulated resistance wire illustrated. It should also be mentioned that, because of the plate interconnections (not shown), the manifold 1110 is stationary relative to the stationary part of the actuator 1104 .
[0083] The nozzle 1112 is connected to the manifold 1110 and defines a plurality of nozzle channels 1128 in communication with the manifold channel 1126 . In this embodiment, the nozzle 1112 includes a nozzle body, a nozzle flange, one or more nozzle heaters (e.g., cartridge heaters) in the nozzle body, a thermocouple, a terminal end for connecting the heater(s) to a power source, nozzle tips, and tip retainers. The nozzle 1112 in combination with the manifold 1110 can define a hot runner.
[0084] The mold plate 1114 has a well to accommodate and support the nozzle 1112 . The well is sized to thermally insulate the nozzle 1112 from the surrounding material.
[0085] The cavity plate 1116 and the core 1118 define cavities 1130 , and the cavity plate 1116 defines mold gates leading to the cavities 1130 . The cavity plate 1116 and the core 1118 are separable from the mold plate 1114 along a parting line to allow ejection of molded products from the cavities 1130 .
[0086] Each of the valve pins 1120 extends from one of the magnetic couplings 1124 through one of the nozzle channels 1128 for controlling flow of molding material through the mold gates and into the cavities 1130 .
[0087] The valve pin bushing 1122 is held to the manifold 1110 by the back plate 1108 . The valve pin bushing 1122 includes a disc-shaped main body and cylindrical bushing portions connected to and extending from the main body and into the manifold 1110 . The valve pin bushing 1122 has valve pin bores, which create seals with the valve pins 1120 while still allowing the valve pins 1120 to slide.
[0088] The magnetic couplings 1124 include a permanent magnet 1132 (first magnetic part) and a plurality of valve pin heads 1134 (second magnetic parts). The magnet 1132 is fixed to the valve pin plate 1106 and each valve pin head 1134 is fixed to or integral with one of the valve pins 1120 . The magnet 1132 can be fixed to the valve pin plate 1106 by magnetic attraction, a friction fit, an adhesive, bolts, or the like. In this embodiment, the magnet 1132 is held to the magnetically responsive valve pin plate 1106 by an attractive magnetic force. The valve pin heads 1134 are positioned below the magnet 1132 and close enough to establish a magnetic force with the magnet 1132 . In this embodiment, the valve pin heads 1134 are made of magnetically responsive material, so that each valve pin head 1134 is attractively aligned with the magnet 1132 . The resulting the magnetic force is an attractive magnetic force that tends to pull each valve pin head 1134 towards the magnet 1132 and into a stopped position against the magnet 1132 . In other embodiments, the magnet 1132 and the valve pin heads 1134 can include or be replaced by other combinations of permanent magnets, electromagnets, and magnetically responsive material. Embodiments using repulsive magnetic forces are also possible (see FIG. 7 ).
[0089] Each magnetic coupling 1124 couples a respective valve pin 1120 to the valve pin plate 1106 . The magnet 1132 directly transmits actuator closing force to the respective valve pin head 1134 when the valve pins 1120 are being closed (i.e., moved down) by pushing on the valve pin heads 1134 . The magnet 1132 also pulls the valve pins 1120 upwards by attractive magnetic forces acting on the valve pin heads 1134 , when the valve pins 1120 are being opened. During normal operation, the magnetic force is sufficient to keep the valve pins 1120 coupled to the valve pin plate 1106 when the valve pins 1120 are opened and closed. If a valve pin becomes immovable, the respective attractive magnetic force is overcome, so that the immobilized valve pin is decoupled from the magnet 1132 .
[0090] During normal operation the actuator 1104 opens and closes the valve pins 1120 via the magnet 1132 and the heads 1134 of the valve pins 1120 . FIG. 11 shows the valve pins 1120 closed, while FIG. 12 shows the valve pins 1120 open. However, when a valve pin 1120 is immobilized (e.g., when a cavity 130 is taken out of service), the head 1134 of the valve pin 1120 decouples from the magnet 1132 when the actuator 1104 pulls the valve pin plate 1106 up, as shown in FIG. 13 .
[0091] FIG. 14 shows an injection molding apparatus 1400 according to an embodiment of the present invention. The features and aspects described for the other embodiments can be used accordingly with the present embodiment.
[0092] The injection molding apparatus includes an actuator plate 1402 , an actuator 1404 , a back plate 1408 , a manifold 1410 , a nozzle 1412 , a mold plate 1414 , a cavity plate 1416 , a core 1418 , a valve pin 1420 , a valve pin bushing 1422 , and a magnetic coupling 1424 . The injection molding apparatus 1400 can include any number of manifolds and nozzles, in any configuration. In this embodiment, one manifold and one nozzle are shown for simplicity. The injection molding apparatus 1400 can include additional components, such as mold plates, alignment dowels, mold gate inserts, and cooling channels, among others.
[0093] The actuator plate 1402 has an opening for accommodating the actuator 1404 . If the actuator 1404 depends on a working fluid for operation, fluid conduits can be provided in the actuator plate 1402 . Should the actuator 1404 be electric or magnetic or of some other design, electrical conduits can be provided.
[0094] The actuator 1404 is disposed in the actuator plate 1402 and can be pneumatic, hydraulic, electric, magnetic, or of some other design. The actuator 1404 can translate the magnetic coupling 1424 by linear motion (e.g., a pneumatic piston) or rotary motion (e.g., an electric screw drive). To accomplish this, the actuator 1404 has a stationary part connected to the actuator plate 1402 and has a movable part 1425 .
[0095] The back plate 1408 is disposed between the magnetic coupling 1424 and the valve in bushing 1422 and serves to secure the valve pin bushing 1422 in the manifold 1410 . The back plate 1408 has a bore through which the valve pin 1420 extends.
[0096] The manifold 1410 defines a manifold channel 1426 and includes a manifold heater. The manifold channel 1426 receives molding material (e.g., plastic melt) from an inlet (not shown) or an upstream manifold (not shown). The manifold heater can be of any design, such as the insulated resistance wire illustrated. It should also be mentioned that, because of the plate interconnections (not shown), the manifold 1410 is stationary relative to the stationary part of the actuator 1404 .
[0097] The nozzle 1412 is connected to the manifold 1410 and defines a nozzle channel 1428 in communication with the manifold channel 1426 . In this embodiment, the nozzle 1412 includes a nozzle body, a nozzle flange, a nozzle heater, a thermocouple, a terminal end for connecting the heater to a power source, a nozzle tip, and a tip retainer. The nozzle 1412 in combination with the manifold 1410 can define a hot runner.
[0098] The mold plate 1414 has a well to accommodate and support the nozzle 1412 . The well is sized to thermally insulate the nozzle 1412 from the surrounding material.
[0099] The cavity plate 1416 and the core 1418 define a cavity 1430 , and the cavity plate 1416 defines a mold gate leading to the cavity 1430 . The cavity plate 1416 and the core 1418 are separable from the mold plate 1414 along a parting line to allow ejection of a molded product from the cavity 1430 .
[0100] The valve pin 1420 extends from the magnetic coupling 1424 through the nozzle channel 1428 for controlling flow of molding material through the mold gate and into the cavity 1430 .
[0101] The valve pin bushing 1422 is held to the manifold 1410 by the back plate 1408 . The valve pin bushing 1422 includes a disc-shaped main body and a cylindrical bushing portion connected to and extending from the main body and into the manifold 1410 . The valve pin bushing 1422 has a valve pin bore, which creates a seal with the valve pin 1420 while still allowing the valve pin 1420 to slide.
[0102] The magnetic coupling 1424 includes a housing 1431 , a permanent magnet 1432 (first magnetic part), a valve pin head 1434 (second magnetic part), and a set screw 1436 . The housing 1431 , which in this embodiment is a simple tube, is fixed to the movable part 1425 of the actuator 1404 and the magnet 1432 is adjustably fixed in the housing 1431 by the set screw 1436 , such that the magnet 1432 is fixed to the movable part 1425 of the actuator 1404 . In other embodiments, the magnet 1432 can be fixed to the housing 1431 by magnetic attraction, a friction fit, an adhesive, bolts, or the like. The valve pin head 1434 is fixed to or integral with the valve pin 1420 . The valve pin head 1434 is positioned below the magnet 1432 and close enough to establish a magnetic force with the magnet 1432 . In this embodiment, the valve pin head 1434 is made of magnetically responsive material, so that the valve pin head 1434 is attractively aligned with the magnet 1432 . The resulting the magnetic force is an attractive magnetic force that tends to pull the valve pin head 1434 towards the magnet 1432 and into a stopped position against the magnet 1432 . In other embodiments, the magnet 1432 and the valve pin head 1434 can include or be replaced by other combinations of permanent magnets, electromagnets, and magnetically responsive material. Embodiments using repulsive magnetic forces are also possible (see FIG. 7 ).
[0103] The magnetic coupling 1424 couples the valve pin 1420 to the movable part 1425 of the actuator 1404 . The magnet 1432 directly transmits actuator closing force to the valve pin head 1434 when the valve pin 1420 is being closed (i.e., moved down) by pushing on the valve pin head 1434 . The magnet 1432 also pulls the valve pin 1420 upwards by the attractive magnetic force acting on the valve pin head 1434 , when the valve pin 1420 is being opened. During normal operation, the magnetic force is sufficient to keep the valve pin 1420 coupled to the movable part 1425 of the actuator 1404 when the valve pin 1420 is opened and closed. If the valve pin becomes immovable, the attractive magnetic force is overcome, so that the immobilized valve pin 1420 is decoupled from the magnet 1432 (see FIG. 13 , for example).
[0104] FIG. 15 shows part of an injection molding apparatus 1500 according to an embodiment of the present invention. The features and aspects described for the other embodiments can be used accordingly with the present embodiment. Only differing features are described in detail.
[0105] An actuator 1504 is coupled to a back plate 1502 . A valve pin 1520 (second magnetic part) is positioned adjacent a moveable part 1525 (first magnetic part) of the actuator 1504 . The valve pin 1520 is made of magnetically responsive material and is attractively aligned with the moveable part 1525 , which is a permanent magnet or an electromagnet. Therefore, the valve pin 1520 and the movable part 1525 of the actuator 1504 form a magnetic coupling. Operation is similar to the other embodiments, with the valve pin 1520 decoupling from the movable part 1525 of the actuator 1504 when the attractive magnetic force is overcome.
[0106] FIG. 16 shows a portion of a valve pin 1600 according to an embodiment of the present invention. The features and aspects described for the other embodiments can be used accordingly with the present embodiment. Only differing features are described in detail.
[0107] The valve pin 1600 includes an upper portion 1602 , a lower portion 1604 , and a magnet 1606 between the upper portion 1602 and the lower portion 1604 . In normal operation, when the upper portion 1602 is pushed down by an actuator (not shown), the upper portion 1602 pushes the magnet 1606 down, which pushes the lower portion 1604 of the valve pin 1600 down in a direct manner. When the upper portion 1602 is pulled up by the actuator, the attractive magnetic force provided by the magnet 1606 magnetically couples the upper portion 1602 to the lower portion 1604 , so that the lower portion 1604 is pulled up as well. In the lower portion 1604 becomes immobilized, when the upper portion 1602 is pulled up by the actuator, the magnet 1606 remains coupled to either the upper portion 1602 or the lower portion 1604 while the attractive magnetic force is overcome and upper portion 1602 and the lower portion 1604 separate. Both the upper and lower portions 1602 , 1604 can be made of magnetically attractive material. Or one of the upper and lower portions 1602 , 1604 can be made of magnetically attractive material while the other is not, in which case, the magnet 1606 is fixed (e.g., by adhesive, mechanically, etc) to the non-magnetically attractive portion. The magnet 1606 can be a permanent magnet or an electromagnet.
[0108] In embodiments described herein, supplementary components have been omitted for clarity. For example, a designer may choose to provide many of the threaded components described with lock nuts or another mechanism to stop the threads from working free over time.
[0109] In addition, the valve pins described are down-closed and up-open.
[0110] Reverse gating (up-closed, down-open) and lateral gating (e.g., edge gating) are also possible.
[0111] Moreover, structure, such as a valve pin plate, located near permanent magnets can be provided with cooling channels or cooling devices, if the expected operating temperature is higher than the allowable temperature for the type of magnet used.
[0112] Regarding the mechanical functionality of the embodiments described above, electromagnets are equivalent to permanent magnets. Electromagnets, however, can be shut off such that a valve pin can be taken out of service regardless of the magnitude of any valve-pin immobilizing force. On the other hand, permanent magnets do not require wiring, electrical conduits, and and/or control. The choice between electromagnets and permanent magnets is left to a designer, who can take into account these differences and any others.
[0113] Lastly, the terms fixed, connected, coupled, etc used herein do not exclude indirect connections between parts. For example, a part can be fixed to another part with any number of parts in between or none at all (i.e., directly fixed). In addition, parts described as fixed, connected, coupled, etc can also be integral, if the resulting functionality is not changed.
[0114] Although many embodiments of the present invention have been described, those of skill in the art will appreciate that other variations and modifications may be made without departing from the spirit and scope thereof as defined by the appended claims. All patents and publications discussed herein are incorporated in their entirety by reference thereto. | A method for taking a nozzle of a valve gated runner apparatus includes releasably attaching a valve pin to a movable part of an actuator for moving the valve pin between an open position and a closed position and detaching the valve pin from the actuator by moving the movable part of the actuator towards the open position when the valve pin is immobilized. The valve pin and the movable part valve pin may be releasably attached by a magnetic force. The step of detaching the valve pin from the actuator may be accomplished by overcoming the magnetic force. A valve pin plate can be provided for a plurality of valve pins to be releasably attached to the actuator. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electromagnetic within-mold stirring method designed to improve the quality of ingots obtained by horizontal continuous casting, and more particularly relates to an electromagnetic within-mold stirring method and an apparatus therefor, designed to minimize occurrence of surface defects such as cold shut and vertical surface cracks.
2. Description of the Prior Art
Intensive studies have been made in various countries for development and practical use of horizontal continuous casting, and investigation has also been made of applying electromagnetic stirring thereto for the same purpose as in secondary cooling zone stirring in vertical continuous casting such as an ordinary upright bending type casting and a curved type continuous casting, that is, for the purpose of increasing the equi-axed crystal zone and remedying central segregation.
For example, Japanese Patent Application Disclosure Nos. 120453/1977, 89829/1978 and 1544/1982 propose methods of stirring molten steel within a mold in horizontal continuous casting.
However, very few can be put to practical use, and electromagnetic stirring has not yet been developed to the extent that its effect can be fully enjoyed. Horizontal continuous casting machines are inevitably operated by intermittent drawing because of their construction being entirely different from that of vertical continuous casting machines, but intermittent drawing entails a surface defect called cold shut, said defect remaining even after rolling. This accounts for the fact that scarfing or cutting of the ingot surface has been practiced with the full knowledge of an inevitable decrease in the yield of good ingots; thus it has been desired to establish measures to prevent occurrence of cold shut itself. Accordingly, a method has been proposed which uses a break ring which causes the inner diameter of the refractory between the mold and the nozzle to approach the inner diameter of the mold. With this method, however, there is a problem in that drawing becomes impossible as the break ring is consumed and thus such is not suitable for a long-term operation. There has also been proposed to increase the drawing cycle so as to decrease the cold shut depth, but the effect of decreasing the cold shut depth is insufficient and there is a disadvantage in that the drawing mechanism becomes too complicated. On the other hand, in the case of horizontal casting of round billets, cooling of the upper and lower surfaces of the billet in the mold tends to be nonuniform, resulting in longitudinal surface cracks in the upper surface, which is insufficiently cooled. However, there has been no report regarding measures to prevent this drawback.
SUMMARY OF THE INVENTION
With this serious situation concerning the prior art problems in mind, the present invention has been accomplished as a result of finding the proper conditions for electromagnetic stirring which are capable of coping with the phenomenon peculiar to horizontal continuous casting. Accordingly, an object of the present invention is to establish conditions for electromagnetic stirring within-mold which are capable of minimizing cold shut and vertical surface cracks which pose a problem to the implementation of horizontal continuous casting. The electromagnetic within-mold stirring method of the present invention which attains said object is characterized in that electromagnetic stirring is imparted to molten steel passing through a mold, under the following conditions: the maximum magnetic flux density (in gauss) of a magnetic field induced by an electromagnetic coil ranges from 1045·e -0 .16f to 2054·e -0 .12f (f: frequency, 1-15 Hz) and the place of said maximum magnetic flux density is within 350 mm from the junction between the pouring nozzle and the mold in the direction of drawing of the cast-piece.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts throughout the several views and wherein:
FIG. 1 is a schematic view showing how electromagnetic stirring is implemented; and
FIGS. 2 through 8 are graphs demonstrating the effectiveness of the present invention, wherein FIGS. 2 and 4 show the relation between drawing cycle and cold shut, FIGS. 3 and 6 show the relation between cold shut and maximum magnetic flux density on the inner wall surface of a mold, FIG. 5 shows the frequency of occurrence of cold shut, FIG. 7 shows the relation between maximum magnetic flux density on the inner wall surface of a mold and longitudinal surface cracks, FIG. 8 shows the relation between frequency and maximum magnetic flux density on the inner wall surface of a mold;
FIG. 9 shows the relation between cold shut depth, percentage occurrence of surface cracks and the position of maximum electromagnetic stirring strength; and
FIG. 10 shows a reference photograph demonstrating the conditions of the upper and lower surface, with and without stirring .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Having made a wide study, paying proper attention to cold shut and longitudinal surface cracks brought to the fore as a problem peculiar to horizontal continuous casting, and having found that electromagnetic stirring strength and the position of application of electromagnetic stirring constitute important factors for solving the aforesaid problem, the present invention was completed.
The invention will now be described in more detail following the trail of study.
First, in order to investigate the effect of electromagnetic stirring within a mold, a rotating magnetic field type stirrer was attached to a mold (110 m.sup.φ, 110 mm.sup.□, 150 mm.sup.φ) in a horizontal continuous casting machine, and 0.23% C steel, 0.40% C steel, 0.6% C steel, 1.00% C steel and SUS 304 stainless steel were cast. The frequency was changed between 2 Hz and 10 Hz, the magnetic flux density was changed up to 1300 gauss (max), and the influences of these stirring conditions on the depth and shape of cold shut were investigated. In addition, the drawing speed was 0.5-2.9 m/min. and the drawing cycle was 20-100 cycles/min. The outline of the stirrer attached to the horizontal continuous casting machine is as shown in FIG. 1. As for the reference characters in FIG. 1, A denotes molten steel; 1 denotes a tundish; 2 denotes a nozzle; 3 denotes a break ring; 4 denotes a mold; 5 denotes an electromagnetic stirrer; 6 denotes spray nozzles; 7 denotes guide rollers; and B denotes a bloom.
FIG. 2 is a graph showing the relation between the drawing cycle and cold shut, it being seen that as the drawing cycle increases, the cold shut tends to become shallower and that the cold shut in the lower surface of the bloom B is generally deeper than that in the upper surface. This is because with the drawing cycle increasing, the bloom is drawn while the solidified shell is still thin and because the solidification of the lower surface is faster, thus causing cold shut formation. These facts teach that increasing the drawing cycle is a point for shallowing cold shut.
FIG. 3 is a graph showing a variation in cold shut depth caused by within-mold electromagnetic stirring, it being seen that irrespective of the frequency, the cold shut depth tends to be shallower where the magnetic flux density is higher (maximum magnetic flux density in the inner wall surface of the mold), such tendency being more pronounced for 6 Hz and 8 Hz than for 4 Hz. Further, a comparison between the upper and lower surfaces shows that the cold shut in the upper surface tends to be shallower. This is because under the condition where the magnetic flux density is the same, the higher the frequency, the greater the stirring flow rate, thus impeding the formation of cold shut and because the within-mold electromagnetic stirring allows for uniform within-mold cooling so that there is no difference between the upper and lower surfaces. These facts teach that suppressing the growth of solidified shell thickness is an important point for shallowing cold shut.
From these findings, a conclusion was drawn that as a means to shallow cold shut it was important to increase the drawing cycle and intensify electromagnetic within-mold stirring and hence an investigation was conducted of the combined influence of these two factors. FIG. 4 shows the result of such investigation. For example, when a group was stirred under the condition of 6 Hz and 400 gauss or more as compared with a non-stirred group, it was seen that there was a tendency that as the drawing cycle increased, the cold shut became remarkably shallower, and it was seen that at a stage of 100 cycles/min., the cold shut depth, which was 2-5.5 mm for the non-stirred group, decreased to 2-3 mm for the stirred group.
It has been found that the effect of cold shut improvements by the within-mold stirring not only reduces the thickness but also acts on the shape. The reference photographs of FIG. 10 are microphotographs (3×magnification) showing the situation of cold shut, the portions of cold shut being indicated by a black delta mark. In the absence of stirring, cold shut appears as a straight sharp flaw in both upper and lower surfaces, often accompanied by internal cracks in the front end portion, which cause segregation, but in the presence of stirring (8 Hz, 970 gauss), the cold shut is very obscure, not leaving any clear solidification interface. As for the reason therefor, it is believed that the solidification interface is washed by the molten steel flow caused by stirring and part of the solidified shell formed in the early stages of solidification is remelted, mixes with new molten steel entering this portion and solidifies. Where stirring is effected, visual detection of cold shut is very difficult. For example, FIG. 5 shows the number of cold shuts found per unit length (cm) of cast-pipe in horizontal continuous casting with a drawing cycle of 51 cycles/min., making a comparison between a case of no stirring and a case of stirring (6 Hz, 400 gauss or more). Flaws were corroded with hot hydrochloric acid to facilitate detection, but it is seen that the percentage detection is low for each sample where stirring is effected, a fact which conforms to the considerations described above.
Although the effect of cold shut improvements by stirring has thus been ascertained, the contents and extent of improvements are not uniform. For example, in the case of a frequency of 6 Hz, the effect of improvements by stirring develops in approximate proportion until a magnetic flux density of 400 gauss, but even if the magnetic flux density is increased to above 400 gauss, no corresponding increase in the effect appears. Thus, it is necessary to find some upper limit in consideration of economic merits.
As for the concentrations of the alloy components in a shell subjected to the flow of molten steel in the course of solidification, it is known that if the equilibrium distribution coefficient of said alloy components is less than 1, negative segregation takes place and if it is above 1, positive segregation takes place. However, since the equilibrium distribution coefficient of such principal alloying elements as C, Si, Mn, P and S is less than 1, negative segregation takes place. Particularly, negative segregation due to C adversely affects hardenability. Thus it is necessary that the degree of negative segregation given by the following formula be 0.10 or less. ##EQU1##
From the standpoint of reducing negative segregation, excessive stirring must be avoided, and it was thought necessary to determine the upper limit of the stirring force. Accordingly, the relation between C and the degree of negative segregation was investigated by maintaining the frequency at 6 Hz and changing the magnetic flux density so as to change the stirring force. The result is shown in FIG. 6. If the magnetic flux density exceeds 1000 gauss, the degree of negative segregation exceeds 0.10; thus it is necessary that said density be 1000 gauss or less. Further, if the density is less than 400 gauss, this often results in the cold shut becoming deeper; thus the density must be 400 gauss or more before the effect of cold shut improvements can be ensured. Thus, it has been found that there is a region in which cold shut improvements and minimization of negative segregation can be attained at the same time.
FIG. 7 is a graph showing the relation between stirring and longitudinal cracks, illustrating the situation of longitudinal cracks in the surface of a round billet when the magnetic flux density is changed at a frequency of 6 Hz, it being seen that longitudinal surface cracks are remedied as the magnetic flux density is increased. This effect is more pronounced than the effect of cold shut improvements and when the magnetic flux density exceeds 400 gauss, cracks are almost zero. Therefore, it has been found that the proper stirring region provided by FIG. 6 is also effective against vertical surface cracks. It is believed that the cause of longitudinal surface cracks is the nonuniform solidification of the upper and lower surfaces, and it seems that enhancement of uniform solidification has led to prevention of vertical surface cracks.
In the experiments described above, the frequency was 6 Hz. Next time, an attempt was made to find the proper magnetic flux density range while changing the frequency. The result is shown in FIG. 8. The region at the upper right in FIG. 8 is where negative segregation is too high, and the region at lower left is also unsuitable since cold shut and vertical surface cracks manifest themselves plainly. Thus, only the central region marked with diagonal lines is the suitable stirring region, which can be expressed by the following relation between frequency and magnetic flux density.
1045·e.sup.-0.16f ≦G≦2054·e.sup.-0.12f
where
G: magnetic flux density (in gauss)
f: frequency of 1-15 Hz
It has been ascertained that this relation is applicable to various types of steel including carbon steels and stainless steels. The reason whey the lower limit of frequency is 1 Hz is that if it is less than 1 Hz the stirring becomes insufficient, while if it exceeds 15 Hz attenuation becomes noticeable in molten steel, resulting in stirring of only the surface, so that the cold shut preventing effect cannot be fully developed.
The proper position for installing the electromagnetic stirring coil will now be described.
FIG. 9 shows the influence of a maximum electromagnetic stirring strength position on cold shut and cast-piece surface cracks when the position of the electromagnetic coil 5 in the continuous casting equipment shown in FIG. 1 is moved along the lateral surface of the mold 4.
In this embodiment, a magnetic field with a flux density of 780 gauss at a frequency of 6 Hz is used. The drawing of the cast-piece in this case is effected at 60 cycles/min. As is clear from this figure, if the electromagnetic coil is installed so that the position of maximum magnetic flux density is within 350 mm, preferably 200 mm from the junction between the coil 5 and the nozzle 2 in the direction of drawing of the cast-piece, desirable improvements in both cold shut and surface cracks can be obtained. Thus, placing the electromagnetic coil within this range results in applying desired stirring to molten steel in the vicinity of the break ring 3, thereby remarkably remedying cold shut and surface cracks. Placement outside this range would weaken the molten steel flow in the vicinity of the break ring 3, failing to remedy cold shut and surface cracks.
As for the direction of electromagnetic stirring, the flow of molten metal may always be in a definite direction, but there are cases where intermittent forward and backward rotation or intermittent rotation irrespective of its direction is useful in increasing the effectiveness of the present invention. Further, the electromagnetic stirring coil may be attached to one or each of the upper and lower surfaces of the cast-piece but its attachment to the lower surface will provide greater effect.
The present invention is arranged in the manner described so far and is capable of decreasing cold shut and surface cracks peculiar to horizontal continuous casting and minimizing the occurrence of negative segregation, thus breaking through the important bottleneck to practical use of horizontal continuous casting.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | An electromagnetic within-mold stirring method and apparatus wherein electromagnetic stirring is imparted to molten steel passing through a mold, under the following conditions where the maximum flux density (in gauss) of a magnetic field induced by an electro-magnetic coil ranges from 1045.e -0 .16f to 2054.e -0 .12f (f: frequency, 1-15 Hz) and the place of the maximum magnetic flux density is within the range of 350 mm from the junction between the pouring nozzle and the mold in the direction of drawing of the cast-piece. | 1 |
This application is a continuation of application Ser. No. 170,494, filed July 21, 1980, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and apparatus for effecting the gravel packing of a plurality of spaced production zones provided in a subterranean well by a single trip of a work string incorporating the gravel packing apparatus into the well.
2. Description of the Prior Art
Of considerable magnitude in the production of hydrocarbons, such as oil and gas, from a producing well is the problem of sand flow into the well bore from unconsolidated formations. Production of sand with the flow of hydrocarbons will cause the well bore to gradually fill up with minute sand particles until production perforations in the casing and, oftentimes, the end of production tubing inserted therein, are covered, resulting in a significant reduction in fluid production. In many instances, sand production will cause the well to stop producing.
In addition to reduction of fluid production, flow of sand also may cause severe damage to equipment, such as pumps, chokes and the like. In flowing wells, fluid velocity may be sufficient to scavenge sand within the well bore and produce it with the fluid hydrocarbon, resulting in holes being cut in the tubing and flow lines.
One well known means of controlling flow of sand into the well bore is the placement of gravel on the exterior of a slotted, perforated, or other similarly formed liner or screen (hereafter referred to as "production screen") to filter out sand produced with the oil or gas, and thus prevent its entry into the well bore. It is important to size the gravel for proper containment of the sand. Additionally, the slotted liner or screen must be designed to prevent entry of the gravel itself into the production tubing.
Although other fluids have been used, treated and filtered production or nearby well or surface water, to which is generally added a desired concentration of calcium chloride or other active substance, is preferably used in most gravel packing processes during the cleaning or flushing procedure. The water is treated to remove contaminates such as cement particules, scale, and other foreign material generally resulting from the circulation of the water in the well bore.
Apparatus for gravel packing production zones of wells are well known, and a variety of apparatus is commercially available for effecting such operation. See for example, U.S. Pat. Nos. 3,901,318, 3,913,676 and 4,044,832.
All of such prior art devices have, however, required multiple trips of the work string incorporating the gravel packing apparatus into the well in order to effect the gravel packing of a plurality of production zones.
It would be economically desirable where multiple production zones are to be gravel packed in a subterranean well, that the required multiple gravel packing operations should be capable of being accomplished in a single trip of the work string into the production zone of the well. The present invention affords such means and method.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for effecting the sequential gravel packing of a plurality of vertically spaced production zones within a subterranean well having casing in place therein. The apparatus comprises primary sealing means, such as a hydraulically set packer, which is adapted for setting in the casing at a position above the production zones. A plurality of sets of production screens and valve means selectively movable between open and closed positions are provided, the valve means being equal in number to the production zones, the valve means being carriable in the well with the primary sealing means and extending in series therebelow. Production zone isolation means, such as a packer, are connected between each said set and are expansible into sealing engagement with the casing intermediate the adjacent production zones. A tubular control mandrel is provided and is carriable on a conduit in the well with the primary sealing means and is movable within all of the sets. The control mandrel includes a single cross-over means for diverting gravel carrying fluid from the interior of the mandrel to the exterior thereof. A plurality of vertically spaced sealing means are provided on the control mandrel for successively isolating each set from the others when the cross-over means on the control mandrel is positioned in proximity to each of the valve means. Means on the control mandrel are provided for opening the valve means by longitudinal movement of the control mandrel in a first direction and closing the valve means by longitudinal movement of the control mandrel in a second direction. Means are provided for supplying gravel carrying fluid to the interior of the control mandrel whereby each successive production zone may be gravel packed by successively moving the conduit and the mandrel assembly to cooperate with each of the sets, without retrieving the conduit from within the well during the sequential gravel packing of the well.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a, 1b, 1c, 1d and 1e together constitute a schematic quarter section vertical elevational view of the zone isolation, production screen and sliding sleeve portions of a gravel packing apparatus of the present invention in a preferred form for the packing of two production zones in a single trip, FIG. 1a being the lowermost portion of the apparatus and FIGS. 1b, 1c, 1d and 1e respectively being successive upward continuation views.
FIGS. 2a, 2b, and 2c together constitute a schematic quarter section vertical elevational view of a control mandrel assembly that is insertable within the gravel packing apparatus of FIG. 1 to control the direction of fluid flow and provide the required seals, FIG. 2a being the bottom of the tool, and FIGS. 2b and 2c respectively being successively upward continuation views.
FIGS. 3a, 3b, and 3c, together constitute a schematic quarter section vertical elevational view of the packing apparatus of FIG. 1 with the mandrel assembly of FIG. 2 inserted within the gravel packing apparatus in position after the run in of the complete tool through the well casing to a selected depth, FIG. 3a being the lowermost portion of the apparatus and FIGS. 3b and 3c being successive upward continuation views.
FIGS. 4a, 4b, 4c, 4d and 4e together constitute a schematic quarter section, vertical elevational view of the gravel packing apparatus with the elements thereof shown in the positions occupied in the initial gravel packing of the lowermost production zone, FIG. 4a being a view of the bottom of the apparatus, and FIGS. 4b, 4c, 4d and 4e respectively constituting successive upward continuation views.
FIGS. 5a, 5b, 5c, 5d and 5e are views respectively similar to FIGS. 4a-4e, but with the control mandrel assembly shifted upwardly to complete the gravel packing of the lower production zone.
FIGS. 6a, 6b and 6c constitute views respectively similar to FIGS. 4b, 4c and 4d, but illustrating the position of the control mandrel assembly during the gravel packing of the upper production zone.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown positioned within a well casing 1 an exterior apparatus for gravel packing two vertically spaced production zones, the interior portion or control mandrel, being shown in FIGS. 2a, 2b and 2c. The production zones are respectively represented at the vertically spaced sets of casing perforations 1a and 1b.
In the specific example to be described, wherein only two production zones 1a and 1b are involved, the required apparatus is assembled in vertically stacked relationship below a zone isolation means, such as a packer 10. The packer 10 is provided with an expandable packing element 11 for effecting a sealed engagement with the interior wall of the casing 1 at a region above the upper production zone. The packer 10 has a plurality of expandable slips 12 which engage the interior wall of the casing 1 to hold the packer 10 in a fixed position with respect to the casing 1. The packer 10 may be of any one of several well known, commercially available packers, such as the SC-1 packer manufactured and sold by Baker Sand Control Division, Baker International Corporation, of Houston, Tex. The particular type of packer is not critical, so long as it is capable of effecting a seal with the internal surface of the casing 1.
To the bottom of the packer 10 is affixed in conventional fashion to a mill-out extension 20, which is merely a sleeve-like element incorporated to provide adequate tubular conduit length below the packer 10 with a full diameter opening so that, in the event it is decided to retrieve the packer 10, the bottom of the retrieving tool can be accommodated.
Proceeding downwardly, a cross-over sub 25 effects the connection of the bottom of the mill-out extension 20 to a reduced diameter seal bore unit 30. As will be later described, the internal bore surface 31 of the seal bore 30 cooperates with annular sealing elements provided on the control mandrel 200 to control the fluid flow during gravel packing operations.
An extension sleeve 35 connects the seal bore unit 30 with the top of a sliding sleeve unit 40 and properly spaces such sliding sleeve unit relative to the seal bore unit. The sliding sleeve unit 40 is of conventional construction and in effect amounts to a sliding valve, operable by the mandrel 200, for controlling radial ports 47 to selectively permit fluid to communicate between the interior 41 of the sliding sleeve and the casing annulus 1c defined between the outside periphery of the gravel packing apparatus and the internal diameter of the casing 1.
The bottom end of the sliding sleeve unit 40 is connected to the top end of another seal bore unit 50, having an internal sealing surface 51, which, in cooperation with seals on the control mandrel 200, effects the direction of the flow of fluid from the interior of the gravel packing assembly to the exterior during the gravel packing operation.
The lower end of the seal bore unit 50 is secured to the top end of a shear-out safety joint 60 which permits release of component parts of the apparatus including the upper packer in the event that the apparatus becomes stuck in the well bore. The shear-out safety joint 60 may be of conventional construction.
The shear-out safety joint 60 is connected to the top end of a tubular section 65 which in turn is connected to the top end of the uppermost production screen 70 which, when the packer 10 is set, axially straddles the perforations 1b within the uppermost production zone. Again, the production screen 70 is of conventional construction and it is effective to filter out sand and other particulates from the produced fluid, permitting the filtered produced fluid to enter the interior of the gravel packing apparatus and through the production string, to the top of the well.
The lower end of the production screen 70 is connected to the top end of a seal bore 75 having an internal sealing surface 76 which functions in cooperation with sealing elements provided on the control mandrel 200, to direct fluid flow during gravel packing of the upper production zone immediate the casing perforations 1b. The lower end of sealing bore unit 75 is connected to the top end of a tell-tale screen 80, which is employed to insure that the gravel placement in the upper production zone 1b extends to the bottom of the intended longitudinal interval for gravel packing.
The bottom end of the tell-tale 80 is secured to a seal bore 90, the internal sealing surface 91 of seal bore 90 cooperating with sealing elements on the control mandrel 200 to, during gravel packing of the upper production zone, act as an isolator between the upper production zone and the lower production zone and, during the gravel packing of the lower production zone 1a, to act as a director of fluid.
The lower end of the seal bore unit 90 is connected to the top of a left-hand threaded connector sub 95 which, in turn, is threadably connected to a lower zone isolation means, such as packer 100 having a packing element 101.
The components below and including the isolation packer 100 constitute one "set" of gravel packing apparatus. The packer 100 may be of any one of a number of well known type of packers which effect a sealing engagement of a packing element 101 with the internal diameter of the casing 1. Its primary function is to isolate the upper production zone, particularly the casing annulus 1c, from the lower production zone, both during the gravel packing operation through the lower production zone and thereafter during production operations. Preferably, the packer 100 is set by fluid pressure transmitted down the tubing string, and into a self-contained setting mechanism.
The lower portion of the packer 100 is affixed to a large diameter sleeve-like extension 105 and the lower portion of the extension 105 is secured to the top end of a sliding sleeve 110. The function of sliding sleeve 110 is to provide temporary communication through radial ports 111 between the interior of the assembly and the annulus 1c between the o.d. of the assembly and the i.d. of the casing 1.
The lower end of the sliding sleeve 110 is affixed to the top end of a seal bore 120 having an internal sealing surface 121, which, in cooperation with sealing elements provided on the control mandrel 200, directs the flow of gravel and completion fluid to the lower production zone 1a.
The bottom end of the seal bore 120 is connected to a shear-out safety joint 130, which may be identical to the shear-out safety joint 60. Such safety joint is incorporated solely for purposes of retrieval of the apparatus. It permits the convenient retrieval of all apparatus above the shear-out safety joint 130 along with the top half of such shear-out safety joint. The bottom half of the safety joint 130 may be retrieved when the lower screen and liner assembly is retrieved.
The lower end of the shear-out safety joint 130 is affixed to the top end of a tubular section 135 and the lower end of the tubular section 135 is connected to the top end of a lower production screen 140.
The bottom end of the production screen 140 extends to a seal bore 150 having an internal sealing surface 151 to cooperate with seals provided on the control mandrel 200, to direct fluid flow through the lowermost tell-tale screen 160 which is connected to the bottom end of the seal bore 150 and, like the tell-tale screen 80 provided in the upper production zone, insures that the gravel placement has extended downwardly past the bottom of the screen interval.
The lower portion of the tell-tale screen 160 is conventionally connected to the top end of a cross-over sub 165 which merely effects a necessary reduction in diameter between the threaded connections on a standard tell-tale screen 160 and a snap latch 170 connected to the bottom end of the cross-over sub 165. The snap latch 170 is provided to engage the top end of a lower packer 180 which is anchored in the casing 1 at a predetermined position below the lowermost end of the perforations 1a. The external seals 171 provided on the body portion of the snap latch 170 are received in the bore 181 of packer 180 to eliminate any fluid flow across the bore 181 of the packer 180.
Referring now to FIGS. 2a, 2b and 2c, there is shown a control mandrel assembly 200 which is inserted within the aligned bores defined by the exterior gravel packing apparatus components shown in FIGS. 1a through 1e.
Now referring to FIG. 2a, the lowermost component of the control mandrel 200 is a check valve 220 which prevents fluid flow through the bottom end of the mandrel 200. This plug thus effectively prevents fluid transmission from within the control mandrel 200 to any area below the zone that is being gravel packed at a particular time. Immediately above the check valve 220 are a plurality of spaced external seals 225. During the gravel packing operation of the upper production zone, (FIG. 6a) the seals 225 cooperate with the interior surface 91 of the seal bore unit 90.
Immediately above the external seals 225, there is provided a plurality of flow passageways 228 which take fluid returns from the lower tell-tale screen 160 when the control mandrel 200 is shifted to the position shown in FIG. 4a.
Above the flow passageways 228 there is provided a second set of external seals 230 which cooperate with the internal bore surface 151 of the seal bore unit 150 to direct fluid flow down through the lowermost tell-tale screen 160 during gravel packing operations in the lower production zone when the control mandrel 200 is positioned as in FIG. 4a.
Immediately above the seal units 230 there is provided a length of tubular conduit section 235. Above the section 235 is mounted a collet-configured shifting tool 240 which cooperates with the sliding sleeve apparatus 110 or 40 to effect the longitudinal movement of the sliding sleeve from one of open and closed positions to the other position as the control mandrel 200 is shifted longitudinally.
Immediately above the shifting tool 240 there is provided an indicating collet 250 which engages the shoulder 122 of the seal bore 120 and the shoulder 52 of the seal bore 50, to provide a signal to the operator at the surface to determine where the cross-over tool is located relative to the sliding sleeves 110 or 40. Additionally, when the control mandrel 200 is elevated to effect the gravel packing of the lower production zone, the indicating collet 250 engages the shoulder 122 on the seal bore 120. The indicating collet 250 may be of conventional construction, being radially compressible to move downwardly past a constricted shoulder, but requiring the application of a substantial tension force to compress the collet to permit it to pass upwardly through the restricted shoulder 122 of the seal bore 120, or shoulder 52 of the seal bore 50.
Immediately above the indicating collet 250, there is provided a series of external seals 255 which function as the bottom seal assembly in the cross-over tool 260. They are provided to prohibit flow going out the cross-over port 261 and down the interior of the screen liner assembly. The cross-over port 261 directs fluid from the flow passageway 262 of the cross-over tool 260 through the port 111 of the sliding sleeve 110 during gravel packing of the lower production zone, or through the port 47 of the sliding sleeve 40, during gravel packing of the upper production zone, to the casing annulus 1c, thence to the exterior of the production screen 140 or 70, respectively. The cross-over tool 260 may be of the same general configuration as that described in U.S. Pat. No. 4,044,832, and incorporates an inner tubular member 263 having the flow passageway 262 communicating with a concentric work string 300 (FIGS. 4d and 4e) which is run from the surface of the well interior of the tubular work string 5.
A fluid annulus 264 is defined between center tubular section 263 and the outer wall of the cross-over tool 260, and permits fluid transmission to the top of the well through the interior of the mandrel assembly 200 and from the flow passageways 228.
At the upper end of the cross-over tool 260, the annulus 264 communicates through radial ports 265 with the annulus 202 (FIG. 3c) between the control mandrel assembly 200 and the interior of the liner assembly.
The internal bore 201 of the control mandrel 200 is provided with an internally projecting ball valve seat 204 in the vicinity of the lowermost seal elements 255. A ball 203 is positioned on the seat 204 and is run into the well initially with the control mandrel 200 to act as a check valve during reverse circulation operations.
Above the cross-over port 261 there is provided a plurality of axially spaced external seals 270. These seals cooperate with the sealing surface 91 provided in the seal bore 90 (FIG. 4c) above the sliding sleeve 110 during the gravel packing of the lower zone, and with seal bore 30 in the upper zone (FIG. 5d) to prohibit fluid flow out of the cross-over port 261 and directly back up to the top of the well.
Above the seals 270, the control mandrel assembly 200 is provided with a second indicating collet 280 to indicate to the operator at the surface the relative position of the cross-over tool 260 with respect to the sliding sleeve assemblies 110 and 40. The indicating collet 280 is a compression indicator which engages the top of a seal bore, such as 90 and 30, as the control mandrel 200 is moved down.
Above the indicating collet 280, the control mandrel 200 is provided with a collet-like closing tool 285 employed to close the sliding sleeve 110 prior to setting the packer 100.
The top end of the closing tool 285 is affixed to the bottom end of an extended length of pipe 288 on top of which is mounted the setting tool 290 for the packer 10 including a seal ring 291. Above setting tool 290 is mounted a seal bore unit 295 which surrounds seal rings 301 provided on a concentric work string 300 which extends to the bore 262 of the cross-over tool 260. The setting tool 290 and the entire assembly including and below the packer 10 are run into the well on a tubular work string 5.
All of the apparatus illustrated in FIGS. 1a-1e will be hereinafter referred to as the outside screen and liner assembly. All of this apparatus is assembled to the bottom end of the packer 10 prior to insertion of the apparatus in the well.
In the same manner, all of the apparatus shown and described in connection with FIGS. 2a-2c will hereinafter be referred to as the mandrel assembly, and this assembly is inserted within the outer screen and liner assembly. Lastly, the work string 300 (FIGS. 4c, 4d and 4e) is run within the control mandrel assembly 200 at the appropriate time.
OPERATION
Prior to running the gravel packing assembly in the well, the lower packer 180 is anchored in the casing 1 as previously mentioned, at a pre-determined position below the lower production zone perforations 1a. Upon running in the entire gravel packing assembly into the well, the snap latches 172 provided on the snap latch 170 on the bottom of the screen and liner assembly are engaged with cooperating elements on the packer 180 and the external seals 171 of the snap latch 170 are sealingly engaged in the bore 181 of the packer 180, as shown in FIG. 3a. In this position the extreme bottom end of the control mandrel 200 represented by the check valve 220 is positioned below the packer 180 (FIG. 3a). The setting tool 290 now is in position to engage the packer 10. The packer 10 is set by manipulation of the setting tool 290, in a known and conventional manner.
The control mandrel assembly 200 now is moved upwardly a sufficient distance to set the cross-over tool 260 carried by control mandrel 200 in position to permit the pressure of fluid in the work string 300 to be increased to hydraulically set the packer 100. In this position, the seals 255 cooperate with seal bore surface 121 and the ports 111 of the sliding sleeve 110 are closed.
With both the upper packer 10 and the packer 100 set, the control mandrel assembly 200 is moved to the position illustrated in FIGS. 4a-4e wherein the lower locating collet 250 is somewhat below the shoulder 122 of the seal bore 120. In this position, the cross-over tool 260 will have its port 261 commuicating with the annulus 202 between the control mandrel 200 and the screen and liner assembly just above the sliding sleeve 110, whose port 111 will be in the open position. Gravel carrying fluid can thus be introduced into the aforementioned annulus to flow around the perimeter of the lower production screen 140 and downwardly around the tell-tale screen 160. The flowpath is downwardly through the wash pipe 300 into the central bore 262 of the cross-over 260, through radial port 261 into the annulus 202, through the radial port 111 in the sliding sleeve 110 and into the annulus 1c. Return fluid flows through tell-tale screen 160, through the passageways 228 into the annular passage 264 of the cross-over tool 260, through the ports 265 into the annulus 202 (above the seal bore 90), and then into the casing annulus above the packer 100.
The flow of such fluid which, of course, contains aggregate in the size and amount appropriate for the particular well formation, will continue until the gravel covers the lower tell-tale screen 160. This will result in a detectable increase in back pressure of the packing fluid which will indicate to the operator at the surface that the gravel has been applied to the lower end of the screen interval. After this operation, the control mandrel 200 is picked up, as shown in FIGS. 5a-5e, and fluid is continued to be pumped through the wash pipe 300 to pack the production screen 140, with the return fluid being routed through the lower production screen 140.
The control mandrel 200 now is moved to the position illustrated in FIGS. 6a, 6b and 6c wherein the check valve 220 of the control mandrel 200 is now placed above the packer 100, and the series of seals 225 surrounding the check valve of the control mandrel 200 are in sealing engagement with the inner sealing surface 91 of the seal bore 90. The raising of the mandrel 200 obviously effects the closing of the port 111 of the lower sliding sleeve assembly 110 through the action of the shifting tool 240 on such sliding sleeve.
The port 261 of the cross-over tool 260 is now positioned just above the open port 47 of the upper sliding sleeve assembly 40. The locating collet 250 is positioned just below the shoulder 52 of the seal bore 50. The seal rings 255 below the cross-over tool 260 are in sealing engagement with the inner surface 51 of the seal bore 50. Thus, the upper production zone, represented by the casing perforations 1b is completely isolated from the lower production zone and the gravel packing apparatus is in the same relationship with work string 300 as previously described in connection with the packing of the lower production zone.
The gravel carrying fluid can now be introduced through the work string 300 into the bore 262 of the cross-over tool 260 of the control mandrel 200, where it will flow outwardly through the port 261 of the cross-over tool 260 into the annulus 202 between the mandrel assembly 200 and the inner wall of the screen and liner assembly through the open port 47 of the sliding sleeve 40. Hence, gravel is packed around the periphery of the tell tale screen 80. When sufficient gravel has been supplied so that the pack covers the tell-tale screen 80, the back pressure of the gravel pack fluid will increase and provide a pressure signal to the operator that the packing has been completed down to the bottom of the desired screen interval.
As before, the control mandrel 200 is then raised to complete the packing of the production screen 70, which will be signalled by a pressure increase.
The control mandrel 200 may now be completely removed from the well, thus closing the ports 47 of the sliding sleeve assembly 40, and the well is ready for production with the gravel packing of the two production zones having been accomplished with a single trip of the aforedescribed gravel packing apparatus into the well.
It should be noted that the distance between the lower tell-tale screen of each gravel packing set and the sliding sleeve of each gravel packing set has to be substantially identical. This is a necessity because of the fixed distances between the sealing elements and the cross-over port of the cross-over tool incorporated in the mandrel assembly. Additionally, to successfully gravel pack a plurality of production zones in a single trip, the lengths of the individual production zones have to be substantially identical.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention. | An apparatus is provided for gravel packing a plurality of zones within a subterranean well. Primary sealing means are adapted for setting in casing at a position above the zones. A plurality of sets of production screens and valve means are provided, the valve means being equal in number to the zones to be packed and being carriable in the well with the primary sealing means. Zone isolation means are connected between each said set and expansible into sealing engagement with the casing. A control mandrel includes a single cross-over means for diverting gravel carrying fluid. A plurality of vertically spaced sealing means are defined on the cross-over means for successively isolating each set from the others when the cross-over means is positioned in proximity to each valve means. Valve opening means are provided on the control mandrel and are operable by longitudinal movement of the mandrel to positions for opening and closing the valve means. Means for supplying gravel carrying fluid to the interior of the control mandrel is provided whereby each successive production zone may be gravel packed by successively moving the conduit and the mandrel assembly to cooperate with each of the sets, without retrieving the conduit from within the well. | 4 |
RELATED APPLICATION
[0001] This application claims priority to U.S. provision patent application No. 60/380,056 filed May 6, 2002 for inventor Terry Douglas Kenney also known as Terry Kenney.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to methods and systems for power generation. More particularly, the present invention is a method and system for power generation including electrical power generation such as by utilizing vehicle traffic on roadways.
BACKGROUND AND RELATED ART
[0003] Energy sources useful for the generation of electricity include wind, water, solar, nuclear and steam energy and various methods and systems have been developed for harnessing such energy to generate electricity, typically by performing useful work to drive an electric generator.
[0004] With the continuing need for energy consumption efficiency and conservation, many efforts have been made to exploit previously unused energy sources. Many methods and systems have been proposed for the harnessing of existing forces or mechanical work to generate electrical power. In particular, several systems and methods have been developed to use the energy and downward force of the wheels of vehicles as they move along a roadway surface.
[0005] The systems can be categorized generally as mechanical systems, air compression systems and hydraulic systems.
[0006] Mechanical Systems.
[0007] Mechanical systems for generating electric power from the downward force of vehicles passing over a roadway typically involve gear mechanisms and other moving parts and are prone to wear and tear from the stress of forced downward movement in response to vehicles and forced upward movement when being reset. One example is U.S. Pat. No. 4,238,687 to Martinez discloses a. system for generating electric power from the passage of motor vehicles over a roadway using turbines that are driven by the downward rotational movement of arc-shaped arms connected to rocker plates installed on a road surface when such rocker plates are forced down by vehicles passing over them.
[0008] Air Compression Systems.
[0009] Air compression systems typically involve an air compression piston being driven by an actuator of some sort that translates the downward force of a vehicle passing over a roadway in which the actuator is installed. For example, U.S. Pat. No. 4,173,431 to Smith discloses a road vehicle-actuated air compressor and system for using compressed air to operate an electrical generator to generate electricity. The road vehicle-actuated compressor includes an actuator that is pushed downward by the weight of vehicle tires passing over it, driving a reciprocating piston in a cylinder, compressing the air in the cylinder. An electric generator is driven by compressed air from the cylinder. Another example is U.S. Pat. No. 5,634,774 to Angel et al. which discloses a road vehicle actuated air compressor which utilizes flaps mounted in pairs in a road or pedestrian walkway surface. When traffic moves over the flaps, the flaps move downward to activate a piston which compresses air. The compressed air is stored and used as needed to generate electricity. Air compression systems, while generally somewhat more durable than mechanical systems, are not efficient in maximizing the amount of energy translated from the downward forces of moving vehicles to drive an electrical generator, due to friction and other losses.
[0010] Hydraulic Systems.
[0011] Several systems utilize hydraulic pumps to absorb the downward force of vehicles passing over a roadway and translate same into useful work, such as to drive an electric generator. For example, U.S. Pat. No. 4,004,422 to Le Van discloses a method and apparatus for producing useful work utilizing the weight of moving traffic by incorporating in a roadway or traffic-way a readily deformable chamber which is filled with a fluid, arranged so that the weight of the vehicle is passing over it causes displacement of the fluid contained therein. The energy of the displaced fluid in turn is translated into mechanical or electric energy. U.S. Pat. No. 4,130,064 to Bridwell discloses a system for utilizing the weight and momentum of moving vehicles to produce usable energy comprising a fluid displacement pump positioned either under a moveable plate in a roadway or between the rail in a railbed in a railway which compresses hydraulic fluid as the vehicle passes over, a low pressure line for supplying fluid to the pump chamber, a high pressure outlet line communicating with the chamber and connected to a manifold which is supplied with high pressure fluid from a number of other similar pumps and which directs the fluid to an energy conversion device such as a fluid motor and electric generator. The invention teaches use of a dual-stroke pump actuated depending on the weight of the passing vehicles. The dual-stroke pump allows greater volumes of hydraulic fluid to be pressurized depending on the weight of the passing vehicle.
[0012] Similarly, U.S. Pat. No. 4,211,078 to Bass is directed to a power source comprising a cylinder arranged to pump hydraulic fluid into a pressure accumulator. The stored hydraulic fluid operates a hydraulic motor to drive an alternator to generate electric power. The cylinder can be a single acting cylinder having a piston rod depressed by the weight of passing traffic on a highway. The system uses an accumulator and a hydraulic motor which drives an alternator to generate electric power. U.S. Pat. No. 4,409,489 to Hayes discloses an apparatus which pressurizes fluid and causes it to flow by capturing energy dissipated by moving vehicles, comprising a network of collapsible bodies containing hydraulic fluid attached to a turbine generator system. The collapsible bodies are resilient tubes, preferably three-part structures made of elastic inner tubes with projections and outer sections of semi-rigid hose. The claimed improvement is in the use of a network of numerous collapsible bodies to capture more weight from passing vehicles.
[0013] More recent efforts include U.S. Pat. No. 6,172,426 to Galich discloses an energy platform system for generating electrical energy from the weight of a moving vehicle comprising a fluid bed containing a volume of fluid which is compressible by the weight of a moving vehicle driven over it. Fluid forced from within the bladder as a result of such compression passes through a circulation system where the moving fluid is used to drive a generator. The circulation assembly comprises an accumulator in fluid communication with the bladder, which receives the forced fluid and releases it at a specified pressure level. A hydraulic pump and reservoir are also used. The electrical generator is a linear generator, comprising an elongate cylinder having a hollow interior. The exterior of the cylinder has a coil around it. A rod is inserted within the cylinder and has a magnet slidably coupled to it. As the rod in the cylinder is moved by the hydraulic fluid, the magnet moves as well, causing an electrical current within the coil. U.S. Pat. No. 6,204,568 to Runner discloses a system for converting mechanical motion of vehicles into electrical energy, comprising a plurality of motion converter assemblies each including a rod which remains in communication with a vertical motion delivery mechanism through a gearing mechanism for rotating the rod in response to vehicle traffic passing over the system, a plurality of fluid pumps each connected to the rotating rod to generate pressurized fluid which in turn drives a turbine generator. The motion converter assemblies have a rectangular base and sides forming a box an are inserted in the road surface. The motion converter assemblies also have a pair of rectangular top plates that are pivotally connected at one end to one side of the motion connection assembly base, with springs urging the plates upward. The top plate has a vertical plate pivotally connected to its under side which has teeth to engage a gear. When a vehicle passes over the top plate of a motion converter assembly, the vertical plate is driven downward and engages the gear, which rotates and drives the fluid pumps.
[0014] These previously described systems, while in principle capable generating electrical power from the downward force of vehicles as they pass over a roadway, are inefficient in their ability to maximize the electrical power generated from each passing vehicle. Vehicles have varying weights; the downward force of a semi-truck is obviously considerably more than that of a compact car. Prior systems do not effectively harness the full force of each vehicle. Additionally, because vehicle traffic is typically irregular, there is an increased need in such a system to maximize the transfer of energy from each vehicle and store energy to provide a steady supply of electric power. An embodiment of the present invention is a system and method for generating power, such as electrical power, from downward vehicle forces on a roadway that effectively harnesses the energy of vehicles of varying weights. Embodiments of the present invention may overcome the shortcomings of prior efforts by employing multiple hydraulic cylinders of different load bearing and hydraulic fluid compression capacities that are selectively activated by a sensor system depending on vehicle weight in a novel combination and configuration with a road plate over which vehicles pass. Embodiments of the present invention can effectively harness the downward force of both moving and stationary vehicles.
SUMMARY OF THE INVENTION
[0015] The invention includes methods and apparatuses for power generation systems. According to an aspect of the invention a power generation system comprises a hydraulic accumulator, a hydraulic reservoir; electric hydraulic cylinders having various weight-handling capacities and a vehicle weight sensor.
[0016] According to a further aspect of the invention, a method for power generation comprises providing electric hydraulic cylinders, sensing a weight, selecting cylinders and directing hydraulic fluid to them and using the weight to force hydraulic fluid.
[0017] According to a still further aspect of the invention a power generation system is disclosed. It may comprise a hydraulic fluid accumulator and a two level road plate.
BRIEF DESCRIPTION OF DRAWINGS
[0018] [0018]FIG. 1 is a diagram depicting certain components of an embodiment of the system of the present invention in a preferred embodiment.
[0019] [0019]FIG. 2 is a diagram depicting additional detail regarding the layout of the components of an embodiment of the system of the present invention in a preferred embodiment.
[0020] [0020]FIG. 3 is a top plan view of certain elements of the road plate component of an embodiment of the system of the present invention in a preferred embodiment.
[0021] [0021]FIG. 4 is a top perspective view of certain elements of the road plate component of an embodiment of the system of the present invention in a preferred embodiment.
[0022] [0022]FIG. 5 depicts a side perspective view of certain elements of the road plate component of an embodiment of the system of the present invention in a preferred embodiment.
[0023] [0023]FIG. 6 depicts a side cross-sectional view of a step assembly of the road plate component of an embodiment of the present invention in a preferred embodiment.
[0024] [0024]FIG. 7 depicts a side cross-sectional view of the road plate component of the system of an embodiment of the present invention in a preferred embodiment utilizing a two-level road plate configuration.
[0025] [0025]FIG. 8 depicts a side perspective view of an electric hydraulic cylinder of the road plate 25 component of an embodiment of the system of the present invention in a preferred embodiment.
[0026] [0026]FIG. 9 depicts a cross-sectional view of an electric hydraulic cylinder of the road plate component of an embodiment of the system of the present invention in a preferred embodiment.
[0027] [0027]FIG. 10 is a diagram of the hydraulic system of an embodiment of the present invention in a preferred embodiment.
[0028] [0028]FIG. 11 depicts a side perspective view of the bottom level road plate assembly used in a preferred embodiment of the invention utilizing a two-level road plate configuration.
[0029] [0029]FIG. 12 depicts a side perspective view of the top level road plate assembly used in a preferred embodiment of the invention utilizing a two-level road plate configuration.
[0030] [0030]FIG. 13 depicts a side and top perspective view of the top level road plate weldment used 10 in a preferred embodiment of the invention utilizing a two-level road plate configuration.
[0031] [0031]FIG. 14 depicts a side and top perspective view of the bottom level road plate weldment used in a preferred embodiment of the invention utilizing a two-level road plate configuration.
[0032] [0032]FIG. 15 depicts the road plate action when a vehicle passes over it.
[0033] [0033]FIG. 16 is a block diagram that shows the relationship between some components of an embodiment of the invention.
[0034] [0034]FIG. 17 is a flow diagram for one or more embodiment of the invention.
[0035] For simplicity in description, identical components are labeled by identical numerals in this document.
DETAILED DESCRIPTION
[0036] In the following description, for purposes of clarity and conciseness of the description, not all of the numerous components shown in the schematic are described. The numerous components are shown in the drawings to provide a person of ordinary skill in the art a thorough enabling disclosure of the present invention. The operation of many of the components would be understood and apparent to one skilled in the art.
[0037] An embodiment of the present invention provides a system and method for electrical power generation utilizing vehicle traffic on roadways. The system of the present invention, in a preferred embodiment may comprise several main components such as a road plate comprising one or more steps and/or arms having electric hydraulic cylinders disposed within them that are actuated when vehicles pass over the road plate and a vehicle weight sensor system that activates specific electric hydraulic cylinders of varying weight handling capacities depending on the vehicle weight sensed by such sensing system; a power generation system that may include a self-contained hydraulic system; and may include an electrical power transmission system.
[0038] Road Plate
[0039] Referring to FIG. 1, which is a general block diagram of the overall system, the road plate component 100 is designed to capture the weight of vehicles passing over it. Multiple road plate components can be used. In one embodiment of the system as depicted in FIG. 7, a two-level road plate configuration is utilized, in which the lower level has higher compression capacity hydraulic cylinders that are activated depending on increased vehicle weight, with the upper level handling lower weight vehicles. FIGS. 11 - 14 depict the main top and bottom level road plate assembly components, showing the weldment assemblies with the level frames, springs, mounts, and hydraulic cylinders. Multiple level road plate configurations can be used in alternate embodiments of the invention.
[0040] Referring to FIG. 4, in a preferred embodiment, the road plate component comprises five main subcomponents: a front step weldment 18 , a rear step weldment 20 , a base plate weldment 16 , aligned with the front step weldment and the rear step weldment and disposed underneath each, forming the base therefor, one or more hydraulic steps or arms, each having one or more electric hydraulic cylinders 10 , and as depicted in FIG. 8 a vehicle weight sensor system that activates specific electric hydraulic cylinders of varying weight handling capacities depending upon the vehicle weight sensed by such sensing system. In a preferred embodiment, one or more piezo-electric traffic sensors may be utilized. Other known sensing mechanisms and systems can be utilized as well. The front step weldment 18 and the rear step weldment 20 may move independently of each other. Although the number of hydraulic cylinders can vary, each weldment is preferably attached to four electric hydraulic cylinders, with one at each corner. The base plate components are preferably constructed from welded aluminum or steel, although other rigid and durable materials such as plastics, fiberglass and other metals and composite materials can be utilized. Additionally, as depicted in FIG. 5, a guide tube 3 fits over another tube welded to the base plate 16 . This guide tube 3 allows each front step weldment and rear step weldment to move vertically up and down, but not move side to side or front to rear. When a vehicle drives on top of a step, the cylinders are forced to retract. Coil springs are used in a preferred embodiment to force the front step weldment and the rear step weldment upward to their extended position after being forced down by passing vehicles. Shocks, struts and hydraulic return systems can also be used to perform this function.
[0041] Referring to FIG. 3, the hydraulic arms 130 and 140 used in combination with steps as 5 described above in a preferred embodiment in the road plate component, resemble railroad track rails in appearance, but have a base plate having a bottom and side walls and a top plate having a top and side walls that are configured to fit over the side walls of the base plate. Within the chamber formed in the space within the base plate and top plate are disposed one or more electric hydraulic cylinders which are connected via hydraulic fluid discharge lines to one or more hydraulic fluid accumulators forming part of the power generation system of the present invention described below. The electric hydraulic cylinders in the arms, as well as those in the steps, can be interconnected via hydraulic fluid lines in parallel, in series, or in other known configurations. Coil springs or other means as described above can be used in the arms to return the top plate to its extended position after being forced down by passing vehicles.
[0042] The layout of the hydraulic arms on the roadway surface may be a factor in the improved efficiency provided by the present invention. As depicted in FIG. 3, in a preferred embodiment, the arms 130 and 140 are configured in a “zigzag” pattern in a direction parallel to oncoming traffic, and are placed before the steps so that vehicle traffic passes over the arms before passing the steps. The layout and spacing of the electric hydraulic cylinders 150 , 151 , 170 , 171 , 180 and 181 within the arms can vary as desired for the specific application, but preferably the electric-hydraulic cylinders may be laid out within the “zigzag” pattern of the arms such that two or more electric hydraulic cylinders are aligned in parallel with vehicle traffic, at or near the road surface where vehicle tires typically make contact.
[0043] Referring to FIG. 8, the electric hydraulic cylinders themselves are preferably made of 25 metal or other materials known to be suitable for such applications, and have a piston slidably disposed within inner cylinder wall. FIG. 9 is a technical drawing of an example of one such supply line and a hydraulic fluid discharge line, as well as positive and negative electrical wires or cables connecting the electric hydraulic cylinder to the solenoid of the sensing system. Hydraulic fluid is supplied to fill the cylinder from the hydraulic fluid reservoir 700 of the power generation system component. The electric hydraulic cylinders are activated by the vehicle weight sensing system based on the vehicle weight sensed and when the sensed vehicle passes over the arms or steps within which the particular activated cylinder is disposed, the cylinder piston is forced downward in the cylinder forcing hydraulic fluid through the hydraulic fluid discharge line to the designated accumulator of the power generation system component.
[0044] As can be recognized, the number of electric hydraulic cylinders used, as well as their size and force handling capacity can vary and can be configured to meet the needs of the desired application. For example, a plurality of electric hydraulic cylinders can be interconnected to a single circulation assembly or manifold or can be connected to respective individual circulation assemblies or manifolds for redundancy of operation.
[0045] Vehicle Weight Sensing.
[0046] In one embodiment which uses piezoelectric sensors for vehicle weight sensing, the piezoelectric sensors may be installed as part of the road plate component in the road surface ahead of the hydraulic arms, and are used to sense vehicle weight and signal specific electric hydraulic cylinders to capture the full weight of, and maximize the power generated from, the passage of each vehicle over the road plate component.
[0047] Referring to FIG. 2, vehicles traveling on the roadway where the improved invention is installed first cross piezoelectric sensors, preferably approximately fifteen to twenty feet ahead of where the hydraulic arms are located. If a vehicle exceeds the pre-set weight, a signal will be sent by the sensor to activate specific electric hydraulic cylinders capable of capturing increased vehicle weight for maximum power generation. The signals may be controlled using an electric solenoid switch. The piezoelectric sensors are installed directly into the road in a manner that allows them to conform to the profile of the road. The sensors may also be used for counting vehicles in order to calculate maintenance and other performance data. Piezo-electric sensing systems such as the Roadtrax® Piezo-electric traffic sensors manufactured by Measurement Specialties, Inc. are suitable in embodiments of the system of the present invention, although other known traffic sensing systems can be used. Such sensors are only {fraction (1/16)}″ thick and ¼″ wide, and can be installed with only ¾″ wide by 314″-1″ deep slots in the road surface, minimizing the damage done to the road, speeding up installation and reducing the amount of grout needed for installation. The sensor can provide high signal output and good dynamic range. The flat construction of the sensor provides improved road noise rejection. Piezoelectric polymer film provides high sensitivity, broad bandwidth and wide dynamic range. A cable form of sensor is preferably used, comprising piezopolymer extruded directly onto a stranded core wire, with conventional braid and jacket similar in appearance to a small coaxial signal cable. One of the inherent advantages of piezo cable over other forms of sensors is the ability of the cable to detect impacts or vibration ranging from very weak pressure signals caused by ground-borne vibration, through to impacts from heavy vehicle axles at high speed. The present invention utilizes this increased sensing capacity to maximize the energy harnessed from each passing vehicle.
[0048] As vehicles move across the arms containing hydraulic cylinders, the weight of the vehicle is captured by the electric hydraulic cylinders, which then feed pressurized fluid into the power generation system component of the present invention. As the vehicles move forward through the road plate component, the rear step weldment adjusts based on the piezoelectric weight sensor input to engage additional cylinders. The vehicles pass over the arms activating the hydraulic cylinders below and the downward force of the vehicle's weight forces hydraulic fluid to be pumped to drive the power generation system component. The piezoelectric sensors send a signal to a solenoid switch to direct the operation of a flow director to direct the flow of hydraulic fluid to the appropriate hydraulic cylinders based on the weight of vehicle. Various flow director manifold components available on the market can be utilized in the present invention. In one embodiment, an integrated hydraulic manifold flow divider manufactured by Moog, Inc. is used.
[0049] Power Generation System
[0050] [0050]FIG. 16 is a block diagram that shows the relationship between some components of an embodiment of the invention. FIG. 17 is a flow diagram for one or more embodiment of the invention.
[0051] Referring to FIG. 1, the power generation system component, in a preferred embodiment, comprises one or more accumulators 300 preferably with one acting as the main accumulator attached to the system to capture average weight of all traffic, and another accumulator connected to the hydraulic cylinders driven by the weight of more heavy vehicles; a hydraulic motor 600 , and an electricity generator 800 driven by the hydraulic motor 600 . The accumulators feed into one motor system. A pressure control/release 400 and regulator 500 control accumulation and release of hydraulic pressure. The accumulators pre-pressurized to a set limit, store the energy until maximum capacity is reached at which time they discharge, releasing 3000 or more pounds per square inch, turning the hydraulic motor 600 . The hydraulic motor 600 operates based on the amount of pressure released and subsequent free flow, which turns a generator 800 to produce electricity. The accumulators are connected to the base plate's electric hydraulic cylinders by hydraulic fluid supply lines and connections. Each different weight of vehicle has the potential to generate a different amount of pressure in the hydraulic cylinders. This is captured and turned into a uniform pressure charging the accumulators. To accomplish this, a gear type flow divider is preferably used to intensify the pressure when a light vehicle passes over the road plate component. For example: a light vehicle passes over the mechanism and generates 500 PSI of pressure and 3.14 cu. inches of volume. The flow divider will reduce the flow to about 0.785 cu. inches but increase the pressure to 2000 PSI. Sequence valves sense the pressure generated by the vehicle and control the flow from each section of the flow divider accordingly. The accumulators start with a set precharge and increase in pressure to a desired setting. The kickdown valve 400 at the accumulator outlet opens when the desired pressure level is reached and spins the hydraulic motor 600 which turns the generator 800 . The hydraulic motor also supplies hydraulic fluid to a hydraulic fluid reservoir 700 which in turn provides a supply of hydraulic fluid to re-fill the electric hydraulic cylinders.
[0052] Electrical Power Transmission System
[0053] The electrical power transmission system component, in a preferred embodiment, comprises a switch gear mechanism 900 and an electrical conduit junction communications with an electrical utility supply grid 1000 . The generator 500 is connected by known electrical connection means through a switching gear 900 to an existing electrical facility junction box 1100 or electrical utility grid 1000 to supply electricity. To further enhance the generation of electricity, a solar panel can be added to the power plant component.
[0054] The solar panel feature is included as part of FIG. 2. The solar panel powers a DC motor to operate a hydraulic pump that feeds fluid into the accumulator. This reduces the volume of traffic required to cross the system to generate electricity and increases the efficiency of the overall unit. Additionally, the solar panel can be used to power a security alarm on the power plant/generation house.
[0055] The overall system is a closed modular designed unit. The road plate can be divided into sections. The system can be pre-assembled on a 10′×8′ skid which would include the accumulator, hydraulic motor and generator. The road plate can be installed in sections with minimal cuts to the roadway and conforms to profile of the road.
[0056] Methods for Generating Electricity Using System.
[0057] The method of the present invention, in a preferred embodiment, may comprise the steps of driving a vehicle over a road plate having one or more steps or arms with electric hydraulic cylinders having varying weight handling capacities disposed within them that are actuated when a vehicle travels over the road plate, and having a vehicle weight sensor system that activates one or more of the specific electrical hydraulic cylinders depending on the vehicle weight sensed by the sensor system; transferring the hydraulic pressure created by the electric hydraulic cylinders when a vehicle travels over the road plate from the electric hydraulic cylinders to a power generation system comprising one or more accumulators connected by hydraulic fluid supply lines to the electric hydraulic cylinders to receive and store pressurized hydraulic fluid supplied by the electric hydraulic cylinders, a hydraulic motor driven by pressurized hydraulic fluid supplied by the accumulators and an electricity generator driven by the hydraulic motor to generate electricity.
[0058] The present invention can be designed to capture as much energy as possible from each vehicle, including light passenger vehicles to buses and heavy trucks. Preferred locations for installation may include parking garages, shopping center or recreation/amusement park parking lots and similar locations with relatively steady vehicle traffic.
[0059] Vehicles on the road have widely varying weights and because the front axle weights versus rear axle weights of vehicles differ substantially, the present invention can capture the energy supplied at many different pressures. The use of dual accumulators each receiving hydraulic fluid from cylinders of different weight handling capacities as activated by the vehicle weight sensing system allow for greater energy harnessing. If a single accumulator is used, a substantial fraction (more than half) of the energy potential of larger vehicles is lost because the accumulator would have to be operated at a low pressure in order to store the energy from smaller vehicles. The present invention provides further efficiency by use of a gear type flow divider to decrease the flow rate but increase the pressure delivered by the lighter vehicles. In sample calculations, overall efficiency of the accumulators in gathering the energy is estimated at approximately 70%, based on a weighted average of the front and rear axle efficiencies of the different sized vehicles.
[0060] While the present invention has been shown and described herein in what is considered to be a preferred embodiment thereof, illustrating the results and advantages over the prior art obtained through the present invention, the invention is not limited to the specific embodiments described above. Thus, the forms of the invention shown and described herein are to be taken as illustrative and other embodiments may be selected without departing from the spirit and scope of the present invention.
[0061] The embodiments described with reference to the Figures are exemplary only, and many other comparable configurations will be apparent to one of ordinary skill in the art
[0062] Embodiments of the invention as described herein have significant advantages over previously developed implementations. As will be apparent to one of ordinary skill in the art, other similar apparatus arrangements are possible within the general scope of the invention. The embodiments described above are intended to be exemplary rather than limiting and the bounds of the invention should be determined from the claims. | The present invention relates to methods and systems for power generation including a method and system for electrical power generation by utilizing forces due to vehicle weights from traffic on roadways. An embodiment of the invention uses multiple compressible hydraulic cylinders of different types, the cylinders used being dynamically selected responsive to the various weights of the vehicles presenting. | 5 |
RELATED APPLICATION
This application is a continuation of application Ser. No. 10/744,101 filed Dec. 24, 2003 now U.S. Pat. No. 6,938,560.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a solid fuel boiler and a method of operating a combustion apparatus.
2. Description of the Related Art
For a solid fuel boiler, there have been demands for combustion at a high efficiency and for reduction of NOx and CO from environmental problems. To meet these demands, methods have been used such as combustion at a low air ratio, a two-stage combustion method, an exhaust gas re-circulation, and the use of a low NOx burner.
In the two-stage combustion method, combustion air is supplied from the burner and air inlet ports (hereinafter referred to as after air ports) disposed on the downstream side of the burner. An air amount in the burner is reduced, and thus, a reducing region in which oxygen is insufficient is formed in a furnace so as to reduce NOx. Furthermore, air is supplied from the after air ports so as to reduce unburned carbon.
In a method of recirculating exhaust gas, a part of the exhaust gas exhausted from the furnace is introduced into the furnace via exhaust gas ports disposed in the furnace on an upstream side of a burner stage or on a downstream side of the after air ports. Since the exhaust gas is recirculated into the furnace, a flow volume of gas flowing through the furnace is increased, and a heat absorption ratio is adjusted in a heat exchanger (water pipe) disposed on a furnace wall, and a heat exchanger disposed in a heat recovery area connected to an outlet of the furnace. Accordingly, steam is stably produced at a higher temperature and pressure, and it is possible to operate the boiler with high efficiency.
In JP-A-2000-46304, a technique is disclosed in which a part of combustion exhaust gas is recirculated to the furnace in order to reduce a thermal NOx concentration.
In this related art, a supply port of the combustion exhaust gas, having an annular section, is disposed in a wind box so as to surround a burner throat, a secondary air supply port and a tertiary air supply port. When such an annular supply port is disposed, an initial flame (having a temperature of about 1000° C.) in the vicinity of the throat of the burner is mixed with the exhaust gas, and the flame sometimes becomes unstable. As a result of the instability of the combustion of the initial flame, fuel NOx cannot be decreased sufficiently. Especially, when air spouted via the air nozzle of the burner is swirled, the initial flame in the vicinity of the burner throat is remarkably mixed with recirculation gas.
Moreover, as disclosed in JP-A-3-95302, there is also a method of supplying the recirculation gas in the vicinity of a bottom of the furnace. However, there is a possibility that the flame is blown off, and stable combustion cannot be performed.
As described above, the decrease of the flame temperature is a problem in a portion of the furnace having a high thermal load. When a maximum temperature of the flame is suppressed, it is possible to suppress ash stick troubles caused by melting or softening of ash on a wall surface, and generation of nitrogen oxide (thermal NOx). When stable combustion can be performed in the portion of the furnace having the low thermal load (corresponding to the initial flame whose temperature is about 1000° C.), fuel NOx and unburned carbon can be reduced.
BRIEF SUMMARY OF THE INVENTION
An object of the present invention is to provide a solid fuel boiler and a combustion method thereof in which thermal NOx, fuel NOx, unburned carbon, and molten ash sticking to a furnace wall can be reduced without impairing flame stability.
According to the present invention, in a solid fuel boiler of a system for recirculating a part of combustion exhaust gas to a furnace, recirculation gas is supplied into the furnace in a manner to prevent the gas from being mixed with a burner initial flame and to mix the gas with a reducing flame just after the initial flame. Accordingly, the temperature of a high temperature region (about 1500° C. or more) in which NOx is produced is lowered so as to reduce thermal NOx.
In the boiler according to the present invention, as shown in FIG. 2 , the recirculation gas spouted from a recirculation gas port is supplied in a manner to be separated from the initial flame in the vicinity of a burner throat, and is supplied in a manner to be well mixed with a reducing flame at a high temperature (about 1500° C. or more).
According to the present invention, there is provided a boiler including: a furnace including a plurality of burners to perform horizontal firing; a duct through which a part of combustion exhaust gas recirculates to a furnace from a downstream side of the furnace; and heat exchanger tubes disposed on a furnace wall and in a heat recovery area of the furnace. Further, gas supply ports are disposed in the furnace on a burner mounting surface or a non-mounting surface, via which the combustion exhaust gas is supplied into the furnace.
For an operation of the boiler, in a usual case, the operation at a low air ratio is performed with high efficiency. Furthermore, in recent years, a two-stage combustion method has frequently been used in order to reduce NOx. In the two-stage combustion, excess fuel combustion is performed near a burner setting area (hereinafter referred to as a burner zone) in the furnace. A flame has the highest temperature in the vicinity of an air ratio of 1.0 (especially, about 0.95, in which air is slightly insufficient), and therefore the flame temperature in the burner zone is increased. Further, the furnace has been requested to be reduced in size in order to save cost, and a thermal load per a furnace section has tended to be high in recent years.
A plurality of burners are arranged to make a plurality of columns (column) and a plurality of stages (row). The recirculation gas ports are disposed above the burners of an upper stage. Other recirculation gas ports are disposed especially near the burners of middle column, and the recirculation gas is entirely supplied to a high-temperature zone in a center part of the furnace.
There are mainly two reaction mechanisms of nitrogen oxide (hereinafter referred to as NOx) in the furnace: NOx produced from nitrogen in fuel (hereinafter referred to as fuel NOx); and NOx produced from nitrogen in the air at high temperature in the flame (hereinafter referred to as thermal NOx).
Therefore, NOx is rapidly increased when the thermal load in the furnace is increased. And when the thermal load on the furnace wall increases, the temperature of ash sticking onto a water pipe disposed on the wall rises, and the ash is sometimes molten. The molten ash is apt to firmly stick to the water pipe and thicken.
Therefore, it is considered that when the thermal load increases, parts of the molten ash sometimes coagulate with each other and make troubles in the boiler operation, for example, to prevent the ash from being discharged. These troubles are easily caused, especially when a melting or softening temperature of the ash is low compared to the furnace temperature.
When a gas recirculation method is applied and recirculation gas is supplied from the bottom of the furnace, the flame temperature is decreased by the thermal capacity of the recirculation gas.
And the residence time at the burner zone is decreased since the flow rate in the furnace is increased. So, the flame temperature at the burner zone is decreased, and the ash trouble is reduced.
However, it is considered that when the recirculation gas is mixed via the bottom of the furnace, the recirculation gas is considered to flow only through a specific portion depending on a flowing situation in the furnace. In the case that the recirculation gas is supplied from the bottom of the furnace and using opposite firing system, when the recirculation gas flows along the front or back wall (burner setting wall), there is a possibility that the ignition of the fuel are forced delay. In such a case, the unburned carbon and CO are sometimes increased. And blow-off or flameout rarely occurred.
Further, when the recirculation gas flows along the side wall, the recirculation gas does not flow through a center portion having the highest temperature zone in the furnace. So, it is considered that the effect of recirculation gas method is not obtained. Especially, in the burner or burners disposed in the lowermost stage among the burners, since the temperature of the peripheral wall of the furnace is low, when the flame temperature is lowered by the recirculation of the exhaust gas, the combustion easily becomes unstable.
According to the present invention, there is provided a solid fuel boiler including: a furnace including a furnace wall provided with a plurality of solid fuel burners so as to perform horizontal firing; a duct through which a part of combustion exhaust gas recirculates to a furnace from a downstream side of the furnace; heat exchanger tubes disposed on the furnace wall and in a heat recovery area of the furnace; and recirculation gas ports which supply the recirculation gas into a reducing flame portion of the furnace without combining the gas with the flame in the vicinity of an outlet of the burners.
In one aspect according to the present invention, the recirculation gas port may be disposed in the furnace on a burner mounting surface. The center of the recirculation gas port may be disposed in a position as high as or higher than the center of the throat of the burner.
In another aspect, the recirculation gas port may be disposed on the burner mounting surface of the furnace outside a wind box of the boiler. In further aspect, a sectional center of the recirculation gas port may be apart from an outer periphery of the throat of the burner by one or more times a diameter (hydraulic diameter) of the throat.
Moreover, the sectional center of the recirculation gas port is preferably disposed apart from the outer periphery of the throat of the burner by 1.1 to four times, especially 1.3 to 1.7 times the diameter of the burner. In the present invention, when the diameter of the burner throat or the recirculation gas port is referred to, hydraulic diameter is meant. The distance between the burners is determined by the design of the heat load, and is usually less than eight times the diameter of the burner throat. Therefore, when the recirculation gas port is disposed apart from each of the burners by an equal distance, the recirculation gas port is apart from the outer periphery of the burner throat by a distance less than four times the diameter of the burner throat.
The sectional shape of the recirculation gas port is preferably substantially circular for the convenience of the manufacturing of the recirculation gas port and in order to avoid unnecessary mixture with the initial flame of the burner. If the recirculation gas port has an elliptical section shape, the recirculation gas is easily mixed with the initial flame of the burner as compared with the recirculation gas port having the circular shape.
The recirculation gas ports can be disposed in the furnace on a surface different from the burner mounting surface. In this case, the setting conditions different from those in the case where the recirculation gas ports are disposed on the burner mounting surface are taken into consideration. That is, the recirculation gas port is disposed in such a manner that the sectional center of the recirculation gas port is disposed substantially as high as or slightly above the sectional center of the burner throat.
When the recirculation gas ports are disposed on the same plane as the burner mounting surface of the furnace, a central axis of the gas port may have right angles, or may be inclined, for example, by 15 or 10 degrees with respect to the furnace surface. It is important to design that the recirculation gas should not be mixed with the initial flame of the burner. When the recirculation gas ports are disposed on the same furnace surface as the burner mounting surface, if the inclination of the gas port is large, the burner throat is too close to the recirculation gas port, and the initial flame is mixed with the recirculation gas. Therefore, such arrangement has to be avoided. However, when the recirculation gas ports are disposed on a furnace wall portion other than the burner mounting surface, the above-described setting conditions can be moderate.
Needless to say, the recirculation gas port can also be disposed on the burner mounting surface of the furnace and the surface different from the mounting surface. In this case, the recirculation gas port disposed in each surface is designed in consideration of the above-described conditions.
The recirculation gas port is preferably disposed in the vicinity of the burner close to the furnace center among the burners. Even when the port is disposed in the vicinity of the burner which is not close to the furnace center, an effect of recirculation gas supply is small. Similarly, the recirculation gas ports may be disposed in the vicinity of the upper burner stage or right above the uppermost burner stage among the burners.
As the gas supplied from the recirculation gas port, it is preferably to use a mixed fluid of the combustion exhaust gas and air. At this time, an oxygen concentration contained in the gas supplied from the recirculation gas port is preferably 3 to 15%. This oxygen rich mixture gas is supplied so that the flame temperature is lowered, and the unburned carbon is reduced by the promotion of the combustion.
In the combustion method of the boiler according to the present invention, a flow volume of the gas spouted from the recirculation gas port is changed in accordance with an operation load of the boiler (fuel supply amount), and the spouted amount is controlled/increased, when the operation load exceeds the set condition.
Moreover, measurement means for measuring at least one of a radiation intensity of the flame, a furnace wall temperature, and a heat exchanger tube temperature is disposed on the furnace wall. When at least one of signal intensities indicating the radiation intensity, furnace wall temperature, and heat exchanger tube temperature by the measurement means exceeds the set condition, the flow volume of the gas spouted from the gas supply port is increased.
The set conditions of the operation load or the signal intensity are determined on the basis of a melting or softening point of the ash of the solid fuel combusted in the furnace.
When the supply port of the gas containing the combustion exhaust gas is disposed on the burner mounting surface, the recirculation gas can effectively be fed into the portion including the highest thermal load in the furnace. Therefore, the flame temperature can be lowered in the portion in which the thermal load is high. With the decrease of the flame temperature the temperature of the ash on the furnace wall will be lower and the slagging trouble of the ash by melting/softening can be prevented. With the decrease of the flame temperature, it is possible to reduce thermal NOx generation.
In another aspect according to the present invention, the invention can be applied to the boiler including the furnace in which a plurality of after air ports for two-stage combustion are disposed after a plurality of burners. Further, it can be applied to another boiler including a duct through which a part of the combustion exhaust gas recirculates into the furnace from the downstream side of the furnace, and heat exchanger tubes disposed on the furnace wall and in the heat recovery area of the furnace. Here, the gas supply port or recirculation gas port for supplying the gas containing the combustion exhaust gas or recirculation gas into the furnace may also be disposed in the furnace on the burner mounting surface.
When the recirculation gas is mixed into the furnace, the flow of the gas in the furnace and the mixture of the fuel and air are promoted. The flow volume of the gas spouted via the recirculation gas port is changed in accordance with the operation load (fuel supply amount) of the boiler, and the spouted amount may also be increased, when the operation load exceeds the set conditions.
The amount of the recirculation gas is usually about 20 volume % of the air amount supplied to the furnace, and the gas flow rate at the recirculation gas port is preferably set to 30 to 50 m/second.
Thermal NOx is remarkably generated with the high operation load. Therefore, the flow volume of the recirculation gas may also be increased only with the high operation load.
With a low operation load, the flow volume of the recirculation gas is reduced so as to reduce the power of a fan, and general efficiency (net thermal efficiency) of the combustion apparatus can be enhanced.
It is to be noted that the set conditions of the furnace wall signal intensity may also be determined on the basis of the melting or softening point of the ash of the solid fuel combusted in the furnace.
The boiler according to the present invention is especially effective for the boiler in which solid fuels such as pulverized coal, biomass, and waste materials are used as fuel.
Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a schematic diagram of a pulverized coal boiler according to a first embodiment of the present invention;
FIG. 2 is an explanatory view showing a relation between a burner flame and a recirculation gas injection in the present invention;
FIG. 3 is a front view showing one example of a method of disposing recirculation gas ports according to the present invention;
FIG. 4 is a perspective view of the boiler according to the example in FIG. 3 ;
FIG. 5 is a front view showing another example of a method of disposing recirculation gas ports according to the present invention;
FIG. 6 is a perspective view of the boiler according to the example in FIG. 5 ; and
FIG. 7 is a schematic diagram of the pulverized coal boiler according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described in detail.
FIRST EMBODIMENT
A first embodiment according to the present invention will hereinafter be described with reference to FIGS. 1 and 2 . FIG. 1 is a schematic diagram of a pulverized coal boiler according to the first embodiment of the present invention. In FIG. 1 , fuel passes through a fuel supply apparatus 1 and a mill 2 , and is supplied to burners 5 via a fuel supply tube 11 . Air for combustion from a blower 4 is branched to burners 5 and after air ports 6 and supplied into the furnace 3 . At this time, the air is adjusted in predetermined flow volumes by a damper (not shown). The combustion air supplied from the burners 5 into the furnace 3 is mixed with the fuel in the vicinity of the burners 5 (in a burner zone 20 ) and used for lean air combustion (reducing combustion).
Furthermore, the air flows upwards in the furnace 3 , unburned carbon and carbon monoxide are burned in a region 21 in which the combustion air from the after air ports 6 is mixed, and the combustion exhaust gas is exhausted to a heat recovery area 7 via an upper part of the furnace 3 . A heat exchanger tube group 8 is disposed over from the upper part of the furnace 3 to the heat recovery area 7 .
FIG. 1 shows opposite combustion in which the burners 5 are disposed on front/rear furnace walls. However, similar effects are obtained in one surface combustion in which the burners are disposed on one wall or in corner firing in which the burners are disposed on the peripheral wall and corners to generate a swirl flow in the furnace 3 .
Recirculation gas ports 9 for recirculating exhaust gas are disposed between the burners 5 of the furnace 3 . A part of the exhaust gas is branched in the heat recovery area 7 , flows back through a gas recirculation blower or fan 10 and piping 12 , and is supplied into the recirculation gas ports 9 .
FIG. 2 is a schematic diagram showing combustion principle of the boiler according to the present invention. In FIG. 2 , fuel 28 blown into the furnace via a fuel nozzle 36 of the burner is mixed with air 29 , ignited in an ignition region (initial flame) 32 , and flows upwards in the furnace in an oxidation region 33 which surrounds a reduction region 34 .
Nozzles are preferably arranged in a wind box (air box 37 ). The air 31 is supplied to the flame 21 via the after air port 6 , and the fuel is completely burned.
When a gas recirculation system is applied as shown in FIGS. 1 and 2 , and the recirculation gas 30 is mixed in the burner zone 20 , flame temperature drops due to thermal capacity of the exhaust gas. Further, since a combustion gas flow rate in the furnace increases, a residence time of the fuel in the burner zone shortens. Therefore, the flame temperature drops, and troubles by the stick of ash onto the furnace wall are not easily caused.
However, it is considered that when the recirculation gas is mixed from the furnace bottom as in the related art, the recirculation gas flows only through specific portions depending on a flow situation in the furnace. Further, in accordance with an example of the furnace including the burners disposed on opposite walls, when the recirculation gas flows along a burner mounting surface, it is possible to prevent from forming the flame in the burners mounted at the lower part of the furnace. This causes a possibility of unburned carbon and CO increase, the flame blowoff, or flameout. Especially in the burners disposed in a bottom stage, since the temperature of the surrounding furnace wall is low, the combustion is easily apt to be unstable.
Moreover, when the recirculation gas flows along the side wall, the recirculation gas does not flow through a furnace middle portion having a highest thermal load. Thus, it is possible to obtain no effect of the recirculation gas mixture. Since the temperature of the surrounding furnace wall is low, in the burners, especially in the burners disposed in a bottom stage, when the flame temperature is lowered by the recirculation gas, the combustion is easily apt to be unstable.
On the other hand, in the embodiment according to the present invention shown in FIG. 1 , since the recirculation gas ports are disposed in the burner mounting surface, the recirculation gas can be effectively fed into the portion having the highest thermal load in the furnace. Therefore, the flame temperature can be lowered in the high thermal load portion. The temperature of ash on the furnace wall is lowered by the drop of the flame temperature, and ash stick troubles by the ash melting/softening can be inhibited from being caused.
Moreover, since the flame temperature is lowered, oxidation reaction into nitrogen oxide (NOx) from nitrogen in the air which becomes active at the high temperature can be inhibited. Therefore, NOx can be reduced in the furnace 3 outlet.
In the first embodiment shown in FIG. 1 , the present invention is applied to the furnace in a two-stage combustion method in which the combustion air is supplied from the burners and the after air ports downstream thereof. Further, when the present invention is applied to a furnace in a single-stage combustion method for charging all the combustion air through the burners, the effect is the same.
Moreover, as shown in FIG. 1 , as the recirculation gas is branched, the recirculation gas ports 9 are disposed on the burner mounting surface, and spouting ports 19 thereof may also be disposed in the furnace bottom. When branch amounts of the recirculation gas are adjusted by control valves 13 , 14 , thermal absorption in the furnace lower part can be adjusted. A relation between the burners and the recirculation gas ports is shown in FIGS. 3 to 6 .
FIG. 3 shows a partial view of the furnace 3 shown in FIG. 1 as seen from a front surface. FIG. 4 is a perspective view of the boiler including the furnace of FIG. 3 , and shows a relation among the burners, after air ports, and recirculation gas ports. In FIG. 3 , the respective circles show the recirculation gas ports and throat 39 portions in the nozzles of the burners. In this case, the supply ports of gas including the recirculation gas are arranged in a direction perpendicular to the burner columns (vertical columns in the drawing).
The fuel spouted from the burners spreads upwards by buoyancy. Therefore, when the recirculation gas ports are disposed above the burners, the recirculation gas easily reaches a high-temperature portion of the flame. Therefore, it is effective for the decrease of the flame temperature. In FIG. 4 , the same reference numerals as those of FIG. 1 denote the same elements.
It is not a prerequisite to dispose the recirculation gas ports perpendicularly to the burner columns.
A distance between the recirculation gas port and the burner closest to the recirculation gas port among the burners is preferably set to a distance of 1.1 times or more, especially 1.3 times or more with respect to an outer diameter of the most constricted portion (throat portion) of the burner nozzle. Moreover, the most constricted portion of the recirculation gas port preferably has an outer diameter of 0.75 time or less with respect to the outer diameter of the most constricted portion (throat portion) of the burner nozzle.
When a distance between the recirculation gas port and the burner has the above-described relation, jet flows (initial flames) from the recirculation gas ports and the burners do not interfere with one another immediately after spouting, and thus, the spouting directions thereof are prevented from flow vibration.
When the gas supply ports 9 are disposed in a horizontal direction of the burners as shown in FIG. 5 , the recirculation gas ports are disposed on right and left sides of or above the burners 5 in the uppermost stage.
FIG. 6 is a perspective view of a boiler including the furnace of FIG. 5 . In FIG. 6 , the same reference numerals as those of FIGS. 1 , 4 denote the same elements. Since portions in the vicinity of a furnace central axis or in the vicinity of the uppermost-stage burners 5 receive a radiant heat from the flame formed by the ambient burners, the thermal load is especially apt to increase. To solve the problem, when the recirculation gas ports are disposed mainly in these portions, the maximum temperature of the flame is effectively lowered.
When the recirculation gas is supplied into the burner zone middle part having the high thermal load in the furnace, a maximum temperature of the flame can be lowered. By the decrease of the flame temperature, the temperature of the ash on the furnace wall is lowered, and the ash stick troubles by the softening/melting are inhibited from being caused. Also, with the decrease of the flame temperature, the oxidation reaction into nitrogen oxide (NOx) from oxygen in the air which becomes active at the high temperature (1500° C. or more) is inhibited, and thermal NOx is reduced.
In the embodiments shown in FIGS. 3 and 5 , the distances from the burners disposed on a front wall 25 and a rear wall 26 in the furnace to the recirculation gas ports 9 are set to be one time or more than the diameter (hydraulic diameter) of the most constricted portion (throat portion) of the burner nozzle.
FIGS. 5 and 6 also show the boiler in the opposite combustion. Further, even in the one-surface combustion in which the burners are disposed on one wall, when the recirculation gas ports are disposed on the wall surface other than the burner mounting surface, the similar effect is obtained. Especially in the one-surface combustion, when the recirculation gas ports are disposed in the wall opposite to the burner mounting surface, the stick of the ash can effectively be suppressed.
As shown in FIG. 1 , when piping 15 for introducing air into the piping 12 for recirculating the combustion exhaust gas to the furnace and a damper 16 are disposed, the gas spouted from the recirculation gas ports is a mixed fluid of the recirculation gas and air.
When a large amount of recirculation gas is supplied in order to well mix the fluid in the furnace, a region having an oxygen concentration of about 8% or less may be formed. In this region, the combustion reaction is interrupted by a rapid decrease of the oxygen concentration, and fuel particles are rapidly cooled. Even when the oxygen concentration increases again, the combustion reaction does not easily advance, and there is a possibility that the unburned carbon and carbon monoxide are increased.
When the concentration of oxygen is set to be higher than that of the recirculation gas, the region having an oxygen concentration of 8% or less can be prevented from being formed. Therefore, together with the decrease of the flame temperature, it is possible to continue the combustion reaction. It is not a prerequisite to raise the oxygen concentration of the recirculation gas.
A measuring unit 22 for measuring at least one of a radiant intensity of the flame, furnace wall temperature, and heat exchanger tube temperature is disposed on the furnace wall. A signal from the measuring unit 22 is connected to a boiler controller 23 . It is possible to adjust a fuel or air flow volume by the boiler controller 23 . In the present embodiment, the boiler controller 23 can send a signal to a control valve 24 for a recirculation gas flow volume.
When the signal of the measuring unit 22 exceeds a set condition of at least one of the radiant intensity of the flame, furnace wall temperature, and heat exchanger tube temperature, the flow volume of the gas spouted from the recirculation gas port is increased, and a maximum temperature of the flame is lowered. The ash stick trouble on the furnace wall can be prevented by the drop of the flame temperature. The reaction (thermal NOx reaction) in which NOx is generated from nitrogen in the air, is inhibited, and the NOx concentration exhausted from the furnace can be inhibited. This control system is also disposed in the example shown in FIG. 4 .
The measuring unit 22 is disposed on the furnace wall as shown in FIG. 1 , and may also be disposed in the lower or upper part of the furnace. For example, a non-contact type measuring unit such as a radiation intensity meter may also be disposed. The signal of an NOx concentration meter disposed in the heat recovery area may also be used. The thermal NOx reaction is activated in the high-temperature portion of the flame.
When this reaction is used to measure the behavior of the NOx concentration, it is possible to judge whether or not the high-temperature portion is formed in the furnace. When the NOx concentration is high, the flow volume of the gas supplied from the recirculation gas ports is increased, the maximum temperature of the flame is lowered, and NOx can be prevented from increasing by the thermal NOx reaction. The ash stick trouble onto the furnace wall surface can be prevented by the drop of the flame temperature.
According to the above-described embodiment of the present invention, when the supply ports of the gas containing the recirculation gas are disposed on the burner mounting surface, the recirculation gas can effectively be supplied into the portion having the highest thermal load in the furnace. Therefore, the flame temperature can be lowered in the portion having the high thermal load. By the decrease of the flame temperature, the temperature of the ash on the furnace wall can be lowered, and the generation of the ash stick trouble by the melting/softening can be inhibited.
Moreover, when the flame temperature is lowered, the oxidation reaction of nitrogen in the air, activated at the high temperature, into nitrogen oxide (NOx) can be inhibited. Therefore, the generation of NOx in the furnace outlet can be inhibited.
SECOND EMBODIMENT
FIG. 7 shows an example in which the recirculation gas ports are disposed on the furnace wall different from the mounting surface of the burners according to the present invention. In FIG. 7 , the same reference numerals as those of FIGS. 1 , 4 , 6 denote the same elements.
In an opposite combustion boiler in which the burners 5 are disposed on the front wall 26 and rear wall 26 of the furnace 3 , the fuel spouted from the burners collides at the furnace center, and a flow toward side walls 27 may be generated. At this time, fuel particles containing the ash are apt to collide with the side walls, and therefore the ash easily sticks to the side wall middle part especially having the high thermal load.
In the embodiment shown in FIG. 7 , the recirculation gas ports 9 are disposed in the vicinity of the middle of the side wall 27 . Thus, the flow toward the side walls 27 from the furnace middle is moderated by the jet flow of the exhaust gas from the supply ports 9 . Since the ash does not easily collide with the side walls, the ash stick onto the side walls can be inhibited.
In this embodiment, the positions of the recirculation gas ports 9 do not correspond to the relation with the burner columns or stages as in the above-described embodiment, and the ports may be disposed in any position as long as the recirculation gas is mixed with the high-temperature reducing flame as shown in FIG. 2 .
It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.
According to the present invention, the strong stick of the molten ash onto the furnace wall can be prevented, and thermal NOx, fuel NOx, and unburned carbon can be reduced. | There is disclosed a solid fuel boiler including: a furnace including a plurality of solid fuel burners and a furnace wall to perform horizontal firing; a duct through which a part of combustion exhaust gas recirculates to a furnace from a downstream side of the furnace; heat exchanger tubes disposed on a furnace wall and in a heat recovery area of the furnace; and recirculation gas ports via which the recirculation gas is supplied to a reducing flame portion of the burners in the furnace without combining the gas with a flame in the vicinity of an outlet of the burner, so that molten ash is prevented from firmly sticking to the furnace wall and thermal NOx, fuel NOx, and unburned carbon. | 5 |
REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 11/421,635, filed Jun. 1, 2006 entitled now abandoned “Multipurpose Interface and Control System”, which is a continuation-in-part application of U.S. application Ser. No. 10/644,383, filed Aug. 19, 2003, entitled “Tangible Security Asset Management System and Methods Thereof”, a non-provisional application to provisional application No. 60/686,181, filed Jun. 1, 2005, entitled “Multipurpose Interface and Controller”.
FIELD OF THE INVENTION
Controlled access to security assets in boxes
BACKGROUND
A box containing a security asset, such as a key, must be secure. It should not easily yield to forced entry, and it should reliably open only to authorized people. A secure box should also be readily adaptable to many different locations and mounting arrangements. These often include, but are not limited to, walls structured in various ways. Security boxes should also be weather resistant so that they can be mounted in outdoor locations. Finally, security boxes should have emergency opening systems so they can admit access to a security asset during a fire, power failure, or other calamity. As these requirements suggest, security boxes can made in many different sizes and shapes that can be characterized as enclosures, containers, safes, compartments, etc. This application uses “box” as a simple term covering all these possibilities.
Previous suggestions for security asset boxes have failed to meet these requirements. The invention aims to remedy the shortcomings of prior art suggestions and to make available a security asset box that meets all of the above requirements at an affordable price.
SUMMARY
The inventive security box is made mechanically strong and resistant to weather and tampering. It includes a personal identifier that can actuate a solenoid to release an openable closure. For emergency access, the box includes an emergency solenoid actuatable by an emergency voltage to release a latching system and allow the box to be opened when its access solenoid is inoperable.
The box preferably includes a web server that can be accessed by a web browser. This allows information to flow into and out of the box, and such information can include changing or adding to the personal identifiers that can open the box, and generating and transmitting information about asset events that occur during normal operation of the box. These features allow information to be gathered remotely and allow remote instructions to be implemented to protect the ongoing security of the box.
DRAWINGS
FIG. 1 is a partially cut-away and partially exploded perspective view of a preferred embodiment of the inventive security box.
FIG. 2 is a side view of a drawer portion of the box of FIG. 1 with a side wall removed to show internal components.
FIG. 3 is a cross-sectional view of FIG. 2 , taken along the line 3 - 3 thereof.
FIG. 4 is an oblique rear perspective view of the box of FIG. 1 with the drawer closed and a trim disk positioned on a front face.
FIGS. 5-7 are fragmentary views of a latching and emergency opening system preferred for the box of FIGS. 1-4 .
FIG. 8 is a perspective view of an alternative preferred embodiment shown without a housing to reveal a different latching system for the box.
DETAILED DESCRIPTION
The security box 10 as illustrated uses an openable closure such as a drawer, door, or lid that can open from a housing 50 to afford access to a security asset. A drawer 20 such as illustrated is convenient for several reasons as a way of accessing contents of box 10 . Closure 20 contains a security asset such as a key ( FIG. 8 ), but things other than keys can also be secured within box 10 . These can include smart cards, special tools or anything of security importance that can fit within box 10 and deserves the expense of controlled access.
Access to box 10 is controlled by a personal identifier so that only authorized persons can gain access to box 10 . One simple way that this can be done is with number pad 25 that can be conveniently arranged on a front face of closure 20 . Biometric devices such as thumb or fingerprint readers, eye image readers, and possibly others, can all be used. The basic idea is to restrict access to box 10 to only the person or people who are authorized.
Box 10 preferably uses an access solenoid 30 arranged in box 10 or in drawer 20 to unlatch closure drawer 20 for opening in response to entry of an authorized personal identifier. Box 10 preferably also has an emergency opening system using an emergency release solenoid 40 that can be arranged in housing 50 . A preferred latching system operable with solenoids 30 and 40 uses a sliding latch bar 41 having a hole 42 that can be engaged by emergency release solenoid 40 , and having another hole 43 that can be engaged by access solenoid 30 .
FIGS. 5-7 show how the access and the emergency release latching system works. The closed position is illustrated in FIG. 5 with solenoid 30 mounted on closure drawer 20 inside of housing 50 where emergency release solenoid 40 is mounted. Each of the solenoids engage slidable latch bar 41 at holes 42 and 43 .
When access solenoid 30 is actuated, its pin retracts from hole 43 so that drawer 20 can open while access solenoid 30 moves with it to the position of FIG. 6 . If access solenoid 30 is disabled, emergency release solenoid 40 can be actuated, as shown in FIG. 7 . This allows sliding latch bar 41 to release and move with access solenoid 30 , allowing closure drawer 20 to open.
An emergency disabling access solenoid 30 is often a power failure, so emergency release solenoid 40 has a different power supply, preferably from a source remote from box 10 . This can be as simple as a 12-volt battery connectable to contacts wired to emergency release solenoid 40 at a location some distance away from box 10 .
Another preferred aspect of the opening of drawer 20 is a push-to-release feature. This involves one or more springs 51 preferably arranged in a rear of housing 50 to bias drawer 20 toward an opening position. When access solenoid 30 is actuated, the pressure of springs 51 pushing forward on drawer 20 frictionally holds pin 44 of access solenoid 30 in place within hole 43 of slide bar 41 . Pushing back on the front 26 of drawer 20 overcomes the spring pressure and allows solenoid pin 44 to release which then allows drawer 20 to move forward under the urging of springs 51 . Drawer 20 can then be pulled out as far as necessary to reach the security asset that it contains.
Box 10 preferably includes a web server 60 , which is conveniently arranged within closure drawer 20 . This makes it accessible if repairs or replacement become necessary. Mother board 61 and other electronics are preferably also mounted in drawer 20 . Power for the electronic components in drawer 20 is preferably derived from a power over Ethernet (POE) connection which preferably enters housing 50 via a rear opening 52 from which it can be plugged into a top of receptacle 70 . A similar plug 71 on wiring tray 75 automatically plugs into receptacle 70 to power drawer components when drawer 20 is moved into a closed position. Wiring tray 75 then detents into housing 50 by means of a projection 73 entering an opening 74 in wiring tray 75 . This holds wiring tray 75 in place as drawer 20 moves in and out, while a flexible cable 76 conveys power between receptacle 70 and components in moving drawer 20 . ( FIG. 3 )
Housing 50 , as shown in FIG. 4 , is designed for secure emplacement within a wall or other permanent structure. A rear end 55 has opening 52 for wiring purposes, and a front face of housing 50 preferably includes a circular trim disk 56 surrounding drawer front 26 . This arrangement allows a circular hole to be drilled in a wall to receive housing 50 with disk 56 fitting tightly over and enclosing the opening.
Securing housing 50 within a wall can be done in several ways. One preferred way is to fill a cavity around housing 50 with an adhesive foam material that strongly resists any removal of housing 50 . This can be enhanced by fixture blocks 57 , one of which is shown in FIG. 4 . Trim disk 56 can be secured to fixture block 57 by a screw extending through disk hole 58 and into block 57 . Many other arrangements of fasteners, set screws, adhesives, welding, and other expedients can be used to secure housing 50 solidly in place.
The front opening 65 of housing 50 is preferably stepped and flared slightly outward to receive front perimeter 61 of drawer 20 , as shown in FIG. 1 . Front face 26 of drawer 20 preferably fits flush with front rim 65 of housing 50 when drawer 20 is closed. This affords no purchase for a pry bar to get a hold of drawer 20 and force it outward. Also, since moisture may enter the preferably thin gap between housing rim 65 and drawer perimeter 61 , their confronting surfaces are preferably covered or coated with a non-stick material such as polytetrafluoroethylene. This helps prevent drawer 20 from freezing shut.
An alternative box 80 , illustrated in FIG. 8 , is similar to box 10 except for a different latching arrangement. Access solenoid 30 still moves with drawer 20 , and emergency release solenoid 40 is still fixed in housing 50 , the rear plate 55 of which is shown in FIG. 8 . Instead of sliding bar latch 41 , box 80 has a pivoting latch 90 normally engaged and disengaged by access solenoid 30 for opening and closing of drawer 20 . Pin 91 of solenoid 40 holds latch arm 90 in place by passing through latch arm 90 and into fixed bracket 92 , which is secured to rear housing wall 55 . In an emergency, solenoid 40 actuates to retract pin 91 and release latch arm 90 from housing rear plate 55 so that latch arm 90 is free to move with drawer 20 even though access drawer solenoid 30 is disabled. | A web accessed security box includes a web server that can communicate with a web browser to control access and account for asset events that occur when the box is used. A personal identifier must be satisfied to open a drawer of the box. A latching system uses both an access solenoid for normal opening and closing in response to the personal identifier, and an emergency release solenoid having a separate power supply to open the box when the access solenoid is disabled. Several features make the box secure against weather and tampering. | 6 |
[0001] This application is a continuation-in-part application of, and claims the benefit of priority to U.S. application Ser. No. 11/026,859, filed on Dec. 30, 2004, which is a continuation-in-part application of U.S. application Ser. No. 10/355,955, filed on Jan. 31, 2003, which claims the benefit of and priority to U.S. Provisional Application Ser. No. 60/354,098, filed on Feb. 4, 2002. These prior applications are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to medical electrical stimulators, such as Spinal Cord Stimulation (SCS) systems and more particularly to methods for efficiently selecting electrode configurations. An SCS system, used herein as an example of a medical electrical stimulator of the invention, treats chronic pain by providing electrical stimulation pulses through the individual contacts (a.k.a., electrodes) of an electrode array (a.k.a., a lead) placed epidurally next to a patient's spinal cord. The combination of stimulation pulses delivered to the electrodes of an electrode array constitutes an electrode configuration. In other words, an electrode configuration represents each polarity, being positive, negative, or zero of each of the electrodes. Other parameters that may be controlled or varied in SCS and other forms of medical electrical stimulation are the frequency of pulses provided through the electrode array, pulse width, and the strength (amplitude) of pulses delivered. Amplitude may be measured in milliamps, volts, etc. In some SCS systems, the “distribution” of the current/voltage across the electrodes may be varied such that the polarity of each electrode is not a whole number value, but represents a fraction of positive or negative values. Moreover, there may be some electrodes that remain inactive for certain electrode configurations, meaning that no current/voltage is applied through the inactive electrode(s). Therefore, for such systems, each electrode configuration also represents a polarity percentage of each active electrode of an electrode array.
[0003] Previous SCS technology identified these parameters and effectuated stimulation through an electrode array or lead at specific electrode configurations. However, previous SCS technologies attempted to evaluate parameters, including electrode configuration, strength, pulse width, etc., one at a time. An optimized stimulation parameter set for a specific patient may be determined from the response of the patient to various sets of stimulation parameters. There is, however, an extremely large number of possible combinations of stimulation parameters, and evaluating all possible sets is very time consuming, and perhaps impractical.
[0004] Spinal cord stimulation is a well accepted clinical method for reducing pain in certain populations of patients. An SCS system typically includes an Implantable Pulse Generator (IPG), electrodes, electrode lead, and, if needed, one or more electrode lead extensions. Some systems, rather than using an IPG, include an implanted Radio-Frequency receiver that receives pulses from an external transmitter. In either case, the electrodes are implanted along the dura of the spinal cord, and the IPG generates electrical pulses that are delivered, through the electrodes, to the dorsal column and dorsal root fibers within the spinal cord. Individual electrode contacts (the “electrodes”) are arranged in a desired pattern and spacing in order to create an electrode array. Individual wires within one or more electrode leads connect with each electrode in the array. The electrode leads exit the spinal column and generally attach to one or more electrode lead extensions or, depending on the length of the leads, they may attach directly to the IPG. The leads and/or lead extensions are typically tunneled around the torso of the patient to a subcutaneous pocket where the IPG is implanted.
[0005] Spinal cord stimulators and other stimulation systems are known in the art. For example, an implantable electronic stimulator is disclosed in U.S. Pat. No. 3,646,940 issued Mar. 7, 1972 for “Implantable Electronic Stimulator Electrode and Method” that provides timed sequenced electrical impulses to a plurality of electrodes. As another example, U.S. Pat. No. 3,724,467 issued Apr. 3, 1973 for “Electrode Implant For The Neuro-Stimulation of the Spinal Cord,” teaches an electrode implant for the neuro-stimulation of the spinal cord. A relatively thin and flexible strip of physiologically inert plastic is provided as a carrier on which a plurality of electrodes are formed. The electrodes are connected by leads to an RF receiver, which is also implanted.
[0006] In U.S. Pat. No. 3,822,708, issued Jul. 9, 1974 for “Electrical Spinal Cord Stimulating Device and Method for Management of Pain,” another type of electrical spinal cord stimulation device is taught. The device disclosed in the '708 patent has five aligned electrodes, which are positioned longitudinally on the spinal cord. Electrical pulses applied to the electrodes block perceived intractable pain, while allowing passage of other sensations. A patient-operated switch allows the patient to adjust the stimulation parameters.
[0007] Electrode arrays currently used with known SCS systems may employ between one and sixteen electrodes on a lead or leads. Electrodes are selectively programmed to act as anodes, cathodes, or left off, creating an electrode configuration. The number of electrode configurations available, combined with the ability of integrated circuits to generate a variety of complex stimulation pulses, presents a huge selection of stimulation parameter sets to the clinician. When an SCS system is implanted, a “fitting” procedure is performed to select an effective stimulation parameter set for a particular patient. Such a session of applying various stimulation parameters and electrode configurations may be referred to as a “fitting” or “programming” session. Additionally, a series of electrode configurations to be applied to a patient may be organized in a steering table or in another suitable manner.
[0008] A known practice is to manually test one parameter set, and then select a new stimulation parameter set to test, and compare the results. Each parameter set is painstakingly configured and increased in amplitude gradually to avoid patient discomfort. A clinician often bases his selection of a new stimulation parameter set on his/her personal experience and intuition. There is no systematic method to guide the clinician. If the selected stimulation parameters are not an improvement, the clinician repeats these steps, using a new stimulation parameter set, based only on dead-reckoning. The combination of the time required to test each parameter set, and the number of parameter sets tested, may result in a very time consuming process. For instance, a system with 16 selectable electrodes contains over 40 million possible combinations of electrode configurations alone. Thus, testing all possible combinations is impractical.
[0009] In order to achieve an effective result from spinal cord stimulation, the lead or leads may be placed in a location such that the electrical stimulation will cause paresthesia. The paresthesia induced by the stimulation and perceived by the patient should be located in approximately the same place in the patient's body as the pain that is the target of treatment. If a lead is not correctly positioned, it is possible that the patient will receive little or no benefit from an implanted SCS system. Thus, correct lead placement can mean the difference between effective and ineffective pain therapy.
[0010] In order to test the effectiveness on a particular patient of various stimulation parameters and electrode configurations, it is necessary to provide a series of stimulation parameters in a systematic method. Several such systems exist including the systems disclosed in U.S. Pat. No. 6,393,325, herein incorporated by reference in its entirety, wherein a patient may direct the movement of the stimulus current through a suitable interface.
[0011] Another method of testing the effectiveness of various stimulation parameters is disclosed in U.S. application Ser. No. 11/026,859, herein incorporated by reference in its entirety. In this Application, during a fitting session with a patient, a clinician uses navigation with two parameter tables to step through and optimize stimulation parameters.
[0012] The inventors have ascertained that improved methods are needed for selection of electrode configurations during navigation through a programming session, whereby each patient may efficiently optimize and personalize his/her stimulation treatment in terms of stimulation strength, pulse rate, pulse width, and electrode configuration.
SUMMARY OF THE INVENTION
[0013] The present invention addresses the above and other needs by providing methods for selecting stimulation electrode configurations, which methods guide users toward effective stimulation treatments.
[0014] In one embodiment of the invention, a method for selecting electrode configurations for use in a medical electrical stimulator is provided. The method may comprise: (1) providing a set of electrode configurations for at least the active electrodes of an electrode array; (2) automatically testing at least a first portion of the set of electrode configurations in a first order; (3) allowing the selection of one or more of the tested electrode configurations; and (4) automatically testing at least a second portion of the set of electrode configurations in a second order if a suitable number of electrode configurations from among said first portion are not selected within a predefined interval.
[0015] The rate at which the electrode configurations are tested may be controlled. For example, the rate at which the configurations are tested may correspond to about a 5% change in current amplitude per second to about a 50% change in current amplitude per second. Selection of the electrode configurations may be by a patient or may be by objective criteria. Methods may further comprise the steps of re-testing the selected electrode configurations for fine-tuning. The selected electrode configurations may be stored and organized.
[0016] The electrode configurations may correspond to stimulation of a particular part or section of a patient's body. For example, a user may select a particular area of the body by virtue of an interface device. The electrode configurations may then be applied to the patient, as the patient (or attending clinician) is allowed to select particular electrode configurations that are effective. A programming tool may be used to group together related series of electrode configurations. Therefore, the starting electrode configuration may correspond to a stimulation directed to a particular part or section of a patient's body. The starting electrode configuration may be selected by a program or by a user or it may correspond to a particular portion of the electrode array corresponding to a particular part of the patient's body or section of the area of potential stimulation.
[0017] The methods may also comprise clinician, automatic or patient control of other stimulation parameters as the electrode configurations are being applied to the patient. For example, a user may adjust one or more stimulation parameters before or during the testing. These stimulation parameters include polarity or polarity percentage, amplitude, pulse width, pulse rate, and combinations thereof. Various levels of shared control of the other stimulation parameters may be distributed between an automated system, a clinician, and the patient.
[0018] The methods may further comprise: (1) interrupting the continuous testing, (2) selecting a second starting electrode configuration, (3) continuously testing the set of electrode configurations in an order based on the second starting electrode configuration, and (4) allowing the selection of one or more of the tested electrode configurations.
[0019] Another embodiment is a method for selecting an electrode configuration for use in a medical electrical stimulator, comprising: (1) providing a set of electrode configurations the active electrodes of an electrode array; (2) automatically testing at least a portion of the set of electrode configurations; (3) allowing the selection of one or more of the tested electrode configurations; (4) adjusting one or more parameters during the testing, wherein the parameters are selected from the group consisting of polarity, polarity percentage, amplitude, pulse width, pulse rate, and combinations thereof, and wherein the adjusting is controllably shared between a clinician and a patient.
[0020] Another embodiment of the present invention is a method for selecting an electrode configuration for use in a medical electrical stimulator, comprising: (1) providing a set of electrode configurations for at least each active electrode of an electrode array; and (2) testing an effective number of electrode configurations of the set of electrode configurations by, wherein the testing comprises: (a) sweeping through each section of an area of potential stimulation provided by one or more implanted electrode arrays; (b) marking electrode configurations that are effective; (c) testing electrode configurations near any marked electrode configurations; and (d) allowing the selection of one or more of the tested electrode configurations. The sweep may be completed in less than about five minutes.
[0021] In another embodiment, an electrode selection system is provided. A system may comprise (1) a neural stimulation system, the neural stimulation system having a multiplicity of implantable electrodes, (2) an implantable pulse generator connected to the implantable electrodes, (3) electrical circuitry means within the implantable pulse generator for applying a prescribed current stimulus through a selected electrode configuration of the implantable electrodes, (4) a device coupled to the implantable pulse generator for storing and delivering a set of electrode configurations to the pulse generator, (5) means for applying the set of electrode configurations to a patient, and (6) means for allowing user selection of one or more of the electrode configurations in the series.
[0022] The system may further comprise means for generating and displaying a sequence of instructional displays that guide a user through the process of selecting one or more electrode configurations. The system may also comprise means for displaying a graphical representation of a human body such that the set of electrode configurations being applied to the patient is correlated to a part of the human body and such correlation is indicated on the graphical representation. The system may also comprise means for displaying a generic graphic that represents a relative two-dimensional map such that the set of electrode configurations being applied to the patient is correlated to the relative two-dimensional position of the stimulation area and such correlation is indicated on the graphical representation.
[0023] Another embodiment of the invention is an electrode selection system comprising: (1) a neural stimulation system, the neural stimulation system having a multiplicity of implantable electrodes, (2) an implantable pulse generator connected to the implantable electrodes, (3) electrical circuitry means within the implantable pulse generator for applying a prescribed current stimulus through a selected electrode configuration of the implantable electrodes, (4) a memory device coupled to the implantable pulse generator for storing a set of electrode configurations, wherein each electrode configuration represents a polarity or a polarity percentage of each active electrode of an electrode array, wherein the implantable pulse generator automatically tests at least a portion of the set of electrode configurations in order based on a starting electrode configuration, and (5) a user interface device for allowing the selection of one or more of the tested electrode configurations.
[0024] It is thus a feature of the present invention to provide a method for determining optimum electrode configurations without requiring exhaustive testing associated with creating, optimizing and testing each parameter of each electrode configuration. A set of electrode configurations is applied to a patient for selection by the patient. By providing a systematic method for searching for effective electrode configurations, a therapeutic session may be specifically developed for each patient.
[0025] Once one or more electrode configurations are selected and identified by a patient or clinician, these selected electrode configurations may be optimized. An electrode configuration may be adjusted for amplitude (stimulation strength), pulse width, and pulse rate. One such an optimizing procedure is described more fully in U.S. application Ser. No. 11/026,859.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The above and other aspects of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
[0027] FIG. 1 shows a Spinal Cord Stimulation (SCS) system, as an example of a medical electrical stimulator.
[0028] FIG. 2 depicts the SCS system of FIG. 1 implanted in a spinal column.
[0029] FIG. 3 depicts a flow chart according to one embodiment of the present invention.
[0030] FIG. 4 depicts a user interface that may be used during navigation through the electrode configurations.
[0031] FIG. 5 depicts a user interface device that may be used during navigation through the electrode configurations.
[0032] Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
[0033] Appendix A, known as a steering table, herein incorporated by reference, is an example of a set of electrode configurations.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
[0035] The methods of the present invention provide systematic approaches for selecting stimulation parameter sets, or electrode configurations, for medical electrical stimulators. A Spinal Cord Stimulation (SCS) system will be used herein as an example of such a medical electrical stimulator. The methods lead a user through a selection process that efficiently locates optimum electrode configurations. The selection process and system may also herein be referred to as “fitting,” “programming,” “navigating” a “fitting system,” or a “fitting program.” Thus, a user is allowed to navigate through the millions of electrode configurations to determine a customized treatment. As used herein, the term “user” may refer to a patient, a clinician, an automated program, or a combination thereof.
[0036] An exemplary Spinal Cord Stimulation (SCS) system 10 is shown in FIG. 1 . SCS system 10 comprises an Implantable Pulse Generator (IPG) 12 , an optional lead extension 14 , an electrode lead 16 , and an electrode array 18 . The IPG 12 generates stimulation current for implanted electrodes that make up the electrode array 18 . When needed, a proximal end of the lead extension 14 is removably connected to the IPG 12 and a distal end of the lead extension 14 is removably connected to a proximal end of the electrode lead 16 . Alternatively, a proximal end of lead 16 is attached directly to the IPG 12 . Electrode array 18 is formed on a distal end of the electrode lead 16 . The in-series combination of the lead extension 14 and electrode lead 16 , carry the stimulation current from the IPG 12 to the electrode array 18 .
[0037] The SCS system 10 described in FIG. 1 above is depicted implanted in the epidural space 20 in FIG. 2 . The electrode array 18 is implanted at the site of nerve fibers that are the target of stimulation, e.g., along the spinal cord. Due to the lack of space near the location where the electrode lead 16 exits the spinal column, the IPG 12 is generally implanted in the abdomen or above the buttocks. When needed, the lead extension 14 facilitates locating the IPG 12 away from the electrode lead exit point.
[0038] In a preferred embodiment, one, two or more electrode arrays 18 may be implanted in the patient. Having a relatively greater number of electrodes increases the area of the body that can be affected by stimulation, or the “area of potential stimulation.” The area of potential stimulation corresponds roughly to the area of the body mapped to the dermatomes for the area of the spine adjacent to the implanted electrodes. The area of potential stimulation may be divided into sections, each section corresponding to the electrodes that typically provide stimulation to that section of the body.
[0039] A more detailed description of a representative SCS system that may be used with the present invention is described in U.S. Pat. No. 6,516,227, incorporated herein by reference in its entirety. It is to be emphasized, however, that the invention herein described may be used with many different types of stimulation systems, and is not limited to use only with the representative SCS system described in the U.S. Pat. No. 6,516,227 patent.
[0040] The systems and methods explained herein provide a programming or navigation system used to select electrode configurations useful for providing stimulation to a patient. Automated systems and methods offer an alternative to manual selection and testing of electrode configurations to find an appropriate stimulation therapy, e.g., for pain management. Manual selection of electrode configurations has proven to be time consuming and complicated. Electrodes may be manually selected to be positive, negative, or turned off, such that a subset of anodes and cathodes are selected from a total set to create a stimulation delivery electrode configuration. One problem with manual selection, as discussed in the background section, is that it is sometimes a trial and error process, requiring a sophisticated understanding of current field generation. The present systems and methods provide for an easy-to-use navigational system, which allows for patient control, while testing a maximum number of electrode configurations. The present systems and methods eliminate the need to manually select electrode polarity. The present systems and methods eliminate the need to train clinicians on the complications of current field generation. Instead, a large number of electrode configurations is consecutively applied to a patient for testing.
[0041] A flow chart representing one embodiment of a method for electrode configuration testing is depicted in FIG. 3 . As with most flow charts, each step or act of the method is represented in a “box” or “block” of the flow chart. Each box or block, in turn, has a reference number associated with it to help explain the process in the description that follows.
[0042] A set of electrode configurations is provided at step 201 , such as the set illustrated in Appendix A. The exemplary electrode configurations may be arranged in a predetermined order, as shown in Appendix A, may be determined by parameters in software, may be established by an algorithm, may be decided by combinations thereof, or equivalents. A table such as shown in Appendix A may be referred to as a steering table. A steering table typically comprises rows, with each row defining each electrode configuration. In a preferred embodiment, each row specifies the polarity or polarity percentage on each electrode of each electrode array 18 ( FIGS. 1 and 2 ). Each electrode array 18 preferably comprises four or eight electrodes, but certain embodiments may only utilize a subset or superset of the electrode array 18 , for example three or twelve electrodes, respectively. In a preferred embodiment, one or two electrode arrays, each having eight electrodes, are used, resulting in a steering table having eight or sixteen entries per row, respectively (the latter is shown in the example of Appendix A), or nine or seventeen entries per row, respectively (one for each electrode and one for the case of the stimulator, which may also function as an electrode). Those skilled in the art will recognize that a steering table may include, in addition to polarity definitions, other parameters, such as pulse duration and/or pulse frequency, and that table with such other variations is intended to come within the scope of the present invention.
[0043] When polarity percentages are used, rather than just simple polarity settings, the polarity distribution of the rows of the steering table may differ by about 0.05 in value, such as the one illustrated in Appendix A, or by any other suitable order of magnitude. The polarity associated with the electrodes in the electrode array, or a subset or superset of the electrode array, may be summed to zero. For example, one electrode of the electrode array may have a polarity of negative one (cathode), while another electrode may have a polarity of positive one (anode), such as the entry corresponding to Entry No. 21 of Appendix A. Entry No. 21 defines Electrode No. 1 as a cathode and Electrode No. 3 as an anode.
[0044] The rows in the steering table may be ordered or arranged based on the physical characteristics of the stimulation provided by each electrode configuration, so that moving from one row to the next in the steering table represents a gradual, and somewhat uniform, change in stimulation. In other words, stepping from one row to an adjacent row in the steering table causes the stimulation applied to the tissue through the individual electrodes of the electrode array 18 to gradually move in a desired direction. This type of current steering is described more fully in U.S. Pat. No. 6,393,325, which is incorporated herein by reference in its entirety.
[0045] Once the desired set of electrode configurations or steering table has been provided, a starting electrode configuration is selected (step 202 ). For example, the first row of the steering table may be tested first, followed in order by the remaining rows. The rows may be ordered, as explained above, by current steering methods. Groups of electrode configurations (groups of rows within a steering table) may correspond to a certain part of a patient's body. For example, electrodes No. 1 through No. 3 may correspond to stimulating the lower right leg of a patient when programmed in a particular configuration. However, the order of rows is not essential to these embodiments, and the rows may be arranged in any order. The starting electrode configuration may also be selected as corresponding to a particular section of the area of potential stimulation created by one or more implanted electrode arrays. The steering table may be arranged by portions of the electrode array corresponding to the sections, as well. For example, in Appendix A, Entries Nos. 21-41 correspond to electrodes No. 1-4, or a first portion of the electrode array, corresponding to a first section of the area of potential stimulation.
[0046] A clinician or patient may select a row as the starting electrode configuration. This selection may be based on an area of the body to be stimulated by the SCS system. Alternatively, the starting electrode may be predetermined, determined by a program or algorithm, through a user interface, or randomly. A patient may choose from a few possibilities of starting electrode configurations. For example, the patient may choose from a discrete number of trial electrode configurations to select the starting configuration. Such a selection from a discrete number of trial configurations is explained more fully in U.S. patent application Ser. No. 11/026,859.
[0047] Once the starting electrode configuration is selected, stimulation is applied to the patient, as a program automatically steps through each entry or row of the steering table from the selected starting electrode configuration. For example as seen in Appendix A, if Entry No. 21 is the starting electrode configuration, this stimulation is applied to the patient, followed by the stimulation represented in Entry Nos. 22, 23, etc. As each electrode configuration is consecutively tested on the patient, the patient or attending clinician has the power to select, highlight or mark any particular electrode configuration of the set being tested. For example, a patient may select a particular configuration that feels good, or specifically targets an area of the body. The patient may provide this feedback as to the effectiveness of the stimulation that has been applied as represented by the electrode configuration entries of the steering table.
[0048] Objective criteria may also be used to select from the electrode configurations being tested. Alternative means (e.g., objective measurements of various physiological parameters of the patient, such as perspiration, muscle tension, respiration rate, heart rate, and the like) may also be used to judge the effectiveness of the applied stimulation. Selected electrode configurations may be stored for further testing.
[0049] The change in polarity or polarity distribution for consecutive electrode configurations tested may be varied during stimulation or predetermined, such as by selection of an appropriate steering table. For example, the entries for one or more electrodes in two consecutive rows in the steering table of Appendix A may differ by about 5% in polarity distribution. An automated program may test electrode configurations at a more drastic change in polarity distribution, such as up to 50% distribution change on one or more electrodes, per electrode configuration tested. The automated program could skip to every tenth row of a table such as the table of Appendix A, or a different steering table could be used, with rows that differ in polarity distribution for one or more electrodes by 0.50 per row. Such change in the polarity distribution may be limited by a patient's discomfort with the distribution changes during row transitions. A more gradual change in the polarity distribution may result in a more comfortable application of the stimulation to the patient. However, changes in the polarity distribution should be large enough so as to effectively test enough electrode configurations in a given clinical time period. A polarity distribution change of about 1% may not be “fast” enough to test a suitable number of electrode configurations during the fitting session.
[0050] To avoid uncomfortable over-stimulation, the stimulation amplitude may be initially set to a relatively low level, perhaps even below the level that will result in the patient perceiving paresthesia. The stimulation level at which the patient begins to perceive paresthesia is called the perception or perceptual threshold. See e.g., U.S. Pat. No. 6,393,325, noted above. The stimulation may be increased until it begins to become uncomfortable for the patient. This level is called the maximum or discomfort threshold. See e.g., U.S. Pat. No. 6,393,325, noted above. These pre-navigation measured thresholds may be noted before the selection of the starting electrode configuration. Alternatively, these thresholds may be determined based on pre-established values, or based on previously-measured thresholds for the patient.
[0051] Additionally, the amplitude may be adjusted by the user during the testing of the electrode configurations. In other words, while the automated program steps through the entries of the steering table, a user may pay attention to the strength of the stimulation being applied. The electrode configurations represent the polarity or the polarity percentage of the individual electrodes of the array. The steering table entries denote polarity using a positive or negative “1” or, for polarity percentage or polarity distribution, a fraction thereof. The total current applied through each electrode may be about 1 to about 13 milliamps, up to a “grand total” of 20 milliamps applied through all active electrodes combined. The values of the electrode configurations therefore represent a percentage of this grand total current applied. Alternatively, the stimulation amplitude may be quantified by voltage applied to the electrodes. A user may vary this strength of stimulation while the automated program circulates through the configuration of polarities as seen in the steering table.
[0052] Therefore, the amplitude or stimulation strength may be adjusted by a patient, clinician or program before or during a testing session. The pulse width and or frequency may also be controlled or adjusted before or during the testing of the electrode configurations.
[0053] The electrode configurations may be tested in any order, such as the order of the rows in the steering table (step 203 ). In order to efficiently move through all the electrode configurations of the set, a pace may be set or adjusted. A suitable rate or pace may be a current shifting rate of about 5% per 1-3 seconds to about 50% per second. A suitable pause in between rows, entries or electrode configurations may be about 0.1 to about 5 seconds. This time allows a patient, clinician, or program to select the tested electrode configuration. Preferably, about 0.2 to about 10 electrode configurations may be tested per second. More preferably, about 1 electrode configuration per 1-3 seconds should be applied to a patient to allow for adequate testing and possible selection of such electrode configuration.
[0054] In order to rapidly move through the steering table and test an effective number of the electrode configurations on the patient, a navigation program may be used. A navigation program may allow a user to “skip” through part of the steering table if a relatively low number of entries are being selected in that particular part of the table. For example, if no selections have been made within about 20 successive rows of a steering table, the program may move ahead a certain number of entries to another point within the steering table. Successive row testing may then resume at this point in the steering table. The point where the testing resumes may also be referred to as a second (or third, etc.) starting electrode configuration if such skipping is accomplished. Interrupting the sequence of the steering table to move ahead may be prompted by any objective criteria. Additionally, a user may be allowed to skip ahead to test another area of the body. Referring to step 204 of FIG. 3 , if no selections have been made within a certain number of configurations (rows or entries), a program allows the user to skip to another section of the steering table (step 205 ). Alternatively, another steering table may be provided having a second order of electrode configurations to be tested. When and how to skip entries is related to known characteristics of the electrode configurations arranged in the steering table, as explained above. If a patient is making selections frequently enough, the program continues to test the electrode configurations in the order as defined by the rows of the steering table (step 206 ).
[0055] As seen in step 207 , testing is resumed through the steering table at the second (or third, etc.) starting electrode configuration. Once testing is resumed, the patient still has an option to select one or more of the configurations. If the user continues not to select electrode configurations frequently enough, the program is prompted again (step 208 ) to forward to another section in the steering table for testing. In this continuous manner (step 209 ), each electrode configuration may be tested or effectively skipped by a user (step 210 ).
[0056] The selected electrode configurations may be further tested on the patient for “fine tuning” (step 212 ). Such fine tuning may be done in the manner described by U.S. application Ser. No. 11/026,859, wherein it is described that once an electrode configuration is selected from one table, a more detailed table may be used to test entries “before” and “after” the selected entry. For example, if an electrode configuration was selected from a steering table that varied from row to row by 0.05 in relative current (milliamps), a more detailed table may vary from row to row by 0.01 current. As explained in U.S. application Ser. No. 11/026,859, if entry No. 1 of the steering table is selected by a user (or program) during the navigation, this entry may correspond to an entry of the more detailed table, e.g., Entry No. 1001 of a more detailed table (not shown). Thus, Entry No. 1001 thus serves as a “benchmark.”
[0057] Once a benchmark is identified in the more detailed table, entries above and below the benchmark are tested for fine tuning. For example, going “down” in the more detailed table, Entry No. 1002 is applied, then No. 1003, and then No. 1004, and so on, until the patient (or other means) determines that no further improvement results, at least going in that direction in the more detailed table. For example, Entry No. 1002 may be found to be the most effective electrode configuration in that direction in the more detailed table.
[0058] In a similar manner, going “up” in the more detailed table from the benchmark (No. 1001), means that Entry No. 1000 is applied, then No. 999, then No. 998, and so on, until the patient (or other means) determines that no further improvement results in that direction in that portion of the table. For example, Entry No. 998 may be found to be the most effective electrode configuration in that direction and that section of the more detailed table.
[0059] Once at least two Stimulation Sets, e.g., No. 998 and 1002, have been identified, then a determination may be made as to which one is the most effective to use for stimulation. The sets chosen to be the most effective, e.g., Stimulation Set No. 998, is selected as the best one to use for stimulation in this instance, and the re-testing for the original selected Entry No. 1 from the steering table is completed. Other fine-tuning methods or re-testing may be employed. Fine-tuning and/or re-testing may be done for all the selected electrode configurations of the steering table. Such selections may be saved for this patient such that fitting does not have to reoccur prior to each treatment session. The selections may also be used in other aspects of the system.
[0060] Furthermore, the methods discussed above are not limited to use with a steering table. Any method in which stimulation is transitioned along the electrode array may be used. For example, stimulation may be defined by parameters specified by software. As another example, stimulation may be activated in one portion of an array and an algorithm may be used to transition stimulation from that portion of the electrode array to another or from one end of the array to the other without the use of a steering table. Fixed step sizes may be used to transition stimulation, or a method such as the method disclosed in U.S. application Ser. No. 11/026,859, may be used to determine the appropriate step sizes to use for ordering the set of electrode configurations.
[0061] In order to rapidly and efficiently move through a fitting session to test an effective number of the electrode configurations on the patient, other parameter controls may be implemented. For example, a suitable time for a fitting session may be determined for a patient, such as, for example, between about 15 to about 60 minutes. A suitable number of configurations should be tested during the fitting session. The number of electrode configurations that are tested during the fitting depends on the patient as well as the therapeutic goals for the fitting. Based on the optimal time of the session and therapeutic goals of the sessions, parameters may be controlled to test this effective number of electrode configurations during the fitting session. For example, the rate of applying successive electrode configurations may be controlled, adjusted, increased, or decreased to effectively move through all of the electrode configurations to be tested. Additionally, the change in the polarity distribution of the electrode configurations being applied may be controlled. In controlling these parameters, effective fitting in the allotted therapy time may be accomplished.
[0062] Other methods may be used to help ensure that a relatively larger number of different electrode configurations are tested in an efficient manner. For example, software (or other means, such as the patient or clinician) controlling a fitting session may be programmed to start with an electrode configuration corresponding to a first section of the area of potential stimulation. The stimulation may then be transitioned (or “swept”) through some electrode configurations for that section and then through some electrode configurations for other sections, in a relatively short period of time, e.g., five minutes. During this first “sweep” through each section, the patient may select or mark electrode configurations and/or stimulation parameter sets that appear to be effective. The software might then optionally sweep through the sections again, using different electrode configurations and/or stimulation parameter sets than were used in the first sweep. Again, the patient may select or mark electrode configurations and/or stimulation parameter sets that appear to be effective. Once one or more sweeps is completed, the software can then return to electrode configurations that the patient marked and “sweep” through various configurations near the marked configurations in order to locate the locally optimal electrode configuration. The “fine tuning” methods described above and in U.S. application Ser. No. 11/026,859 may also be used to test configurations near the marked configurations. The patient or clinician can then select the optimal electrode configuration(s) from the locally optimal configurations. If a suitable number of configurations are not marked within a sweep through a section (which number may be, for example, two, five, ten, or determined by the system, the clinician, the patient, or a combination thereof), the system may skip to the next section. Thus, the method of this example enables the testing of electrode configurations from different portions of the electrode array(s) as well as localized testing of electrode configurations near configurations identified by the patient as effective in an efficient and effective manner.
[0063] Various levels of patient control may be used before and during a fitting session, such as navigation. Control may be shared between the clinician and the patient. Patients may use a handheld device or other suitable interface that allows her to control the navigation and the adjustment of parameters between identified bounds. There may be a program that allows the clinician to select the level of patient control. Because no two patients are alike, the degree of patient control may be assessed for each patient. Thus, a system that allows the clinician to select the degree, level or amount of patient control would be more time efficient and allow for individualized fitting sessions. A clinician may select this level of control before or during a fitting session. Additionally, a clinician may use information from previous stimulation sessions with such patient to determine stimulation control. Allowing an appropriate level of patient control reduces patient anxiety over the fitting session and also enhances the effectiveness of patient/clinician communication.
[0064] In fitting sessions, control may be parallel between the clinician and the patient. However, based upon the patient's level of control, the patient may be given priority of control over a clinician, effectively allowing the patient control to override the clinician control. Such priority to the patient's selection, decisions, and control may be given only to specific parameters. For example, the patient may be given priority control for the adjustment of amplitude, pulse width, and/or pulse rate. The clinician, however, may have the priority in deciding how to steer navigation through the navigational fitting session.
[0065] Other combinations of patient, clinician and automated control are possible. For example, electrode configuration variations (e.g., via movement through a steering table) may be fully automated and thus blocked from patient control, while a patient is free to adjust amplitude. A patient may also have both amplitude and current field steering control. Most likely, all patients should have priority control to lower or reduce the applied amplitude of any stimulation. Thus, the patient controlled amplitude down “button” would have priority over either clinician or automated controls. These programmable control variations allow for flexibility in safe fitting sessions. Better patient outcomes are received due to reduced communication difficulties.
[0066] Any suitable user interface may be incorporated into embodiments of the invention. For example, the interfaces described in U.S. Pat. No. 6,393,325 may be used or altered for the navigational fitting system described herein. Additionally, the interface displayed in FIG. 4 may be used to guide a user through the fitting program. As seen in FIG. 4 , the interface may include three panels, or any combination or portion of the three panels ( 401 , 402 , 403 ). In the 401 panel, automatic navigation parameters may be set such as pulse width 404 , rate 405 and amplitude or strength 406 . The interface may also have a start 407 and stop 408 switch that halts or resumes the automated navigation, respectively. The user may be able to adjust the pulse width 409 , amplitude 410 or rate 411 , as well as entirely halt delivery of stimulation pulses, i.e., turn simulation off 418 , within the interface displayed at panel 402 . In panel 403 , a user may be able to adjust the amplitude 412 . The user is also able to highlight, mark, or select 413 the electrode configurations being tested. The user may be able to select from 414 , 415 , and 416 , which correspond to sets of electrode configurations to be tested. Finally, the pace 417 may be varied during the navigation so as to adjust the speed at which consecutive electrode configurations are applied. As described above, a suitable pace may be about 1 electrode configuration per 1-3 seconds. Each parameter may be adjusted by the user within the bounds determined by the clinician and/or automated system.
[0067] Although the interface controls of FIG. 4 are illustrated as being a touch screen, any other interface device that allows adjustment of these various parameters may be designed. For example, a hand-held user control device may be used having these parameter controls. Also, although the controls of FIG. 4 may appear to be “buttons” any other suitable controls may be used, such as sliding scales or dials.
[0068] One such suitable hand-held device for allowing user adjustment of the stimulation parameters is depicted in FIG. 5 . The hand-held device 500 may be small and easy to manipulate. The patient is given control to mark, highlight or select 501 electrode configurations. Additionally, the patient may turn the navigation session “off” 502 with a suitable safety or escape button. The patient may adjust the amplitude 503 through a pair of increase and decrease buttons. Finally, with a series of four directional buttons 504 , the patient may be able to gradually shift paresthesia locations on the body until pain coverage is obtained.
[0069] Clinician and patient control may be shared as explained above. In one embodiment, the clinician uses the interface described in FIG. 4 , while the patient uses the hand-held device depicted in FIG. 5 . Thus, during navigation, the clinician has the ability to control all of the parameters, while the patient may have a simplified hand-held device that allows for control of only a few parameters. The selection of a suitable hand-held device may depend of patient sophistication. In other words, a patient may “graduate” from a simplified device to a more advanced device, allowing her greater control over the navigation session.
[0070] The methods of the present invention may be incorporated into any medical electrical stimulator, such as any SCS, neural or muscle stimulation system. Thus, in another embodiment, a stimulation system is provided. A system may comprise: (1) a neural stimulation system, the neural stimulation system having a multiplicity of implantable electrodes, (2) an implantable pulse generator connected to the implantable electrodes, (3) electrical circuitry means within the implantable pulse generator for applying a prescribed current stimulus through a selected electrode configuration of the implantable electrodes, (4) a device coupled to the implantable pulse generator for storing and delivering a set of electrode configurations to the pulse generator, (5) means for applying the set of electrode configurations to a patient in one or more series, and (6) means for allowing user selection of one or more of the electrode configurations in the series.
[0071] Another embodiment of the invention is an electrode selection system comprising: (1) a neural stimulation system, the neural stimulation system having a multiplicity of implantable electrodes, (2) an implantable pulse generator connected to the implantable electrodes, (3) electrical circuitry means within the implantable pulse generator for applying a prescribed current stimulus through a selected electrode configuration of the implantable electrodes, (4) a memory device coupled to the implantable pulse generator for storing a set of electrode configurations, wherein each electrode configuration represents a polarity or polarity percentage of each active electrode of an electrode array, wherein the implantable pulse generator automatically tests at least a portion of the set of electrode configurations based on a starting electrode configuration, and (5) a user interface device for allowing the selection of one or more of the tested electrode configurations. Such stimulation systems and devices involved in such systems are more fully described in U.S. Pat. No. 6,393,325 and related applications and issued patents.
[0072] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. For example, the methods discussed above are not limited to spinal cord stimulation systems and may be used with many kinds of stimulation systems such as, but not limited to, cochlear implants, cardiac stimulation systems, peripheral nerve stimulation systems, brain stimulation systems and microstimulators.
Simplified Steering Table Stimulation Electrode Set 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 −1 0 0 0 0 0 0.5 0.5 0 0 0 0 0 0 0 0 2 −1 0 0.05 0 0 0 0.45 0.5 0 0 0 0 0 0 0 0 3 −1 0 0.1 0 0 0 0.4 0.5 0 0 0 0 0 0 0 0 4 −1 0 0.15 0 0 0 0.4 0.45 0 0 0 0 0 0 0 0 5 −1 0 0.2 0 0 0 0.4 0.4 0 0 0 0 0 0 0 0 6 −1 0 0.25 0 0 0 0.35 0.4 0 0 0 0 0 0 0 0 7 −1 0 0.3 0 0 0 0.3 0.4 0 0 0 0 0 0 0 0 8 −1 0 0.35 0 0 0 0.3 0.35 0 0 0 0 0 0 0 0 9 −1 0 0.4 0 0 0 0.3 0.3 0 0 0 0 0 0 0 0 10 −1 0 0.45 0 0 0 0.25 0.3 0 0 0 0 0 0 0 0 11 −1 0 0.5 0 0 0 0.2 0.3 0 0 0 0 0 0 0 0 12 −1 0 0.55 0 0 0 0.2 0.25 0 0 0 0 0 0 0 0 13 −1 0 0.6 0 0 0 0.2 0.2 0 0 0 0 0 0 0 0 14 −1 0 0.65 0 0 0 0.15 0.2 0 0 0 0 0 0 0 0 15 −1 0 0.7 0 0 0 0.1 0.2 0 0 0 0 0 0 0 0 16 −1 0 0.75 0 0 0 0.1 0.15 0 0 0 0 0 0 0 0 17 −1 0 0.8 0 0 0 0.1 0.1 0 0 0 0 0 0 0 0 18 −1 0 0.85 0 0 0 0.05 0.1 0 0 0 0 0 0 0 0 19 −1 0 0.9 0 0 0 0 0.1 0 0 0 0 0 0 0 0 20 −1 0 0.95 0 0 0 0 0.05 0 0 0 0 0 0 0 0 21 −1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 22 −1 0 0.95 0.05 0 0 0 0 0 0 0 0 0 0 0 0 23 −1 0 0.9 0.1 0 0 0 0 0 0 0 0 0 0 0 0 24 −1 0 0.85 0.15 0 0 0 0 0 0 0 0 0 0 0 0 25 −1 0 0.8 0.2 0 0 0 0 0 0 0 0 0 0 0 0 26 −1 0 0.75 0.25 0 0 0 0 0 0 0 0 0 0 0 0 27 −1 0 0.7 0.3 0 0 0 0 0 0 0 0 0 0 0 0 28 −1 0 0.65 0.35 0 0 0 0 0 0 0 0 0 0 0 0 29 −1 0 0.6 0.4 0 0 0 0 0 0 0 0 0 0 0 0 30 −1 0 0.55 0.45 0 0 0 0 0 0 0 0 0 0 0 0 31 −1 0 0.5 0.5 0 0 0 0 0 0 0 0 0 0 0 0 32 −1 0 0.45 0.55 0 0 0 0 0 0 0 0 0 0 0 0 33 −1 0 0.4 0.6 0 0 0 0 0 0 0 0 0 0 0 0 34 −1 0 0.35 0.65 0 0 0 0 0 0 0 0 0 0 0 0 35 −1 0 0.3 0.7 0 0 0 0 0 0 0 0 0 0 0 0 36 −1 0 0.25 0.75 0 0 0 0 0 0 0 0 0 0 0 0 37 −1 0 0.2 0.8 0 0 0 0 0 0 0 0 0 0 0 0 38 −1 0 0.15 0.85 0 0 0 0 0 0 0 0 0 0 0 0 39 −1 0 0.1 0.9 0 0 0 0 0 0 0 0 0 0 0 0 40 −1 0 0.05 0.95 0 0 0 0 0 0 0 0 0 0 0 0 41 −1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 42 −1 −0.1 0 0.95 0 0 0 0.05 0 0 0 0 0 0 0 0 43 −0.9 −0.1 0 0.9 0 0 0 0.1 0 0 0 0 0 0 0 0 44 −0.9 −0.2 0 0.85 0 0 0 0.15 0 0 0 0 0 0 0 0 45 −0.8 −0.2 0 0.8 0 0 0 0.2 0 0 0 0 0 0 0 0 46 −0.8 −0.3 0 0.75 0 0 0 0.25 0 0 0 0 0 0 0 0 47 −0.7 −0.3 0 0.7 0 0 0 0.3 0 0 0 0 0 0 0 0 48 −0.7 −0.4 0 0.65 0 0 0 0.35 0 0 0 0 0 0 0 0 49 −0.6 −0.4 0 0.6 0 0 0 0.4 0 0 0 0 0 0 0 0 50 −0.6 −0.5 0 0.55 0 0 0 0.45 0 0 0 0 0 0 0 0 51 −0.5 −0.5 0 0.5 0 0 0 0.5 0 0 0 0 0 0 0 0 52 −0.5 −0.6 0 0.45 0 0 0 0.55 0 0 0 0 0 0 0 0 53 −0.4 −0.6 0 0.4 0 0 0 0.6 0 0 0 0 0 0 0 0 54 −0.4 −0.7 0 0.35 0 0 0 0.65 0 0 0 0 0 0 0 0 55 −0.3 −0.7 0 0.3 0 0 0 0.7 0 0 0 0 0 0 0 0 56 −0.3 −0.8 0 0.25 0 0 0 0.75 0 0 0 0 0 0 0 0 57 −0.2 −0.8 0 0.2 0 0 0 0.8 0 0 0 0 0 0 0 0 58 −0.2 −0.9 0 0.15 0 0 0 0.85 0 0 0 0 0 0 0 0 59 −0.1 −0.9 0 0.1 0 0 0 0.9 0 0 0 0 0 0 0 0 60 −0.1 −1 0 0.05 0 0 0 0.95 0 0 0 0 0 0 0 0 61 0 −1 0 0 0 0 0 1 0 0 0 0 0 0 0 0 62 0 −1 0 0.05 0 0 0 0.95 0 0 0 0 0 0 0 0 63 0 −1 0 0.1 0 0 0 0.9 0 0 0 0 0 0 0 0 64 0 −1 0 0.15 0 0 0 0.85 0 0 0 0 0 0 0 0 65 0 −1 0 0.2 0 0 0 0.8 0 0 0 0 0 0 0 0 66 0 −1 0 0.25 0 0 0 0.75 0 0 0 0 0 0 0 0 67 0 −1 0 0.3 0 0 0 0.7 0 0 0 0 0 0 0 0 68 0 −1 0 0.35 0 0 0 0.65 0 0 0 0 0 0 0 0 69 0 −1 0 0.4 0 0 0 0.6 0 0 0 0 0 0 0 0 70 0 −1 0 0.45 0 0 0 0.55 0 0 0 0 0 0 0 0 71 0 −1 0 0.5 0 0 0 0.5 0 0 0 0 0 0 0 0 72 0 −1 0 0.55 0 0 0 0.45 0 0 0 0 0 0 0 0 73 0 −1 0 0.6 0 0 0 0.4 0 0 0 0 0 0 0 0 74 0 −1 0 0.65 0 0 0 0.35 0 0 0 0 0 0 0 0 75 0 −1 0 0.7 0 0 0 0.3 0 0 0 0 0 0 0 0 76 0 −1 0 0.75 0 0 0 0.25 0 0 0 0 0 0 0 0 77 0 −1 0 0.8 0 0 0 0.2 0 0 0 0 0 0 0 0 78 0 −1 0 0.85 0 0 0 0.15 0 0 0 0 0 0 0 0 79 0 −1 0 0.9 0 0 0 0.1 0 0 0 0 0 0 0 0 80 0 −1 0 0.95 0 0 0 0.05 0 0 0 0 0 0 0 0 81 0 −1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 82 0 −1 0 0.95 0.05 0 0 0 0 0 0 0 0 0 0 0 83 0 −1 0 0.9 0.1 0 0 0 0 0 0 0 0 0 0 0 84 0 −1 0 0.85 0.15 0 0 0 0 0 0 0 0 0 0 0 85 0 −1 0 0.8 0.2 0 0 0 0 0 0 0 0 0 0 0 86 0 −1 0 0.75 0.25 0 0 0 0 0 0 0 0 0 0 0 87 0 −1 0 0.7 0.3 0 0 0 0 0 0 0 0 0 0 0 88 0 −1 0 0.65 0.35 0 0 0 0 0 0 0 0 0 0 0 89 0 −1 0 0.6 0.4 0 0 0 0 0 0 0 0 0 0 0 90 0 −1 0 0.55 0.45 0 0 0 0 0 0 0 0 0 0 0 91 0 −1 0 0.5 0.5 0 0 0 0 0 0 0 0 0 0 0 92 0 −1 0 0.45 0.55 0 0 0 0 0 0 0 0 0 0 0 93 0 −1 0 0.4 0.6 0 0 0 0 0 0 0 0 0 0 0 94 0 −1 0 0.35 0.65 0 0 0 0 0 0 0 0 0 0 0 95 0 −1 0 0.3 0.7 0 0 0 0 0 0 0 0 0 0 0 96 0 −1 0 0.25 0.75 0 0 0 0 0 0 0 0 0 0 0 97 0 −1 0 0.2 0.8 0 0 0 0 0 0 0 0 0 0 0 98 0 −1 0 0.15 0.85 0 0 0 0 0 0 0 0 0 0 0 99 0 −1 0 0.1 0.9 0 0 0 0 0 0 0 0 0 0 0 100 0 −1 0 0.05 0.95 0 0 0 0 0 0 0 0 0 0 0 101 0 −1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 102 0 −1 −0.1 0 0.95 0 0 0.05 0 0 0 0 0 0 0 0 103 0 −0.9 −0.1 0 0.9 0 0 0.1 0 0 0 0 0 0 0 0 104 0 −0.2 0 0.85 0 0 0.15 0 0 0 0 0 0 0 0 105 0 −0.8 −0.2 0 0.8 0 0 0.2 0 0 0 0 0 0 0 0 106 0 −0.8 −0.3 0 0.75 0 0 0.25 0 0 0 0 0 0 0 0 107 0 −0.7 −0.3 0 0.7 0 0 0.3 0 0 0 0 0 0 0 0 108 0 −0.7 −0.4 0 0.65 0 0 0.35 0 0 0 0 0 0 0 0 109 0 −0.6 −0.4 0 0.6 0 0 0.4 0 0 0 0 0 0 0 0 110 0 −0.6 −0.5 0 0.55 0 0 0.45 0 0 0 0 0 0 0 0 111 0 −0.5 −0.5 0 0.5 0 0 0.5 0 0 0 0 0 0 0 0 112 0 −0.5 −0.6 0 0.45 0 0 0.55 0 0 0 0 0 0 0 0 113 0 −0.4 −0.6 0 0.4 0 0 0.6 0 0 0 0 0 0 0 0 114 0 −0.4 −0.7 0 0.35 0 0 0.65 0 0 0 0 0 0 0 0 115 0 −0.3 −0.7 0 0.3 0 0 0.7 0 0 0 0 0 0 0 0 116 0 −0.3 −0.8 0 0.25 0 0 0.75 0 0 0 0 0 0 0 0 117 0 −0.2 −0.8 0 0.2 0 0 0.8 0 0 0 0 0 0 0 0 118 0 −0.2 −0.9 0 0.15 0 0 0.85 0 0 0 0 0 0 0 0 119 0 −0.1 −0.9 0 0.1 0 0 0.9 0 0 0 0 0 0 0 0 120 0 −0.1 −1 0 0.05 0 0 0.95 0 0 0 0 0 0 0 0 121 0 0 −1 0 0 0 0 1 0 0 0 0 0 0 0 0 122 0.05 0 −1 0 0 0 0 0.95 0 0 0 0 0 0 0 0 123 0.1 0 −1 0 0 0 0 0.9 0 0 0 0 0 0 0 0 124 0.15 0 −1 0 0 0 0 0.85 0 0 0 0 0 0 0 0 125 0.2 0 −1 0 0 0 0 0.8 0 0 0 0 0 0 0 0 126 0.25 0 −1 0 0 0 0 0.75 0 0 0 0 0 0 0 0 127 0.3 0 −1 0 0 0 0 0.7 0 0 0 0 0 0 0 0 128 0.35 0 −1 0 0 0 0 0.65 0 0 0 0 0 0 0 0 129 0.4 0 −1 0 0 0 0 0.6 0 0 0 0 0 0 0 0 130 0.45 0 −1 0 0 0 0 0.55 0 0 0 0 0 0 0 0 131 0.5 0 −1 0 0 0 0 −0.5 0 0 0 0 0 0 0 0 132 0.55 0 −1 0 0 0 0 0.45 0 0 0 0 0 0 0 0 133 0.6 0 −1 0 0 0 0 0.4 0 0 0 0 0 0 0 0 134 0.65 0 −1 0 0 0 0 0.35 0 0 0 0 0 0 0 0 135 0.7 0 −1 0 0 0 0 0.3 0 0 0 0 0 0 0 0 136 0.75 0 −1 0 0 0 0 0.25 0 0 0 0 0 0 0 0 137 0.8 0 −1 0 0 0 0 0.2 0 0 0 0 0 0 0 0 138 0.85 0 −1 0 0 0 0 0.15 0 0 0 0 0 0 0 0 139 0.9 0 −1 0 0 0 0 0.1 0 0 0 0 0 0 0 0 140 0.95 0 −1 0 0 0 0 0.05 0 0 0 0 0 0 0 0 141 1 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 0 142 0.95 0 −1 0 0.05 0 0 0 0 0 0 0 0 0 0 0 143 0.9 0 −1 0 0.1 0 0 0 0 0 0 0 0 0 0 0 144 0.85 0 −1 0 0.15 0 0 0 0 0 0 0 0 0 0 0 145 0.8 0 −1 0 0.2 0 0 0 0 0 0 0 0 0 0 0 146 0.75 0 −1 0 0.25 0 0 0 0 0 0 0 0 0 0 0 147 0.7 0 −1 0 0.3 0 0 0 0 0 0 0 0 0 0 0 148 0.65 0 −1 0 0.35 0 0 0 0 0 0 0 0 0 0 0 149 0.6 0 −1 0 0.4 0 0 0 0 0 0 0 0 0 0 0 150 0.55 0 −1 0 0.45 0 0 0 0 0 0 0 0 0 0 0 151 0.5 0 −1 0 0.5 0 0 0 0 0 0 0 0 0 0 0 152 0.45 0 −1 0 0.55 0 0 0 0 0 0 0 0 0 0 0 153 0.4 0 −1 0 0.6 0 0 0 0 0 0 0 0 0 0 0 154 0.35 0 −1 0 0.65 0 0 0 0 0 0 0 0 0 0 0 155 0.3 0 −1 0 0.7 0 0 0 0 0 0 0 0 0 0 0 156 0.25 0 −1 0 0.75 0 0 0 0 0 0 0 0 0 0 0 157 0.2 0 −1 0 0.8 0 0 0 0 0 0 0 0 0 0 0 158 0.15 0 −1 0 0.85 0 0 0 0 0 0 0 0 0 0 0 159 0.1 0 −1 0 0.9 0 0 0 0 0 0 0 0 0 0 0 160 0.05 0 −1 0 0.95 0 0 0 0 0 0 0 0 0 0 0 161 0 0 −1 0 1 0 0 0 0 0 0 0 0 0 0 0 162 0 0 −1 0 0.95 0.05 0 0 0 0 0 0 0 0 0 0 163 0 0 −1 0 0.9 0.1 0 0 0 0 0 0 0 0 0 0 164 0 0 −1 0 0.85 0.15 0 0 0 0 0 0 0 0 0 0 165 0 0 −1 0 0.8 0.2 0 0 0 0 0 0 0 0 0 0 166 0 0 −1 0 0.75 0.25 0 0 0 0 0 0 0 0 0 0 167 0 0 −1 0 0.7 0.3 0 0 0 0 0 0 0 0 0 0 168 0 0 −1 0 0.65 0.35 0 0 0 0 0 0 0 0 0 0 169 0 0 −1 0 0.6 0.4 0 0 0 0 0 0 0 0 0 0 170 0 0 −1 0 0.55 0.45 0 0 0 0 0 0 0 0 0 0 171 0 0 −1 0 0.5 0.5 0 0 0 0 0 0 0 0 0 0 172 0 0 −1 0 0.45 0.55 0 0 0 0 0 0 0 0 0 0 173 0 0 −1 0 0.4 0.6 0 0 0 0 0 0 0 0 0 0 174 0 0 −1 0 0.35 0.65 0 0 0 0 0 0 0 0 0 0 175 0 0 −1 0 0.3 0.7 0 0 0 0 0 0 0 0 0 0 176 0 0 −1 0 0.25 0.75 0 0 0 0 0 0 0 0 0 0 177 0 0 −1 0 0.2 0.8 0 0 0 0 0 0 0 0 0 0 178 0 0 −1 0 0.15 0.85 0 0 0 0 0 0 0 0 0 0 179 0 0 −1 0 0.1 0.9 0 0 0 0 0 0 0 0 0 0 180 0 0 −1 0 0.05 0.95 0 0 0 0 0 0 0 0 0 0 181 0 0 −1 0 0 1 0 0 0 0 0 0 0 0 0 0 182 0.05 0 −1 −0.1 0 0.95 0 0 0 0 0 0 0 0 0 0 183 0.1 0 −0.9 −0.1 0 0.9 0 0 0 0 0 0 0 0 0 0 184 0.15 0 −0.9 −0.2 0 0.85 0 0 0 0 0 0 0 0 0 0 185 0.2 0 −0.8 −0.2 0 0.8 0 0 0 0 0 0 0 0 0 0 186 0.25 0 −0.8 −0.3 0 0.75 0 0 0 0 0 0 0 0 0 0 187 0.3 0 −0.7 −0.3 0 0.7 0 0 0 0 0 0 0 0 0 0 188 0.35 0 −0.7 −0.4 0 0.65 0 0 0 0 0 0 0 0 0 0 189 0.4 0 −0.6 −0.4 0 0.6 0 0 0 0 0 0 0 0 0 0 190 0.45 0 −0.6 −0.5 0 0.55 0 0 0 0 0 0 0 0 0 0 191 0.5 0 −0.5 −0.5 0 0.5 0 0 0 0 0 0 0 0 0 0 192 0.55 0 −0.5 −0.6 0 0.45 0 0 0 0 0 0 0 0 0 0 193 0.6 0 −0.4 −0.6 0 0.4 0 0 0 0 0 0 0 0 0 0 194 0.65 0 −0.4 −0.7 0 0.35 0 0 0 0 0 0 0 0 0 0 195 0.7 0 −0.3 −0.7 0 0.3 0 0 0 0 0 0 0 0 0 0 196 0.75 0 −0.3 −0.8 0 0.25 0 0 0 0 0 0 0 0 0 0 197 0.8 0 −0.2 −0.8 0 0.2 0 0 0 0 0 0 0 0 0 0 198 0.85 0 −0.2 −0.9 0 0.15 0 0 0 0 0 0 0 0 0 0 199 0.9 0 −0.1 −0.9 0 0.1 0 0 0 0 0 0 0 0 0 0 200 0.95 0 −0.1 −1 0 0.05 0 0 0 0 0 0 0 0 0 0 201 1 0 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 202 0.95 0.05 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 203 0.9 0.1 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 204 0.85 0.15 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 205 0.8 0.2 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 206 0.75 0.25 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 207 0.7 0.3 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 208 0.65 0.35 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 209 0.6 0.4 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 210 0.55 0.45 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 211 0.5 0.5 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 212 0.45 0.55 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 213 0.4 0.6 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 214 0.35 0.65 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 215 0.3 0.7 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 216 0.25 0.75 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 217 0.2 0.8 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 218 0.15 0.85 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 219 0.1 0.9 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 220 0.05 0.95 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 221 0 1 0 −1 0 0 0 0 0 0 0 0 0 0 0 0 222 0 0.95 0 −1 0 0.05 0 0 0 0 0 0 0 0 0 0 223 0 0.9 0 −1 0 0.1 0 0 0 0 0 0 0 0 0 0 224 0 0.85 0 −1 0 0.15 0 0 0 0 0 0 0 0 0 0 225 0 0.8 0 −1 0 0.2 0 0 0 0 0 0 0 0 0 0 226 0 0.75 0 −1 0 0.25 0 0 0 0 0 0 0 0 0 0 227 0 0.7 0 −1 0 0.3 0 0 0 0 0 0 0 0 0 0 228 0 0.65 0 −1 0 0.35 0 0 0 0 0 0 0 0 0 0 229 0 0.6 0 −1 0 0.4 0 0 0 0 0 0 0 0 0 0 230 0 0.55 0 −1 0 0.45 0 0 0 0 0 0 0 0 0 0 231 0 0.5 0 −1 0 0.5 0 0 0 0 0 0 0 0 0 0 232 0 0.45 0 −1 0 0.55 0 0 0 0 0 0 0 0 0 0 233 0 0.4 0 −1 0 0.6 0 0 0 0 0 0 0 0 0 0 234 0 0.35 0 −1 0 0.65 0 0 0 0 0 0 0 0 0 0 235 0 0.3 0 −1 0 0.7 0 0 0 0 0 0 0 0 0 0 236 0 0.25 0 −1 0 0.75 0 0 0 0 0 0 0 0 0 0 237 0 0.2 0 −1 0 0.8 0 0 0 0 0 0 0 0 0 0 238 0 0.15 0 −1 0 0.85 0 0 0 0 0 0 0 0 0 0 239 0 0.1 0 −1 0 0.9 0 0 0 0 0 0 0 0 0 0 240 0 0.05 0 −1 0 0.95 0 0 0 0 0 0 0 0 0 0 241 0 0 0 −1 0 1 0 0 0 0 0 0 0 0 0 0 242 0 0 0 −1 0 0.95 0.05 0 0 0 0 0 0 0 0 0 243 0 0 0 −1 0 0.9 0.1 0 0 0 0 0 0 0 0 0 244 0 0 0 −1 0 0.85 0.15 0 0 0 0 0 0 0 0 0 245 0 0 0 −1 0 0.8 0.2 0 0 0 0 0 0 0 0 0 246 0 0 0 −1 0 0.75 0.25 0 0 0 0 0 0 0 0 0 247 0 0 0 −1 0 0.7 0.3 0 0 0 0 0 0 0 0 0 248 0 0 0 −1 0 0.65 0.35 0 0 0 0 0 0 0 0 0 249 0 0 0 −1 0 0.6 0.4 0 0 0 0 0 0 0 0 0 250 0 0 0 −1 0 0.55 0.45 0 0 0 0 0 0 0 0 0 251 0 0 0 −1 0 0.5 0.5 0 0 0 0 0 0 0 0 0 252 0 0 0 −1 0 0.45 0.55 0 0 0 0 0 0 0 0 0 253 0 0 0 −1 0 0.4 0.6 0 0 0 0 0 0 0 0 0 254 0 0 0 −1 0 0.35 0.65 0 0 0 0 0 0 0 0 0 255 0 0 0 −1 0 0.3 0.7 0 0 0 0 0 0 0 0 0 256 0 0 0 −1 0 0.25 0.75 0 0 0 0 0 0 0 0 0 257 0 0 0 −1 0 0.2 0.8 0 0 0 0 0 0 0 0 0 258 0 0 0 −1 0 0.15 0.85 0 0 0 0 0 0 0 0 0 259 0 0 0 −1 0 0.1 0.9 0 0 0 0 0 0 0 0 0 260 0 0 0 −1 0 0.05 0.95 0 0 0 0 0 0 0 0 0 261 0 0 0 −1 0 0 1 0 0 0 0 0 0 0 0 0 262 0 0.05 0 −1 −0.1 0 0.95 0 0 0 0 0 0 0 0 0 263 0 0.1 0 −0.9 −0.1 0 0.9 0 0 0 0 0 0 0 0 0 264 0 0.15 0 −0.9 −0.2 0 0.85 0 0 0 0 0 0 0 0 0 265 0 0.2 0 −0.8 −0.2 0 0.8 0 0 0 0 0 0 0 0 0 266 0 0.25 0 −0.8 −0.3 0 0.75 0 0 0 0 0 0 0 0 0 267 0 0.3 0 −0.7 −0.3 0 0.7 0 0 0 0 0 0 0 0 0 268 0 0.35 0 −0.7 −0.4 0 0.65 0 0 0 0 0 0 0 0 0 269 0 0.4 0 −0.6 −0.4 0 0.6 0 0 0 0 0 0 0 0 0 270 0 0.45 0 −0.6 −0.5 0 0.55 0 0 0 0 0 0 0 0 0 271 0 0.5 0 −0.5 −0.5 0 0.5 0 0 0 0 0 0 0 0 0 272 0 0.55 0 −0.5 −0.6 0 0.45 0 0 0 0 0 0 0 0 0 273 0 0.6 0 −0.4 −0.6 0 0.4 0 0 0 0 0 0 0 0 0 274 0 0.65 0 −0.4 −0.7 0 0.35 0 0 0 0 0 0 0 0 0 275 0 0.7 0 −0.3 −0.7 0 0.3 0 0 0 0 0 0 0 0 0 276 0 0.75 0 −0.3 −0.8 0 0.25 0 0 0 0 0 0 0 0 0 277 0 0.8 0 −0.2 −0.8 0 0.2 0 0 0 0 0 0 0 0 0 278 0 0.85 0 −0.2 −0.9 0 0.15 0 0 0 0 0 0 0 0 0 279 0 0.9 0 −0.1 −0.9 0 0.1 0 0 0 0 0 0 0 0 0 280 0 0.95 0 −0.1 −1 0 0.05 0 0 0 0 0 0 0 0 0 281 0 1 0 0 −1 0 0 0 0 0 0 0 0 0 0 0 282 0 0.95 0.05 0 −1 0 0 0 0 0 0 0 0 0 0 0 283 0 0.9 0.1 0 −1 0 0 0 0 0 0 0 0 0 0 0 284 0 0.85 0.15 0 −1 0 0 0 0 0 0 0 0 0 0 0 285 0 0.8 0.2 0 −1 0 0 0 0 0 0 0 0 0 0 0 286 0 0.75 0.25 0 −1 0 0 0 0 0 0 0 0 0 0 0 287 0 0.7 0.3 0 −1 0 0 0 0 0 0 0 0 0 0 0 288 0 0.65 0.35 0 −1 0 0 0 0 0 0 0 0 0 0 0 289 0 0.6 0.4 0 −1 0 0 0 0 0 0 0 0 0 0 0 290 0 0.55 0.45 0 −1 0 0 0 0 0 0 0 0 0 0 0 291 0 0.5 0.5 0 −1 0 0 0 0 0 0 0 0 0 0 0 292 0 0.45 0.55 0 −1 0 0 0 0 0 0 0 0 0 0 0 293 0 0.4 0.6 0 −1 0 0 0 0 0 0 0 0 0 0 0 294 0 0.35 0.65 0 −1 0 0 0 0 0 0 0 0 0 0 0 295 0 0.3 0.7 0 −1 0 0 0 0 0 0 0 0 0 0 0 296 0 0.25 0.75 0 −1 0 0 0 0 0 0 0 0 0 0 0 297 0 0.2 0.8 0 −1 0 0 0 0 0 0 0 0 0 0 0 298 0 0.15 0.85 0 −1 0 0 0 0 0 0 0 0 0 0 0 299 0 0.1 0.9 0 −1 0 0 0 0 0 0 0 0 0 0 0 300 0 0.05 0.95 0 −1 0 0 0 0 0 0 0 0 0 0 0 301 0 0 1 0 −1 0 0 0 0 0 0 0 0 0 0 0 302 0 0 0.95 0 −1 0 0.05 0 0 0 0 0 0 0 0 0 303 0 0 0.9 0 −1 0 0.1 0 0 0 0 0 0 0 0 0 304 0 0 0.85 0 −1 0 0.15 0 0 0 0 0 0 0 0 0 305 0 0 0.8 0 −1 0 0.2 0 0 0 0 0 0 0 0 0 306 0 0 0.75 0 −1 0 0.25 0 0 0 0 0 0 0 0 0 307 0 0 0.7 0 −1 0 0.3 0 0 0 0 0 0 0 0 0 308 0 0 0.65 0 −1 0 0.35 0 0 0 0 0 0 0 0 0 309 0 0 0.6 0 −1 0 0.4 0 0 0 0 0 0 0 0 0 310 0 0 0.55 0 −1 0 0.45 0 0 0 0 0 0 0 0 0 311 0 0 0.5 0 −1 0 0.5 0 0 0 0 0 0 0 0 0 312 0 0 0.45 0 −1 0 0.55 0 0 0 0 0 0 0 0 0 313 0 0 0.4 0 −1 0 0.6 0 0 0 0 0 0 0 0 0 314 0 0 0.35 0 −1 0 0.65 0 0 0 0 0 0 0 0 0 315 0 0 0.3 0 −1 0 0.7 0 0 0 0 0 0 0 0 0 316 0 0 0.25 0 −1 0 0.75 0 0 0 0 0 0 0 0 0 317 0 0 0.2 0 −1 0 0.8 0 0 0 0 0 0 0 0 0 318 0 0 0.15 0 −1 0 0.85 0 0 0 0 0 0 0 0 0 319 0 0 0.1 0 −1 0 0.9 0 0 0 0 0 0 0 0 0 320 0 0 0.05 0 −1 0 0.95 0 0 0 0 0 0 0 0 0 321 0 0 0 0 −1 0 1 0 0 0 0 0 0 0 0 0 322 0 0 0 0 −1 0 0.95 0.05 0 0 0 0 0 0 0 0 323 0 0 0 0 −1 0 0.9 0.1 0 0 0 0 0 0 0 0 324 0 0 0 0 −1 0 0.85 0.15 0 0 0 0 0 0 0 0 325 0 0 0 0 −1 0 0.8 0.2 0 0 0 0 0 0 0 0 326 0 0 0 0 −1 0 0.75 0.25 0 0 0 0 0 0 0 0 327 0 0 0 0 −1 0 0.7 0.3 0 0 0 0 0 0 0 0 328 0 0 0 0 −1 0 0.65 0.35 0 0 0 0 0 0 0 0 329 0 0 0 0 −1 0 0.6 0.4 0 0 0 0 0 0 0 0 330 0 0 0 0 −1 0 0.55 0.45 0 0 0 0 0 0 0 0 331 0 0 0 0 −1 0 0.5 0.5 0 0 0 0 0 0 0 0 332 0 0 0 0 −1 0 0.45 0.55 0 0 0 0 0 0 0 0 333 0 0 0 0 −1 0 0.4 0.6 0 0 0 0 0 0 0 0 334 0 0 0 0 −1 0 0.35 0.65 0 0 0 0 0 0 0 0 335 0 0 0 0 −1 0 0.3 0.7 0 0 0 0 0 0 0 0 336 0 0 0 0 −1 0 0.25 0.75 0 0 0 0 0 0 0 0 337 0 0 0 0 −1 0 0.2 0.8 0 0 0 0 0 0 0 0 338 0 0 0 0 −1 0 0.15 0.85 0 0 0 0 0 0 0 0 339 0 0 0 0 −1 0 0.1 0.9 0 0 0 0 0 0 0 0 340 0 0 0 0 −1 0 0.05 0.95 0 0 0 0 0 0 0 0 341 0 0 0 0 −1 0 0 1 0 0 0 0 0 0 0 0 342 0 0 0.05 0 −1 −0.1 0 0.95 0 0 0 0 0 0 0 0 343 0 0 0.1 0 −0.9 −0.1 0 0.9 0 0 0 0 0 0 0 0 344 0 0 0.15 0 −0.9 −0.2 0 0.85 0 0 0 0 0 0 0 0 345 0 0 0.2 0 −0.8 −0.2 0 0.8 0 0 0 0 0 0 0 0 346 0 0 0.25 0 −0.8 −0.3 0 0.75 0 0 0 0 0 0 0 0 347 0 0 0.3 0 −0.7 −0.3 0 0.7 0 0 0 0 0 0 0 0 348 0 0 0.35 0 −0.7 −0.4 0 0.65 0 0 0 0 0 0 0 0 349 0 0 0.4 0 −0.6 −0.4 0 0.6 0 0 0 0 0 0 0 0 350 0 0 0.45 0 −0.6 −0.5 0 0.55 0 0 0 0 0 0 0 0 351 0 0 0.5 0 −0.5 −0.5 0 0.5 0 0 0 0 0 0 0 0 352 0 0 0.55 0 −0.5 −0.6 0 0.45 0 0 0 0 0 0 0 0 353 0 0 0.6 0 −0.4 −0.5 0 0.4 0 0 0 0 0 0 0 0 354 0 0 0.65 0 −0.4 −0.7 0 0.35 0 0 0 0 0 0 0 0 355 0 0 0.7 0 −0.3 −0.7 0 0.3 0 0 0 0 0 0 0 0 356 0 0 0.75 0 −0.3 −0.8 0 0.25 0 0 0 0 0 0 0 0 357 0 0 0.8 0 −0.2 −0.8 0 0.2 0 0 0 0 0 0 0 0 358 0 0 0.85 0 −0.2 −0.9 0 0.15 0 0 0 0 0 0 0 0 359 0 0 0.9 0 −0.1 −0.9 0 0.1 0 0 0 0 0 0 0 0 360 0 0 0.95 0 −0.1 −1 0 0.05 0 0 0 0 0 0 0 0 361 0 0 1 0 0 −1 0 0 0 0 0 0 0 0 0 0 362 0 0 0.95 0.05 0 −1 0 0 0 0 0 0 0 0 0 0 363 0 0 0.9 0.1 0 −1 0 0 0 0 0 0 0 0 0 0 364 0 0 0.85 0.15 0 −1 0 0 0 0 0 0 0 0 0 0 365 0 0 0.8 0.2 0 −1 0 0 0 0 0 0 0 0 0 0 366 0 0 0.75 0.25 0 −1 0 0 0 0 0 0 0 0 0 0 367 0 0 0.7 0.3 0 −1 0 0 0 0 0 0 0 0 0 0 368 0 0 0.65 0.35 0 −1 0 0 0 0 0 0 0 0 0 0 369 0 0 0.6 0.4 0 −1 0 0 0 0 0 0 0 0 0 0 370 0 0 0.55 0.45 0 −1 0 0 0 0 0 0 0 0 0 0 371 0 0 0.5 0.5 0 −1 0 0 0 0 0 0 0 0 0 0 372 0 0 0.45 0.55 0 −1 0 0 0 0 0 0 0 0 0 0 373 0 0 0.4 0.6 0 −1 0 0 0 0 0 0 0 0 0 0 374 0 0 0.35 0.65 0 −1 0 0 0 0 0 0 0 0 0 0 375 0 0 0.3 0.7 0 −1 0 0 0 0 0 0 0 0 0 0 376 0 0 0.25 0.75 0 −1 0 0 0 0 0 0 0 0 0 0 377 0 0 0.2 0.8 0 −1 0 0 0 0 0 0 0 0 0 0 378 0 0 0.15 0.85 0 −1 0 0 0 0 0 0 0 0 0 0 379 0 0 0.1 0.9 0 −1 0 0 0 0 0 0 0 0 0 0 380 0 0 0.05 0.95 0 −1 0 0 0 0 0 0 0 0 0 0 381 0 0 0 1 0 −1 0 0 0 0 0 0 0 0 0 0 382 0 0 0 0.95 0 −1 0 0.05 0 0 0 0 0 0 0 0 383 0 0 0 0.9 0 −1 0 0.1 0 0 0 0 0 0 0 0 384 0 0 0 0.85 0 −1 0 0.15 0 0 0 0 0 0 0 0 385 0 0 0 0.8 0 −1 0 0.2 0 0 0 0 0 0 0 0 386 0 0 0 0.75 0 −1 0 0.25 0 0 0 0 0 0 0 0 387 0 0 0 0.7 0 −1 0 0.3 0 0 0 0 0 0 0 0 388 0 0 0 0.65 0 −1 0 0.35 0 0 0 0 0 0 0 0 389 0 0 0 0.6 0 −1 0 0.4 0 0 0 0 0 0 0 0 390 0 0 0 0.55 0 −1 0 0.45 0 0 0 0 0 0 0 0 391 0 0 0 0.5 0 −1 0 0.5 0 0 0 0 0 0 0 0 392 0 0 0 0.45 0 −1 0 0.55 0 0 0 0 0 0 0 0 393 0 0 0 0.4 0 −1 0 0.6 0 0 0 0 0 0 0 0 394 0 0 0 0.35 0 −1 0 0.65 0 0 0 0 0 0 0 0 395 0 0 0 0.3 0 −1 0 0.7 0 0 0 0 0 0 0 0 396 0 0 0 0.25 0 −1 0 0.75 0 0 0 0 0 0 0 0 397 0 0 0 0.2 0 −1 0 0.8 0 0 0 0 0 0 0 0 398 0 0 0 0.15 0 −1 0 0.85 0 0 0 0 0 0 0 0 399 0 0 0 0.1 0 −1 0 0.9 0 0 0 0 0 0 0 0 400 0 0 0 0.05 0 −1 0 0.95 0 0 0 0 0 0 0 0 401 0 0 0 0 0 −1 0 1 0 0 0 0 0 0 0 0 402 0.05 0 0 0 0 −1 0 0.95 0 0 0 0 0 0 0 0 403 0.1 0 0 0 0 −1 0 0.9 0 0 0 0 0 0 0 0 404 0.15 0 0 0 0 −1 0 0.85 0 0 0 0 0 0 0 0 405 0.2 0 0 0 0 −1 0 0.8 0 0 0 0 0 0 0 0 406 0.25 0 0 0 0 −1 0 0.75 0 0 0 0 0 0 0 0 407 0.3 0 0 0 0 −1 0 0.7 0 0 0 0 0 0 0 0 408 0.35 0 0 0 0 −1 0 0.65 0 0 0 0 0 0 0 0 409 0.4 0 0 0 0 −1 0 0.6 0 0 0 0 0 0 0 0 410 0.45 0 0 0 0 −1 0 0.55 0 0 0 0 0 0 0 0 411 0.5 0 0 0 0 −1 0 0.5 0 0 0 0 0 0 0 0 412 0.55 0 0 0 0 −1 0 0.45 0 0 0 0 0 0 0 0 413 0.6 0 0 0 0 −1 0 0.4 0 0 0 0 0 0 0 0 414 0.65 0 0 0 0 −1 0 0.35 0 0 0 0 0 0 0 0 415 0.7 0 0 0 0 −1 0 0.3 0 0 0 0 0 0 0 0 416 0.75 0 0 0 0 −1 0 0.25 0 0 0 0 0 0 0 0 417 0.8 0 0 0 0 −1 0 0.2 0 0 0 0 0 0 0 0 418 0.85 0 0 0 0 −1 0 0.15 0 0 0 0 0 0 0 0 419 0.9 0 0 0 0 −1 0 0.1 0 0 0 0 0 0 0 0 420 0.95 0 0 0 0 −1 0 0.05 0 0 0 0 0 0 0 0 421 1 0 0 0 0 −1 0 0 0 0 0 0 0 0 0 0 422 0.95 0 0 0.05 0 −1 −0.1 0 0 0 0 0 0 0 0 0 423 0.9 0 0 0.1 0 −0.9 −0.1 0 0 0 0 0 0 0 0 0 424 0.85 0 0 0.15 0 −0.9 −0.2 0 0 0 0 0 0 0 0 0 425 0.8 0 0 0.2 0 −0.8 −0.2 0 0 0 0 0 0 0 0 0 426 0.75 0 0 0.25 0 −0.8 −0.3 0 0 0 0 0 0 0 0 0 427 0.7 0 0 0.3 0 −0.7 −0.3 0 0 0 0 0 0 0 0 0 428 0.65 0 0 0.35 0 −0.7 −0.4 0 0 0 0 0 0 0 0 0 429 0.6 0 0 0.4 0 −0.6 −0.4 0 0 0 0 0 0 0 0 0 430 0.55 0 0 0.45 0 −0.6 −0.5 0 0 0 0 0 0 0 0 0 431 0.5 0 0 0.5 0 −0.5 −0.5 0 0 0 0 0 0 0 0 0 432 0.45 0 0 0.55 0 −0.5 −0.6 0 0 0 0 0 0 0 0 0 433 0.4 0 0 0.6 0 −0.4 −0.6 0 0 0 0 0 0 0 0 0 434 0.35 0 0 0.65 0 −0.4 −0.7 0 0 0 0 0 0 0 0 0 435 0.3 0 0 0.7 0 −0.3 −0.7 0 0 0 0 0 0 0 0 0 436 0.25 0 0 0.75 0 −0.3 −0.8 0 0 0 0 0 0 0 0 0 437 0.2 0 0 0.8 0 −0.2 −0.8 0 0 0 0 0 0 0 0 0 438 0.15 0 0 0.85 0 −0.2 −0.9 0 0 0 0 0 0 0 0 0 439 0.1 0 0 0.9 0 −0.1 −0.9 0 0 0 0 0 0 0 0 0 440 0.05 0 0 0.95 0 −0.1 −1 0 0 0 0 0 0 0 0 0 441 0 0 0 1 0 0 −1 0 0 0 0 0 0 0 0 0 442 0 0 0 0.95 0.05 0 −1 0 0 0 0 0 0 0 0 0 443 0 0 0 0.9 0.1 0 −1 0 0 0 0 0 0 0 0 0 444 0 0 0 0.85 0.15 0 −1 0 0 0 0 0 0 0 0 0 445 0 0 0 0.8 0.2 0 −1 0 0 0 0 0 0 0 0 0 446 0 0 0 0.75 0.25 0 −1 0 0 0 0 0 0 0 0 0 447 0 0 0 0.7 0.3 0 −1 0 0 0 0 0 0 0 0 0 448 0 0 0 0.65 0.35 0 −1 0 0 0 0 0 0 0 0 0 449 0 0 0 0.6 0.4 0 −1 0 0 0 0 0 0 0 0 0 450 0 0 0 0.55 0.45 0 −1 0 0 0 0 0 0 0 0 0 451 0 0 0 0.5 0.5 0 −1 0 0 0 0 0 0 0 0 0 452 0 0 0 0.45 0.55 0 −1 0 0 0 0 0 0 0 0 0 453 0 0 0 0.4 0.6 0 −1 0 0 0 0 0 0 0 0 0 454 0 0 0 0.35 0.65 0 −1 0 0 0 0 0 0 0 0 0 455 0 0 0 0.3 0.7 0 −1 0 0 0 0 0 0 0 0 0 456 0 0 0 0.25 0.75 0 −1 0 0 0 0 0 0 0 0 0 457 0 0 0 0.2 0.8 0 −1 0 0 0 0 0 0 0 0 0 458 0 0 0 0.15 0.85 0 −1 0 0 0 0 0 0 0 0 0 459 0 0 0 0.1 0.9 0 −1 0 0 0 0 0 0 0 0 0 460 0 0 0 0.05 0.95 0 −1 0 0 0 0 0 0 0 0 0 461 0 0 0 0 1 0 −1 0 0 0 0 0 0 0 0 0 462 0.05 0 0 0 0.95 0 −1 0 0 0 0 0 0 0 0 0 463 0.1 0 0 0 0.9 0 −1 0 0 0 0 0 0 0 0 0 464 0.15 0 0 0 0.85 0 −1 0 0 0 0 0 0 0 0 0 465 0.2 0 0 0 0.8 0 −1 0 0 0 0 0 0 0 0 0 466 0.25 0 0 0 0.75 0 −1 0 0 0 0 0 0 0 0 0 467 0.3 0 0 0 0.7 0 −1 0 0 0 0 0 0 0 0 0 468 0.35 0 0 0 0.65 0 −1 0 0 0 0 0 0 0 0 0 469 0.4 0 0 0 0.6 0 −1 0 0 0 0 0 0 0 0 0 470 0.45 0 0 0 0.55 0 −1 0 0 0 0 0 0 0 0 0 471 0.5 0 0 0 0.5 0 −1 0 0 0 0 0 0 0 0 0 472 0.55 0 0 0 0.45 0 −1 0 0 0 0 0 0 0 0 0 473 0.6 0 0 0 0.4 0 −1 0 0 0 0 0 0 0 0 0 474 0.65 0 0 0 0.35 0 −1 0 0 0 0 0 0 0 0 0 475 0.7 0 0 0 0.3 0 −1 0 0 0 0 0 0 0 0 0 476 0.75 0 0 0 0.25 0 −1 0 0 0 0 0 0 0 0 0 477 0.8 0 0 0 0.2 0 −1 0 0 0 0 0 0 0 0 0 478 0.85 0 0 0 0.15 0 −1 0 0 0 0 0 0 0 0 0 479 0.9 0 0 0 0.1 0 −1 0 0 0 0 0 0 0 0 0 480 0.95 0 0 0 0.05 0 −1 0 0 0 0 0 0 0 0 0 481 1 0 0 0 0 0 −1 0 0 0 0 0 0 0 0 0 482 0.95 0 0 0 0.05 0 −1 −0.1 0 0 0 0 0 0 0 0 483 0.9 0 0 0 0.1 0 −0.9 −0.1 0 0 0 0 0 0 0 0 484 0.85 0 0 0 0.15 0 −0.9 −0.2 0 0 0 0 0 0 0 0 485 0.8 0 0 0 0.2 0 −0.8 −0.2 0 0 0 0 0 0 0 0 486 0.75 0 0 0 0.25 0 −0.8 −0.3 0 0 0 0 0 0 0 0 487 0.7 0 0 0 0.3 0 −0.7 −0.3 0 0 0 0 0 0 0 0 488 0.65 0 0 0 0.35 0 −0.7 −0.4 0 0 0 0 0 0 0 0 489 0.6 0 0 0 0.4 0 −0.6 −0.4 0 0 0 0 0 0 0 0 490 0.55 0 0 0 0.45 0 −0.6 −0.5 0 0 0 0 0 0 0 0 491 0.5 0 0 0 0.5 0 −0.5 −0.5 0 0 0 0 0 0 0 0 492 0.45 0 0 0 0.55 0 −0.5 −0.6 0 0 0 0 0 0 0 0 493 0.4 0 0 0 0.6 0 −0.4 −0.6 0 0 0 0 0 0 0 0 494 0.35 0 0 0 0.65 0 −0.4 −0.7 0 0 0 0 0 0 0 0 495 0.3 0 0 0 0.7 0 −0.3 −0.7 0 0 0 0 0 0 0 0 496 0.25 0 0 0 0.75 0 −0.3 −0.8 0 0 0 0 0 0 0 0 497 0.2 0 0 0 0.8 0 −0.2 −0.8 0 0 0 0 0 0 0 0 498 0.15 0 0 0 0.85 0 −0.2 −0.9 0 0 0 0 0 0 0 0 499 0.1 0 0 0 0.9 0 −0.1 −0.9 0 0 0 0 0 0 0 0 500 0.05 0 0 0 0.95 0 −0.1 −1 0 0 0 0 0 0 0 0 501 0 0 0 0 1 0 0 −1 0 0 0 0 0 0 0 0 502 0 0 0 0 0.95 0.05 0 −1 0 0 0 0 0 0 0 0 503 0 0 0 0 0.9 0.1 0 −1 0 0 0 0 0 0 0 0 504 0 0 0 0 0.85 0.15 0 −1 0 0 0 0 0 0 0 0 505 0 0 0 0 0.8 0.2 0 −1 0 0 0 0 0 0 0 0 506 0 0 0 0 0.75 0.25 0 −1 0 0 0 0 0 0 0 0 507 0 0 0 0 0.7 0.3 0 −1 0 0 0 0 0 0 0 0 508 0 0 0 0 0.65 0.35 0 −1 0 0 0 0 0 0 0 0 509 0 0 0 0 0.6 0.4 0 −1 0 0 0 0 0 0 0 0 510 0 0 0 0 0.55 0.45 0 −1 0 0 0 0 0 0 0 0 511 0 0 0 0 0.5 0.5 0 −1 0 0 0 0 0 0 0 0 512 0 0 0 0 0.45 0.55 0 −1 0 0 0 0 0 0 0 0 513 0 0 0 0 0.4 0.6 0 −1 0 0 0 0 0 0 0 0 514 0 0 0 0 0.35 0.65 0 −1 0 0 0 0 0 0 0 0 515 0 0 0 0 0.3 0.7 0 −1 0 0 0 0 0 0 0 0 516 0 0 0 0 0.25 0.75 0 −1 0 0 0 0 0 0 0 0 517 0 0 0 0 0.2 0.8 0 −1 0 0 0 0 0 0 0 0 518 0 0 0 0 0.15 0.85 0 −1 0 0 0 0 0 0 0 0 519 0 0 0 0 0.1 0.9 0 −1 0 0 0 0 0 0 0 0 520 0 0 0 0 0.05 0.95 0 −1 0 0 0 0 0 0 0 0 521 0 0 0 0 0 1 0 −1 0 0 0 0 0 0 0 0 522 0 0.05 0 0 0 0.95 0 −1 0 0 0 0 0 0 0 0 523 0 0.1 0 0 0 0.9 0 −1 0 0 0 0 0 0 0 0 524 0.05 0.1 0 0 0 0.85 0 −1 0 0 0 0 0 0 0 0 525 0.1 0.1 0 0 0 0.8 0 −1 0 0 0 0 0 0 0 0 526 0.1 0.15 0 0 0 0.75 0 −1 0 0 0 0 0 0 0 0 527 0.1 0.2 0 0 0 0.7 0 −1 0 0 0 0 0 0 0 0 528 0.15 0.2 0 0 0 0.65 0 −1 0 0 0 0 0 0 0 0 529 0.2 0.2 0 0 0 0.6 0 −1 0 0 0 0 0 0 0 0 530 0.2 0.25 0 0 0 0.55 0 −1 0 0 0 0 0 0 0 0 531 0.2 0.3 0 0 0 0.5 0 −1 0 0 0 0 0 0 0 0 532 0.25 0.3 0 0 0 0.45 0 −1 0 0 0 0 0 0 0 0 533 0.3 0.3 0 0 0 0.4 0 −1 0 0 0 0 0 0 0 0 534 0.3 0.35 0 0 0 0.35 0 −1 0 0 0 0 0 0 0 0 535 0.3 0.4 0 0 0 0.3 0 −1 0 0 0 0 0 0 0 0 536 0.35 0.4 0 0 0 0.25 0 −1 0 0 0 0 0 0 0 0 537 0.4 0.4 0 0 0 0.2 0 −1 0 0 0 0 0 0 0 0 538 0.4 0.45 0 0 0 0.15 0 −1 0 0 0 0 0 0 0 0 539 0.4 0.5 0 0 0 0.1 0 −1 0 0 0 0 0 0 0 0 540 0.45 0.5 0 0 0 0.05 0 −1 0 0 0 0 0 0 0 0 541 0.5 0.5 0 0 0 0 0 −1 0 0 0 0 0 0 0 0 | A method for selecting Spinal Cord Stimulation (SCS) stimulation parameter sets guides a clinician towards an effective set of stimulation parameters. The clinician first evaluates the effectiveness of a small number of trial stimulation parameters sets from a Measurement Table comprising for example, four stimulation parameter sets. Based on the patient's assessment, the trial stimulation parameter sets are ranked. Then the clinician selects a starting or benchmark row in a Steering Table corresponding to the highest ranked trial stimulation parameter set. The clinician moves either up or down form the starting row, testing consecutive parameter sets. The clinician continues as long as the patient indicates that the stimulation results are improving. When a local optimum is found, the clinician returns to the benchmark row, and tests in the opposite direction for another local optimum. If an acceptable set of stimulation parameters is found, the selection process is complete. If an acceptable set is not found, a new starting row in the Steering Table is selected based on the next ranked trial set from the Measurement Table, and the process of searching for local optima is repeated. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of Korean Patent Application No. 10-2010-0093307, filed on Sep. 27, 2010, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] One or more example embodiments of the present disclosure relate to a processor and an operating method of the processor, more particularly, a processor and an operating method of the processor supporting a coarse-grained array mode and a very long instruction word (VLIW) mode.
[0004] 2. Description of the Related Art
[0005] Generally, in consideration of performance and cost, a data memory structure of a processor may be configured to incorporate an L1 memory having a small size and a relatively high speed within the processor, and to cause a memory having a larger size and a relatively low speed to use a source outside of (i.e., external to) the processor, such as a system dynamic random access memory (DRAM), and the like.
[0006] FIG. 1 illustrates a configuration of a processor 100 supporting a coarse-grained array mode and a very long instruction word (VLIW) mode according to conventional art.
[0007] Referring to FIG. 1 , the processor 100 supporting the coarse-grained array mode and the VLIW mode according to the conventional art may include a core 110 , a data memory controller 120 , and a scratch pad memory 130 .
[0008] The core 110 of the processor 100 according to the conventional art may have a structure disposing of a number of functional units (FUs) in a grid pattern, and may obtain enhanced performance by easily performing operations in parallel in the FUs through performing the coarse-grained array mode.
[0009] The processor 100 according to the conventional art may successively read a value in an input data array among software codes and perform an operation. When a reoccurring routine that is performed using a loop and that is in a form of using a result value in an output data array exists, the reoccurring routine may be processed through the coarse-grained array mode. Accordingly, a data memory access pattern in the coarse-grained array mode may usually correspond to a sequential access pattern. In a case of the sequential access pattern, a temporal/spatial locality may be low. Thus, when a cache memory is used as an L1 data memory, an area used for storage capacity may increase, a miss rate may increase, and a performance may deteriorate.
[0010] To enable the coarse-grained array mode to exhibit the best efficiency, the scratch pad memory 130 having a low area cost for unit capacity may be suitable for the data memory structure so that the input and output data array may be relatively large.
[0011] However, since the coarse-grained array mode may accelerate only a loop operation portion, a general routine other than the loop operation may be executed in the VLIW mode.
[0012] Since the VLIW mode may use only a portion of FUs among a plurality of FUs, performing the operation in parallel may result in poor performance. However, since the VLIW mode may perform a general software code, a function call, and the like in addition to the loop operation, the VLIW mode may be an essential function for the processor to fully execute a single software code.
[0013] Since a stack access, a global variable access, and the like may unrestrictedly occur during an execution of code in the VLIW mode, the data memory access pattern may have a relatively high temporal/spatial locality.
[0014] To enable the VLIW mode to exhibit the best efficiency, the cache memory, capable of enhancing performance using locality and reducing an external memory bandwidth, may be suitable for an L1 data memory structure.
[0015] The processor 100 according to a conventional art may include only the scratch pad memory 130 as the L1 memory. Thus, in the processor 100 according to a conventional art, both of a shared section in which a variable used in the coarse-grained array mode is stored and a local/stack section in which a variable used in the VLIW mode is stored may be included in the scratch pad memory 130 . In this instance, the core 110 according to a conventional art may access the scratch pad memory 130 through the data memory controller 120 based on an execution mode to be executed, that is, one of the coarse-grained array mode and the VLIW mode.
[0016] Thus, in the processor 100 according to the conventional art, the core 110 may access the scratch pad memory 130 at all times regardless of the execution mode of the core 110 . When external accesses simultaneously occur through a bus slave besides the core 110 with respect to the scratch pad memory 130 , an execution performance of the scratch pad memory 130 may deteriorate.
SUMMARY
[0017] The foregoing and/or other aspects are achieved by providing a processor supporting a coarse-grained array mode and a very long instruction word (VLIW) mode, including a core of the processor, a scratch pad memory including a shared section in which a variable used in the coarse-grained array mode is stored, a cache memory to cache a variable used in the VLIW mode, from a dynamic random access memory (DRAM) including a local/stack section in which the variable used in the VLIW mode is stored, and an address decoding unit to determine which section a memory access request received from the core is associated with, of the shared section and the local/stack section, based on a memory address corresponding to the memory access request received from the core, In an embodiment, when the memory address corresponds to the shared section, the core accesses the scratch pad memory, and when the memory address corresponds to the local/stack section, the core accesses the cache memory.
[0018] The foregoing and/or other aspects are achieved by providing an operating method of a processor supporting a coarse-grained array mode and a VLIW mode, including receiving a memory access request from a core of the processor, and determining which section the memory access request received from the core is associated with, of a shared section and a local/stack section, based on a memory address corresponding to the memory access request received from the core. In an embodiment, the scratch pad memory is accessed when the memory address corresponds to the shared section and the cache memory is accessed when the memory address corresponds to the local/stack section.
[0019] Additional aspects of embodiments will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] These and/or other aspects will become apparent and more readily appreciated from the following description of embodiments, taken in conjunction with the accompanying drawings of which:
[0021] FIG. 1 illustrates a configuration of a processor supporting a coarse-grained array mode and a very long instruction word (VLIW) mode according to a conventional art;
[0022] FIG. 2 illustrates a configuration of a processor according to example embodiments; and
[0023] FIG. 3 illustrates an operating method of a processor according to example embodiments.
DETAILED DESCRIPTION
[0024] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. Embodiments are described below to explain the present disclosure by referring to the figures.
[0025] FIG. 2 illustrates a configuration of a processor 200 according to example embodiments.
[0026] Referring to FIG. 2 , a processor 200 supporting a coarse-grained array mode and a very long instruction word (VLIW) mode according to example embodiments may include, for example, a core 210 , an address decoding unit 220 , a cache memory 240 , and a scratch pad memory 250 .
[0027] The cache memory 240 may cache a variable used in the VLIW mode, from a dynamic random access memory (DRAM) 270 .
[0028] The DRAM 270 , according to example embodiments, may include a local/stack section in which the variable used in the VLIW mode is stored. In this instance, the DRAM 270 according to example embodiments may be located external to the processor 200 .
[0029] The scratch pad memory 250 may include a shared section in which a variable used in the coarse-grained array mode is stored.
[0030] According to an embodiment of the present disclosure when a programmer programs software and declares a global variable, the programmer may designate a data section, that is, the shared section or the local/stack section, as the section in which the global variable is located. For example, the programmer may declare that the variable used in the coarse-grained array mode is located in the shared section, and the variable used in the VLIW mode is located in the local/stack section.
[0031] A compiler may separately dispose the global variable in a predetermined address section for each data section in response to the declaration of the location.
[0032] Accordingly, the variable used in the coarse-grained array mode according to example embodiments may be disposed in a first memory address section set in response to the shared section. The variable used in the VLIW mode may be disposed in a second memory address set in response to the local/stack section.
[0033] For example, when an address range of 1 through 100 is set in response to the local/stack section, the compiler may separately dispose the global variable, declared to be located in the local/stack section, in the address range of 1 through 100. When an address range of 101 through 200 are set in response to the shared section, the compiler may separately dispose the global variable, declared to be located in the shared section, in one of the addresses in the address range of 101 through 200.
[0034] In this instance, when a memory access request occurs from the core 210 , the address decoding unit 220 may determine which of the shared section and the local/stack section the memory access request is associated with, based on a memory address corresponding to the memory access request.
[0035] For example, when the memory address of the memory access request corresponds to a memory address of the shared section, the address decoding unit 220 may determine that the memory access request is a memory access request associated with the shared section. In this instance, the core 210 may access the scratch pad memory 250 including the shared section.
[0036] When the memory address of the memory access request corresponds to a memory address of the local/stack section, the address decoding unit 220 may determine that the memory access request is a memory access request associated with the local/stack section. In this instance, the core 210 may access the cache memory 240 . When a cache miss occurs as a result of an access to the cache memory 240 , the core 210 may access the DRAM 270 including the local/stack section.
[0037] According to an embodiment of the present disclosure, the processor 200 may further include a data memory controller 260 .
[0038] The data memory controller 260 may control a memory access of the core 210 .
[0039] Depending on embodiments, when the memory access request of the core 210 is determined to be the memory access request with respect to the shared section, the core 210 may access the scratch pad memory 250 through the data memory controller 260 .
[0040] When the memory access request of the core 210 is determined to be the memory access request with respect to the local/stack section, and as a result of the access to the cache memory 240 of the core 210 the cache miss occurs, the core 210 may access the DRAM 270 through the data memory controller 260 .
[0041] When a memory access request with respect to an external section occurs from the core 210 , the core 210 may memory-access the external section through the data memory controller 260 .
[0042] The data memory controller, 260 according to an embodiment, may be connected to the core 210 . The cache memory 240 , according to an embodiment, may be connected to each of the data memory controller 260 and the address decoding unit 220 .
[0043] FIG. 3 illustrates an operating method of a processor according to example embodiments.
[0044] According to an embodiment of the present disclosure, when a programmer programs software and declares a global variable, the programmer may designate a data section, that is, the shared section or the local/stack section, as the section in which the global variable is located. For example, the programmer may declare that the variable used in the coarse-grained array mode is located in the shared section, and the variable used in the VLIW mode is located in the local/stack section.
[0045] A compiler may separately dispose the global variable in a predetermined address section for each data section in response to the declaration of the location.
[0046] Accordingly, the variable used in the coarse-grained array mode according to example embodiments may be disposed in a first memory address section set in response to the shared section. The variable used in the VLIW mode may be disposed in a second memory address section set in response to the local/stack section.
[0047] For example, when an address range of 1 through 100 is set in response to the local/stack section, the compiler may separately dispose the global variable, declared to be located in the local/stack section, in the address range of 1 through 100. When an address range of 101 through 200 is set in response to the shared section, the compiler may separately dispose the global variable, declared to be located in the shared section, in the address range of 101 through 200.
[0048] In the operating method of the processor supporting the coarse-grained array mode and the VLIW mode, in operation 310 , a core of the processor may generate a memory access request.
[0049] In operation 320 , one of the shared section and the local/stack section is determined to be associated with the memory access request, based on a memory address corresponding to the memory access request.
[0050] When the memory address of the memory access request corresponds to a memory address of the shared section, the operating method may determine that the memory access request is a memory access request associated with the shared section. In operation 330 , the operating method may access a scratch pad memory including the shared section.
[0051] The scratch pad memory, according to an embodiment, may include the shared section in which a variable used in the coarse-grained array mode is stored.
[0052] When the memory address of the memory access request corresponds to a memory address of the local/stack section, the operating method may determine that the memory access request is a memory access request associated with the local/stack section. In operation 340 , the operating method may access a cache memory.
[0053] The cache memory may cache a variable used in the VLIW mode, from a DRAM.
[0054] The DRAM according to an embodiment may include the local/stack section in which the variable used in the VLIW mode is stored. In this instance, the DRAM according to an embodiment may be located external to a processor.
[0055] When a cache miss occurs as a result of an access to the cache memory, the operating method may access the DRAM including the local/stack section in operation 350 .
[0056] The operating method of the processor according to the above-described embodiments may be recorded in non-transitory computer-readable media including program instructions to implement various operations embodied by a computer. The media may also include, alone or in combination with the program instructions, data files, data structures, and the like. Examples of non-transitory computer-readable media include magnetic media such as hard disks, floppy disks, and magnetic tape; optical media such as CD ROM disks and DVDs; magneto-optical media such as optical disks; and hardware devices that are specially configured to store and perform program instructions, such as read-only memory (ROM), random access memory (RAM), flash memory, and the like. Examples of program instructions include both machine code, such as produced by a compiler, and files containing higher level code that may be executed by the computer using an interpreter. The described hardware devices may be configured to act as one or more software modules in order to perform the operations of the above-described embodiments, or vice versa. Any one or more of the software modules described herein may be executed by a dedicated processor unique to that unit or by a processor common to one or more of the modules. The described methods may be executed on a general purpose computer or processor or may be executed on a particular machine such as the processor supporting a coarse-grained array mode and a very long instruction word (VLIW) mode described herein.
[0057] . Although embodiments have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the disclosure, the scope of which is defined by the claims and their equivalents. | A processor and an operating method are described. By diversifying an L1 memory being accessed, based on an execution mode of the processor, an operating performance of the processor may be enhanced. By disposing a local/stack section in a system dynamic random access memory (DRAM) located external to the processor, a size of a scratch pad memory may be reduced without deteriorating a performance. While a core of the processor is performing in a very long instruction word (VLIW) mode, the core may data-access a cache memory and thus, a bottleneck may not occur with respect to the scratch pad memory even though a memory access occurs with respect to the scratch pad memory by an external component. | 6 |
RELATED APPLICATIONS
This application is a divisional patent application from and which claims the benefit of the filing date of U.S. patent application Ser. No. 10/291,125, filed Nov. 8, 2002, which claims the benefit of U.S. Provisional Application No. 60/337,527, filed Nov. 9, 2001; U.S. Provisional Application No. 60/337,528, filed Nov. 9, 2001; U.S. Provisional Application No. 60/337,529, filed Nov. 9, 2001; U.S. Provisional Application No. 60/338,055, filed Nov. 9, 2001; U.S. Provisional Application No. 60/338,069, filed Nov. 9, 2001; U.S. Provisional Application No. 60/338,072, filed Nov. 9, 2001, the disclosures of which are incorporated by reference herein in their entirety. Additionally, the disclosures of the following U.S. Patent Applications commonly assigned and simultaneously filed with U.S. patent application Ser. No. 10/291,125, are all incorporated by reference herein in their entirety: U.S. Pat. No. 6,876,047 (application Ser. No. 10/290,779), filed Nov. 8, 2002; U.S. Pat. No. 6,746,891 (application Ser. No. 10/290,920), filed Nov. 8, 2002; U.S. Pat. No. 6,876,482 (application Ser. No. 10/291,107), filed Nov. 8, 2002; and U.S. Pat. No. 6,882,264 (application Ser. No. 10/290,807), filed Nov. 8, 2002.
TECHNICAL FIELD
The present invention generally relates to micro-electro-mechanical systems (MEMS) devices and methods. More particularly, the present invention relates to the design and fabrication of movable MEMS microscale structures.
BACKGROUND ART
An electrostatic MEMS switch is a switch operated by an electrostatic charge and manufactured using MEMS techniques. A MEMS switch can control electrical, mechanical, or optical signal flow. MEMS switches have typical application to telecommunications, such as DSL switch matrices and cell phones, Automated Testing Equipment (ATE), and other systems that require low cost switches or low-cost, high-density arrays.
As can be appreciated by persons skilled in the art, many types of MEMS switches and related devices can be fabricated by either bulk or surface micromachining techniques. Bulk micromachining generally involves sculpting one or more sides of a substrate to form desired three-dimensional structures and devices in the same substrate material. The substrate is composed of a material that is readily available in bulk form, and thus ordinarily is silicon or glass. Wet and/or dry etching techniques are employed in association with etch masks and etch stops to form the microstructures. Etching is typically performed through the backside of the substrate. The etching technique can generally be either isotropic or anisotropic in nature. Isotropic etching is insensitive to the crystal orientation of the planes of the material being etched (e.g., the etching of silicon by using a nitric acid as the etchant). Anisotropic etchants, such as potassium hydroxide (KOH), tetramethyl ammonium hydroxide (TMAH), and ethylenediamine pyrochatechol (EDP), selectively attack different crystallographic orientations at different rates, and thus can be used to define relatively accurate sidewalls in the etch pits being created. Etch masks and etch stops are used to prevent predetermined regions of the substrate from being etched.
On the other hand, surface micromachining generally involves forming three-dimensional structures by depositing a number of different thin films on the top of a silicon wafer, but without sculpting the wafer itself. The films usually serve as either structural or sacrificial layers. Structural layers are frequently composed of polysilicon, silicon nitride, silicon dioxide, silicon carbide, or aluminum. Sacrificial layers are frequently composed of polysilicon, photoresist material, polyimide, metals or various kinds of oxides, such as PSG (phosphosilicate glass) and LTO (low-temperature oxide). Successive deposition, etching, and patterning procedures are carried out to arrive at the desired microstructure. In a typical surface micromachining process, a silicon substrate is coated with an isolation layer, and a sacrificial layer is deposited on the coated substrate. Windows are opened in the sacrificial layer, and a structural layer is then deposited and etched. The sacrificial layer is then selectively etched to form a free-standing, movable microstructure such as a beam or a cantilever out of the structural layer. The microstructure, or microcomponent, is ordinarily anchored to the silicon substrate, and can be designed to be movable in response to an input from an appropriate actuating mechanism.
Many current MEMS switch designs employ a cantilievered beam (or plate), or multiple-supported beam geometry for the switching structure. In the case of cantilevered beams, these MEMS switches include a movable, bimaterial beam comprising a structural layer of dielectric material and a layer of metal. Typically, the dielectric material is fixed at one end with respect to the substrate and provides structural support for the beam. The layer of metal is attached on the underside of the dielectric material and forms a movable electrode and a movable contact. The layer of metal can form part of the anchor. The movable beam is actuated in a direction toward the substrate by the application of a voltage difference across the electrode and another electrode attached to the surface of the substrate. The application of the voltage difference to the two electrodes creates an electrostatic field, which pulls the beam towards the substrate. The beam and substrate each have a contact which is separated by an air gap when no voltage is applied, wherein the switch is in the “open” position. When the voltage difference is applied, the beam is pulled to the substrate and the contacts make an electrical connection, wherein the switch is in the “closed” position.
One of the problems that faces current MEMS switches having a bimaterial beam is curling or other forms of static displacement or deformation of the beam. The static deformation can be caused by a stress mismatch or a stress gradient within the films. At some equilibrium temperature, the mismatch effects could be balanced to achieve a flat bimaterial structure, but this does not fix the temperature dependent effects. The mismatch could be balanced through specific processes (i.e., deposition rates, pressures, method, etc.), through material selection, and through geometrical parameters such as thickness. This bimaterial structure of metal and dielectric introduces a large variation in function over temperature, because the metal will typically have a higher thermal expansion rate than the dielectric. Because of the different states of static stress in the two materials, the switch can be deformed with a high degree of variability. Switch failure can result from deformation of the beam. Switch failure results when electrical contact is not established between the movable and stationary contacts due to static deformation or because of the deformation introduced as a function of temperature. A second mode of failure is observed when the movable contact and the stationary contact are prematurely closed, resulting in a “short”. Because of the deformation of the beam, the actuation voltage is increased or decreased depending on whether it is curved away from the substrate or towards the substrate, respectively. Because of this variability, the available voltage may not be adequate to achieve the desired contact force and, thus, contact resistance.
Many MEMS switches are designed with stiffer beams in order to avoid curling or deformation for improving switch reliability. These MEMS switches require higher actuation voltage in order to deflect the beam to a “closed” position. It is desirable to reduce the actuation voltage required to close MEMS switches for power conservation. A higher voltage is required to deflect the beam to a “closed” position than to maintain the beam in a “closed” position. Thus, in order to minimize the power required for operating the switch, it is desirable to use minimal power to reduce the power for actuating the beam and maintaining the beam in the “closed” position.
Typically, the beam of a MEMS switch is restored to an “open” position from a “closed” position by reducing the actuation voltage an amount sufficient for the resilient forces of the beam to deflect the beam back to the “open” position. The contacts of a MEMS switch frequently adhere to one another due metallurgical adhesion, cold welding, or hot welding forces. These forces are sometimes greater than the resilient forces of the beam, thus preventing the deflection of the beam to the “open” position. In such cases, switch failure results because the beam does not return to the “open” position. Therefore, it is desired to have a MEMS switch having a mechanism for generating a force to return the beam to an “open” position.
SUMMARY
According to one embodiment, a movable microcomponent suspended over a substrate is provided. The movable microcomponent can include a dielectric layer having at least one end fixed with respect to the substrate. The microcomponent can also include a movable electrode attached to the dielectric layer and separated from the substrate. Furthermore, the microcomponent can include an electrothermal component attached to the dielectric layer and operable to produce heat for deflecting the dielectric layer.
According to a second embodiment, a microscale switch for electrostatic and electrothermal actuation is provided. The switch can include a substrate and a stationary electrode and stationary contact formed on the substrate. The switch can also include a movable microcomponent suspended above the substrate. The microcomponent can include a dielectric layer including at least one end fixed with respect to the substrate. The microcomponent can also include a movable electrode spaced from the stationary electrode and a movable contact spaced from the stationary electrode. Furthermore, the microcomponent can include an electrothermal component attached to the dielectric layer and operable to produce heating for generating force for moving the dielectric layer.
According to a third embodiment, a method for implementing a switching function in a microscale device is provided. The method can include providing a stationary electrode and a stationary contact formed on a substrate. The method can further include providing a movable microcomponent suspended above the substrate. The microcomponent can include a dielectric layer including at least one end fixed with respect to the substrate. The microcomponent can also include a movable electrode spaced from the stationary electrode and a movable contact spaced from the stationary electrode. The movable contact can be positioned farther from the at least one end than the movable electrode. The microcomponent can include an electrothermal component attached to the dielectric layer. The method can include applying a voltage between the movable electrode and the stationary electrode to electrostatically couple the movable electrode with the stationary electrode, whereby the movable component is deflected toward the substrate and the movable contact moves into contact with the stationary contact to permit an electrical signal to pass through the movable and stationary contacts. Furthermore, the method can include applying a current through the first electrothermal component to produce heating for generating force for moving the microcomponent.
According to a fourth embodiment, a method for fabricating a microscale switch is provided. The method can include depositing a first conductive layer on a substrate and forming a stationary electrode and a stationary contact by removing a portion of the first conductive layer. The method can also include depositing a sacrificial layer on the stationary electrode, the stationary contact, and the substrate. Additionally, the method can include depositing a second conductive layer on the sacrificial layer and forming a movable electrode and a movable contact by removing a portion of the second conductive layer. The method can also include depositing a third conductive layer on the dielectric layer and removing a portion of the third conductive layer to form an electrothermal component. Furthermore, the method can include removing a sufficient amount of the sacrificial layer so as to define a first gap between the stationary electrode and the movable electrode, and to define a second gap between the stationary contact and the movable contact.
According to a fifth embodiment, a method for fabricating a microscale switch is provided. The method can include depositing a first conductive layer on a substrate and forming a stationary electrode and a stationary contact by removing a portion of the first conductive layer. The method can further include depositing a sacrificial layer on the stationary electrode, the stationary contact, and the substrate. Additionally, the method can include depositing a second conductive layer on the sacrificial layer and forming a movable electrode, a movable contact, and an electrothermal component by removing a portion of the second conductive layer. Furthermore, the method can include removing a sufficient amount of the sacrificial layer so as to define a first gap between the stationary electrode and the movable electrode, and to define a second gap between the stationary contact and the movable contact.
According to a sixth embodiment, a method for implementing a switching function in a microscale device having a movable microcomponent is provided. The method can include applying a voltage between a movable electrode and a stationary electrode of the microscale device for electrostatically coupling the movable electrode with the stationary electrode, whereby the movable microcomponent is deflected and a movable contact moves into contact with a stationary contact to permit an electrical signal to pass through the movable and stationary contacts. The method can also includes applying a current through a first electrothermal component of the microscale device to produce heating for generating force for moving the microcomponent.
Accordingly, it is an object of the present invention to provide a movable microcomponent for improving the yield, performance over temperature, actuation, and quality of MEMS switches.
An object having been stated hereinabove, and which is achieved in whole or in part by the described MEMS device having electrothermal actuation and release and method for fabricating described herein, other objects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention will now be explained with reference to the accompanying drawings, of which:
FIG. 1 illustrates a cross-sectional side view of a MEMS switch having electrothermal actuation and release in an “open” position;
FIG. 2 illustrates a top plan view of a MEMS switch having electrothermal actuation and release;
FIG. 3 illustrates a bottom plan view of a beam of a MEMS switch having electrothermal actuation and release;
FIG. 4 illustrates a cross-sectional side view of a MEMS switch having electrothermal actuation and release in a “closed” position;
FIG. 5 illustrates a cross-sectional front elevation view of the stationary electrode, structural layer, movable electrode, electrode interconnect, release electrothermal component, and actuation electrothermal component of a MEMS switch having electrothermal actuation and release; and
FIGS. 6A-K illustrate fabrication steps of an embodiment of a method for fabricating a MEMS switch having electrothermal actuation and release.
DETAILED DESCRIPTION OF THE INVENTION
For purposes of the description herein, it is understood that when a component such as a layer or substrate is referred to as being “disposed on”, “attached to” or “formed on” another component, that component can be directly on the other component or, alternatively, intervening components (for example, one or more buffer or transition layers, interlayers, electrodes or contacts) can also be present. Furthermore, it is understood that the terms “disposed on”, “attached to” and “formed on” are used interchangeably to describe how a given component can be positioned or situated in relation to another component. Therefore, it will be understood that the terms “disposed on”, “attached to” and “formed on” do not introduce any limitations relating to particular methods of material transport, deposition, or fabrication.
Contacts, interconnects, conductive vias, electrothermal components and electrodes of various metals can be formed by sputtering, CVD, or evaporation. If gold, nickel or PERMALLOY™ (Ni x Fe y ) is employed as the metal element, an electroplating process can be carried out to transport the material to a desired surface. The chemical solutions used in the electroplating of various metals are generally known. Some metals, such as gold, might require an appropriate intermediate adhesion layer to prevent peeling. Examples of adhesion material often used include chromium, titanium, or an alloy such as titanium-tungsten (TiW). Some metal combinations can require a diffusion barrier to prevent a chromium adhesion layer from diffusing through gold. Examples of diffusion barriers between gold and chromium include platinum or nickel.
Conventional lithographic techniques can be employed in accordance with fabrication, such as micromachining, of the invention described herein. Accordingly, basic lithographic process steps such as photoresist application, optical exposure, and the use of developers are not described in detail herein.
Similarly, generally known etching processes can be suitably employed to selectively remove material or regions of material. An imaged photoresist layer is ordinarily used as a masking template. A pattern can be etched directly into the bulk of a substrate, or into a thin film or layer that is then used as a mask for subsequent etching steps.
The type of etching process employed in a particular fabrication step (e.g., wet, dry, isotropic, anisotropic, anisotropic-orientation dependent), the etch rate, and the type of etchant used will depend on the composition of material to be removed, the composition of any masking or etch-stop layer to be used, and the profile of the etched region to be formed. As examples, poly-etch (HF:HNO 3 :CH 3 COOH) can generally be used for isotropic wet etching. Hydroxides of alkali metals (e.g., KOH), simple ammonium hydroxide (NH 4 OH), quaternary (tetramethyl) ammonium hydroxide ((CH 3 ) 4 NOH, also known commercially as TMAH), and ethylenediamine mixed with pyrochatechol in water (EDP) can be used for anisotropic wet etching to fabricate V-shaped or tapered grooves, trenches or cavities. Silicon nitride can typically be used as the masking material against etching by KOH, and thus can used in conjunction with the selective etching of silicon. Silicon dioxide is slowly etched by KOH, and thus can be used as a masking layer if the etch time is short. While KOH will etch undoped silicon, heavily doped (p++) silicon can be used as an etch-stop against KOH as well as the other alkaline etchants and EDP. Silicon oxide and silicon nitride can be used as masks against TMAH and EDP. The preferred metal used to form contacts and interconnects in accordance with the invention is gold and its alloys.
It will be appreciated that electrochemical etching in hydroxide solution can be performed instead of timed wet etching. For example, if a p-type silicon wafer is used as a substrate, an etch-stop can be created by epitaxially growing an n-type silicon end layer to form a p-n junction diode. A voltage can be applied between the n-type layer and an electrode disposed in the solution to reverse-bias the p-n junction. As a result, the bulk p-type silicon is etched through a mask down to the p-n junction, stopping at the n-type layer. Furthermore, photovoltaic and galvanic etch-stop techniques are also suitable.
Dry etching techniques such as plasma-phase etching and reactive ion etching (RIE) can also be used to remove silicon and its oxides and nitrides, as well as various metals. Deep reactive ion etching (DRIE) can be used to anisotropically etch deep, vertical trenches in bulk layers. Silicon dioxide is typically used as an etch-stop against DRIE, and thus structures containing a buried silicon dioxide layer, such as silicon-on-insulator (SOI) wafers, can be used according to the methods of the invention as starting substrates for the fabrication of microstructures.
An alternative patterning process to etching is the lift-off process as known to those of skill in the art. In this case, the conventional photolithography techniques are used for the negative image of the desired pattern. This process is typically used to pattern metals, which are deposited as a continuous film or films when adhesion layers and diffusion barriers are needed. The metal is deposited on the regions where it is to be patterned and on top of the photoresist mask (negative image). The photoresist and metal on top are removed to leave behind the desired pattern of metal.
As used herein, the term “device” is interpreted to have a meaning interchangeable with the term “component.” As used herein, the term “conductive” is generally taken to encompass both conducting and semi-conducting materials.
Examples will now be described with reference to the accompanying drawings.
Referring to FIGS. 1-5 , different views of a MEMS switch, generally designated 100 , having electrothermal enhanced actuation and release are illustrated. Referring specifically to FIG. 1 , a cross-sectional side view of MEMS switch, generally designated 100 , is illustrated in an “open” position. MEMS switch 100 includes a substrate 102 . Non-limiting examples of materials which substrate 102 can comprise silicon (in single-crystal, polycrystalline, or amorphous forms), silicon oxinitride, glass, quartz, sapphire, zinc oxide, alumina, silica, or one of the various Group III-V compounds in either binary, ternary or quaternary forms (e.g., GaAs, InP, GaN, AlN, AlGaN, InGaAs, and so on). If the composition of substrate 102 is chosen to be a conductive or semi-conductive material, a non-conductive, dielectric layer can be deposited on the top surface of substrate 102 , or at least on portions of the top surface where electrical contacts or conductive regions are desired.
Substrate 102 includes a first stationary contact 104 , a second stationary contact (not shown in this view due to its positioning behind first stationary contact 104 ), and a stationary electrode 106 formed on a surface thereof. First stationary contact 104 , the second stationary contact, and stationary electrode 106 can comprise a conductive material such as a metal. Specifically, first stationary contact 104 , the second stationary contact, and stationary electrode 106 can comprise different conductive materials such as gold-nickel alloy (AuNi 5 ) and aluminum or other suitable conductive materials known to those of skill in the art. The conductivity of stationary electrode 106 can be much lower than the conductivity of first stationary contact 104 and the second stationary contact. Preferably, first stationary contact 104 and the second stationary contact can comprise a very high conductive material such as copper. Preferably, first stationary contact 104 and the second stationary contact can have a width range of 7 μm to 100 μm and a length range of 15 μm to 75 μm. Stationary electrode 106 can have a wide range of dimensions depending on the required actuation voltages, contact resistance, and other functional parameters.
MEMS switch 100 further comprises a movable, trilayered beam, generally designated 108 , suspended over first stationary contact 104 , the second stationary contact, and stationary electrode 106 . Beam 108 is fixedly attached at one end to a mount 110 , which can be fixedly attached to substrate 102 . Beam 108 extends substantially parallel to the top surface of substrate 102 when MEMS switch 100 is in an “open” position. Beam 108 generally comprises a dielectric structural layer 112 disposed between two electrically conductive layers described in more detail below. Structural layer 112 can comprise a bendable material, preferably silicon oxide (SiO 2 , as it is sputtered, electroplated, spun-on, or otherwise deposited), to deflect towards substrate 102 for operating in a “closed” position. Structural layer 112 provides electrical isolation and desirable mechanical properties including resiliency properties. Alternatively, structural layer 112 can comprise silicon nitride (Si x N y ), silicon oxynitride, alumina or aluminum oxide (Al x O y ), polymers, CVD diamond, their alloys, or any other suitable resilient materials known to those of skill in the art. Beam 108 is designed to be resilient for generating a restorative force to return the beam to its natural position when beam 108 is deflected or bent.
In this embodiment, beam 108 further includes a top and bottom layer attached to a top side 114 and an underside 116 , respectively, thereof. The bottom layer comprises a movable electrode 118 , a release electrothermal component 120 , and a movable contact 122 . Movable electrode 118 is shown with broken lines in this view due to its position behind release electrothermal component 120 . The top layer comprises an electrode interconnect 124 , an actuation electrothermal component 126 , and a contact interconnect 128 . Electrode interconnect 124 is shown with broken lines in this view due to its position behind actuation electrothermal component 126 . As shown, movable contact 118 and contact interconnect 128 are positioned further away from mount 110 than movable electrode 118 and electrode interconnect 124 . Release electrothermal component 120 and actuation electrothermal component 126 extend substantially the length of beam 108 . Alternatively, release electrothermal component 120 and actuation electrothermal component 126 can extend from mount 110 to any other suitable location on beam 108 .
Movable electrode 118 is positioned over stationary electrode 106 and displaced from stationary electrode 106 such that application of a voltage difference across electrodes 106 and 118 creates an electrostatic field, which causes an attractive force between electrodes 106 and 118 . Upon application of the voltage difference across electrodes 106 and 118 , beam 108 bends in a direction towards substrate 102 . In this embodiment, actuation electrothermal component 126 is a closed electrical circuit including current paths and resistance path transitions, shown and described in more detail below. Alternatively, the resistance path transition can be realized by a change in thickness instead of the change in width that is portrayed. Alternatively, electrothermal components 120 and 126 can comprise material transitions rather than area transitions to accomplish the resistance path transitions. The material transitions are realized by patterning different materials on either side of the resistance path transition. For example, nickel (Ni) and gold (Au) can be patterned on the first and second side of the resistance path transition. Any suitable materials having differing thermal and mechanical properties known to those of skill in the art can be used to achieve resistance path transitions. The magnitude of the localized heating is determined by the difference in the geometric or material properties. The resistance path transitions provide local heating and local generation of force at a suitable location on the top side 114 of structural layer 112 for facilitating deflection of beam 108 towards substrate 102 . The combination of electrostatic and electrothermal forces deflect beam 108 towards substrate 102 . The operation of the actuation electrothermal component 126 and electrodes 106 and 118 is described in further detail below.
The applied voltage difference between electrodes 106 and 118 can be reduced with the addition of the force generated by electrothermal actuation of electrothermal component 126 . This voltage reduction is desirable for achieving switching voltages on the order of 5 volts. Further, with the addition of electrothermal actuation, structural layer 112 can be designed stiffer and still actuate at a lower applied voltage. The increased beam stiffness tends to lower the switching speed and increase the reliability of achieving release from a “closed” position.
Electrodes 106 and 118 , contacts 104 and 122 , release electrothermal component 120 , actuation electrothermal component 126 , and interconnects 124 and 128 can comprise similar materials, such as gold, whereby the manufacturing process is simplified by the minimization of the number of different materials required for fabrication. Additionally, electrodes 106 and 118 , contacts 104 and 122 , release electrothermal component 120 , actuation electrothermal component 126 , and interconnects 124 and 128 can comprise conductors (platinum, aluminum, palladium, copper, tungsten, nickel, and other materials known to those of skill in the art), conductive oxides (indium tin oxide), and low resistivity semiconductors (silicon, polysilicon, and other materials known to those of skill in the art). These components can include adhesion layers (Cr, Ti, TiW, etc.) disposed between the component and structural layer 112 . These components can comprise a conductive material and an adhesion layer that includes diffusion barriers for preventing diffusion of the adhesion layer through the electrode material, or diffusion through the conductive material into the structural material. These components can also comprise different materials for breakdown or arcing considerations, for “stiction” considerations during wet chemical processing, or because of fabrications process compatibility issues. Contacts 104 and 122 can comprise a material having good conductive properties and other desirable properties of suitable contacts known to those of skill in the art, such as low hardness and low wear. Preferably, electrodes 106 and 118 comprise a material having low resistivity, low hardness, low oxidation, low wear, and other desirable properties of suitable contacts known to those of skill in the art. Preferably, electrothermal components 120 and 126 comprise a material having high resistivity, high softening/melting point, and high current capacity. The preferred properties contribute to high localized heating for development of larger deflections and forces. The high softening/melting point and high current capacity increase the reliability of the device during electrothermal operation. In this embodiment, electrothermal components 120 and 126 comprise the same material. Alternatively, electrothermal components 120 and 126 can comprise different materials.
Movable contact 122 is positioned over first stationary contact 104 and the second stationary contact such that it contacts first stationary contact 104 and the second stationary contact when beam 108 is moved to the “closed” position, thus providing electrical communication between first stationary contact 104 and the second stationary contact through movable contact 122 . Movable contact 122 is displaced from first stationary contact 104 and the second stationary contact when MEMS switch 100 operates in the “open” position such that there is no electrical communication between first stationary contact 104 and the second stationary contact. Movable contact 122 can be dimensioned smaller than first stationary contact 104 and the second stationary contact to facilitate contact when process variability and alignment variability are taken into consideration. First stationary contact 104 and the second stationary contact need to be sized appropriately so that movable contact 122 always makes contact with first stationary contact 104 and the second stationary contact when in the “closed” position. A second consideration that determines the size of movable contact 122 , first stationary contact 104 , and the second stationary contact is the parasitic response of switch 100 . The parasitic actuation response is generated by electric fields produced by potential differences between movable electrodes 106 and 118 , or by charge (or potential) differences between first stationary electrode 106 and second stationary contact and beam 108 that produce electric fields and a force on movable contact 122 . The dimensions of movable contact 122 are related to the dimensions of movable electrode 118 to achieve a specific ratio of the parasitic actuation to the actuation voltage.
Electrode interconnect 124 and movable electrode 118 are attached to opposing sides of structural layer 112 . Preferably, movable electrode 118 and electrode interconnect 124 have substantially the same dimensions and are aligned with one another for achieving a manufacturable flatness that is maintained over temperature. In this embodiment, electrode interconnect 124 comprises a conductive material having the same coefficient of thermal expansion, elastic modulus, residual film stress, and other electrical/mechanical properties as movable electrode 118 .
Movable electrode 118 and electrode interconnect 124 are in electrical communication with one another by connection to a first interconnect via 130 . First interconnect via 130 is indicated by broken lines in this view due to its placement inside structural layer 112 . First interconnect via 130 comprises a conductive material formed through structural layer 112 . In this embodiment, first interconnect via 130 comprises the same conductive material as movable electrode 118 and electrode interconnect 124 . Alternatively, first interconnect via 130 can comprise any suitable conductive material known to those of skill in the art, such as low wear and low hardness.
Movable contact 122 and contact interconnect 128 are attached to and aligned on opposing sides of structural layer 112 . Contact interconnect 128 is dimensioned substantially the same as movable contact 122 . Alternatively, contact interconnect 128 can have different dimensions and extent than movable contact 122 . It is intended to maintain geometric equivalence by management of the mechanical form. Contact interconnect 128 and movable contact 122 are intended to share a geometrical and thermo-mechanical equivalence. This equivalence provides a beam, which can achieve a manufacturable flatness that is maintained over temperature and other environmental conditions, such as die attachment, package lid seal processes, or solder reflow process. In this embodiment, contact interconnect 128 comprises a conductive material, such as copper for example, having the same coefficient of thermal expansion, elastic modulus, residual film stress, and other desirable electrical/mechanical properties known to those of skill in the art as movable contact 122 .
Movable contact 122 and contact interconnect 128 are in electrical communication with one another by connection to a second interconnect via 132 . Second interconnect via 132 is indicated by broken lines due to its placement inside structural layer 112 . Second interconnect via 132 comprises a conductive material, such as copper for example, formed through structural layer 112 for electrically connecting movable contact 122 and contact interconnect 128 . In this embodiment, second interconnect via 132 can comprise the same conductive material as contact interconnect 128 and movable contact 122 . Alternatively, second interconnect via 132 can comprise a different conductive material as contact interconnect 128 and movable contact 122 .
MEMS switch 100 further includes a switch controller 134 connected to and operable to transmit control signals to a first current source 136 , a second current source 138 , and a voltage source 140 for controlling the electrostatic and electrothermal actuation of switch 100 by application of voltage and current. Switch controller 134 is also operable to transmit control signals to other switches in an array of switches. First current source 136 , second current source 138 , and voltage source 140 are operable to output voltage and current in response to receiving control signals from switch controller 134 .
Referring to FIG. 2 , a top view of MEMS switch 100 is illustrated. As shown, actuation electrothermal component 126 is connected at two ends 200 and 202 to the output of first current source 136 . In this embodiment, actuation electrothermal component 126 extends from ends 200 and 202 around electrode interconnect 124 for providing a conductive path along the length of beam 108 for current applied by first current source 136 . Alternatively, the conductive path can extend around both electrode interconnect 124 and contact interconnect 128 . Actuation electrothermal component 126 further includes resistance path transitions 204 and 206 at which the current paths change from a low resistance path to a high resistance path for providing local heating and local generation of force to aid actuation of beam 108 . The location of resistance path transitions 204 and 206 and the ratio of the transition can be optimized for maximal force without damaging the component due to electrical overstress. Resistive heating along the length of the actuation electrothermal component 126 will also provide the elongation that aids the actuation of beam 108 . Thermal isolation is provided between actuation electrothermal component 126 and electrode interconnect 124 by an air gap, generally designated 142 , between the components and structural layer 112 which serves as an insulator.
As shown, electrode interconnect 124 and contact interconnect 128 are generally rectangular in shape. The external corners of electrode interconnect 124 and contact interconnect 128 can be rounded to contain internal reentrant corners for reducing the intensification in the electric fields produced by the potential differences between conductors. In this embodiment, electrode interconnect 124 can be dimensioned the same as movable electrode 118 . Alternatively, electrode interconnect 124 can be any suitable non-rectangular shape that substantially matches the shape of movable electrode 118 . The shape of contact interconnect 128 substantially matches the shape of movable contact 122 . Interconnect vias 130 and 132 are rectangular and shown by broken lines due to their position behind electrode interconnect 124 and contact interconnect 128 , respectively. Alternatively, interconnect vias 130 and 132 can be any geometry suitable for vias including circular, elliptical, or rectangular with rounded corners.
Referring to FIG. 3 , a bottom view of beam 108 of MEMS switch 100 is illustrated. Release electrothermal component 120 is connected at two ends 300 and 302 to the output of second current source 138 . In this embodiment, release electrothermal component 120 extends from ends 300 and 302 around movable contact 122 along the length of beam 108 for providing a conductive path for current applied by second current source 138 . Alternatively, the conductive path can extend around movable electrode 118 and movable contact 122 . Release electrothermal component 120 further includes resistance path transitions 304 and 306 at which the current paths change from a low resistance path to a high resistance path for providing local heating and local generation of force to aid release of beam 108 from a “closed” position, as described below. The location of resistance path transitions 304 and 306 and the ratio of the transition can be optimized for maximal force without damaging the component due to electrical overstress. Resistive heating along the length of the release electrothermal component 120 will also provide the elongation that aids the release of beam 108 from the “open” position. Thermal isolation is provided between release electrothermal component 120 and movable electrode 118 by air gap 142 between the components and structural layer 112 which serves as an insulator.
Upon the application of sufficient voltage and current by voltage source 140 and first current source 136 , respectively, beam 108 moves toward substrate 102 in a stable manner until beam 108 is close enough to substrate 102 for “pull-in” voltage, or “snap-in” voltage, to occur. After “pull-in” voltage occurs, beam 108 moves towards substrate 102 in an unstable manner until movable contact 122 touches first stationary contact 104 and the second stationary contact, thus establishing an electrical connection between first stationary contact 104 and the second stationary contact. Referring to FIG. 4 , a cross-sectional side view of MEMS switch 100 in a “closed” position is illustrated. In the “closed” position, movable contact 122 is touching first stationary contact 104 and the second stationary contact, thus establishing an electrical connection between first stationary contact 104 and the second stationary contact. As described below, the components of MEMS switch 100 can be dimensioned such that movable electrode 118 and stationary electrode 106 do not contact in the “closed” position, thus preventing a short between components 106 and 118 . MEMS switch 100 can be maintained in position by applying only the potential voltage difference between movable electrode 118 and stationary electrode 106 . The application of current to actuation electrothermal component 126 is not required to maintain MEMS switch 100 in the “closed” position, thus reducing the power required for operating actuation electrothermal component 126 . Switch controller 134 is operable to receive feedback signals indicating a “closed” condition and turn off first current source 136 in response to receiving the signal.
MEMS switch 100 is returned to an “open” position by sufficiently reducing or removing the voltage difference applied across stationary electrode 106 and movable electrode 118 . This in turn reduces the attractive force between stationary electrode 106 and movable electrode 118 such that the resilient force of structural layer 112 restores structural layer 112 to an “open” position. If movable contact 118 adheres to stationary contact 104 , current can be briefly applied by second current source 138 to the release electrothermal component 120 to “break” the contact. After release from the contact, the resilient force of structural layer 112 can restore beam 108 to an “open” position. Switch controller 134 is operable to control voltage source 140 for reducing or removing the applied voltage and activating second current source 136 to apply current to release electrothermal component 120 for restoring beam 108 to the “open” position.
Referring again to FIG. 1 , voltage source 140 can be directly connected to stationary electrode 106 and electrode interconnect 124 . Movable electrode 118 is electrically connected to voltage source 140 through first interconnect via 130 and electrode interconnect 124 . First interconnect via 130 provides an electrical connection between electrode interconnect 124 and movable electrode 118 . Therefore, upon the application of a voltage by voltage source 140 , a voltage difference is created between stationary electrode 106 and movable electrode 118 . This establishes electrostatic coupling between movable electrode 118 and stationary electrode 106 across air gap 142 . Alternatively, the gap between movable electrode 118 and stationary electrode 106 can be any suitable isolating fluid/gas as known to those of skill in the art, such as for example SF 6 , a high breakdown voltage and arc quenching gas.
Preferably, movable electrode 118 and electrode interconnect 124 are fabricated of the same material and dimensioned the same. Additionally, movable contact 122 and contact interconnect 128 are fabricated of the same material and dimensioned the same. First, it provides mechanical balance on both sides of structural layer 112 . The mechanical balance is provided because of the elastic symmetry, because the films are deposited in the same way to produce a symmetric stress field, and because the thermal expansion properties are symmetric. The elastic symmetry is preserved by using the same material and by using the same dimensions. The symmetric stress field is produced by depositing the same materials using the same process and thicknesses. The symmetric thermal expansion properties minimize any variation in the switch operation with respect to temperature because the same material is on either side of structural layer 112 . This means that any functional variation exhibited by MEMS switch 100 depends primarily on the process variation, which can be minimized by the appropriate optimization of the design in the process. Secondly, because movable contact 122 and contact interconnect 128 are fabricated of the same material and dimensioned the same, the current carrying capacity of contacts 122 and 128 is aided. It is preferable that beam 108 has the same type of metal, deposited by the same process, patterned in the same geometry, and deposited to the same thickness, but the use of different materials could be accommodated with the appropriate design and characterization. To address the issues of contact adhesion, cold welding, or hot welding, first stationary contact 104 , the second stationary contact, and movable contact 122 could be different materials or different alloys of the same materials. The material selection can minimize contact resistance and failures such as stiction.
In the “open” position, movable contact 118 is separated from first stationary contact 104 and second stationary contact by a gap distance a 144 as shown in FIG. 1 . Movable electrode 118 is separated from stationary electrode 106 by a gap distance b 146 . In this embodiment, distance a 142 is less distance b 146 . If distance a 144 is less distance b 146 , the operation of MEMS switch 100 is more reliable because potential for shorting between stationary electrode 106 and movable electrode 118 is reduced. The length of beam 108 is indicated by a distance c 148 . The center of movable contact 122 is a distance d 150 from mount 110 and a distance e 152 from the end of beam 108 that is distal mount 110 . The edge of electrode interconnect 124 distal mount 110 is a distance f 154 from mount 110 . The edge of electrode interconnect 124 near mount 110 is a distance g 156 from mount 110 . In this embodiment, distance a 144 is nominally 1.5 microns; distance b 146 is preferably 2 microns; distance c 148 is preferably 155 microns; distance d 148 is preferably 135 microns; distance e 152 is preferably 20 microns; distance f 154 is preferably 105 microns; and distance g 156 is 10 microns. The distances a 144 , b 146 , c 148 , d 150 , e 152 , f 154 , and g 156 provide desirable functional performance, but other dimensions can be selected to optimize other functional characteristics, manufacturability, and reliability.
Referring to FIG. 5 , a cross-sectional front view of stationary electrode 106 , structural layer 112 , movable electrode 118 , actuation electrothermal component 120 , electrode interconnect 124 , and release electrothermal component 126 of MEMS switch 100 is illustrated. The width of movable electrode 118 and electrode interconnect 124 is indicated by a distance a 500 . Preferably, movable electrode 118 and electrode interconnect 124 are equal in width. Alternatively, movable electrode 118 and electrode interconnect 124 can have different widths. The width of stationary electrode 106 is indicated by distance b 502 . The width of structural layer 112 is indicated by distance c 504 . The thickness of structural layer 112 is indicated by distance d 506 . The thickness of stationary electrode 106 is indicated by distance e 508 . The thickness of movable electrode 118 and release electrothermal component 120 is indicated by distance f 510 . The thickness of electrode interconnect 124 and actuation electrothermal component 126 is indicated by distance g 512 . The conductive paths of release electrothermal component 120 and actuation electrothermal component 126 are indicated by distance h 514 and 1516 . First stationary contact 104 and stationary electrode 106 can be dimensioned greater than movable electrode 118 and movable contact 122 , respectively, in order to facilitate shielding MEMS switch 100 from any parasitic voltages. In this embodiment, distance a 500 is preferably 75 microns; distance b 502 is preferably 125 microns; distance c 504 is preferably 105 microns; distance d 506 is preferably 2 microns; distance e 508 is preferably 0.5 microns; distance f 510 is preferably 0.5 microns; distance g 512 is preferably 0.5 microns; and distances h 514 and i 516 are preferably microns. The distances a 500 , b 502 , c 504 , d 506 , e 508 , f 510 , g 512 , h 514 and i 516 provide desirable functional performance, but other dimensions can be selected to optimize other functional characteristics, manufacturability, and reliability.
Referring to FIGS. 6A-6K , an embodiment of a method for fabricating a MEMS switch having electrothermal actuation and release according to a surface micromachining process of the present invention will now be described. Referring specifically to FIG. 6A , a substrate 600 is provided, which preferably comprises silicon. Because substrate 600 is a semi-conductive material, a first dielectric layer 602 is deposited on the top surface of substrate 600 . Alternatively, dielectric material can be deposited on portions of the top surface where electrical contacts or conductive regions are desired.
Referring to FIG. 6B-6C , a process for producing a first stationary contact 604 , a second stationary contact (not shown due to its positioning behind first stationary contact 604 ), and a stationary electrode 606 is illustrated. Referring specifically to FIG. 6B , a first conductive layer 608 is deposited on first dielectric layer 602 . First conductive layer 608 is patterned as described above. Referring to FIG. 6C , first stationary contact 604 , the second stationary contact, and stationary electrode 606 are formed simultaneously in first conductive layer 608 . Alternatively, first stationary contact 604 , the second stationary contact, and stationary electrode 606 can be formed in separate processes.
Referring to FIG. 6D , a sacrificial layer 610 is deposited to a uniform thickness such that its top surface is preferably planarized. Sacrificial layer 610 defines the gap between a beam structure, described in further detail below, and first stationary contact 604 , the second stationary contact, and stationary electrode 606 . Sacrificial layer 610 can be a metal, dielectric or any other suitable material known to those of skill in the art such that the removal chemistry is compatible with the other electrical and structural materials.
Referring to FIGS. 6E-6F , a process for producing a movable contact 612 , a movable electrode 614 , and a release electrothermal component 616 , as described above, is illustrated. Referring specifically to FIG. 6E , grooves 618 , 620 , and 622 are etched in sacrificial layer 610 for forming movable contact 612 , movable electrode 614 , and release electrothermal component 616 , respectively. Groove 624 is formed in sacrificial layer 610 for forming a structure to attach the beam to substrate 600 and suspend the beam above first stationary contact 604 , the second stationary contact, and stationary electrode 606 . Referring now to FIG. 6F , a conductive layer is deposited on sacrificial layer 610 until grooves 618 , 620 , and 622 are filled. Next, the conductive layer is patterned as described above to form movable contact 612 , movable electrode 614 , and release electrothermal component 616 .
Referring FIG. 6G , a structural layer 626 is deposited on movable contact 612 , movable electrode 614 , release electrothermal component 616 , sacrificial layer 610 , and first dielectric layer 602 . Structural layer 626 comprises oxide in this embodiment.
Referring to 6 H- 6 J, a process for simultaneously producing the following conductive microstructures: a contact interconnect 628 , an electrode interconnect 630 , an actuation electrothermal component 632 , and interconnect vias 634 and 636 . Referring specifically to FIG. 6H , recesses 638 and 640 are etched into structural layer 626 for forming interconnect vias 634 and 636 , respectively. Recesses 638 and 640 are etched through structural layer 626 to movable contact 612 and movable electrode 614 , respectively.
Referring now to FIG. 6I , a second conductive layer 642 is deposited on structural layer 626 and into recesses 638 and 640 as shown for forming an electrical connection from movable contact 612 and movable electrode 614 to the top surface of structural layer 626 . Next, second conductive layer 642 is patterned for forming contact interconnect 628 , electrode interconnect 630 , and actuation electrothermal component 632 as shown in FIG. 6J . Interconnect vias 634 and 636 can be formed by another conductive layer that would precede the deposition of second conductive layer 642 described above.
Referring to FIG. 6K , the final step in fabricating the MEMS switch is illustrated. In this step, sacrificial layer 610 is removed to form a trilayered beam, generally designated 644 . Sacrificial layer 610 can be removed by any suitable method known to those of skill in the art.
It may be desired to have a MEMS switch that takes advantage of either the enhanced actuation or enhanced release. In that case, an alternate MEMS switch having either one of an actuation electrothermal component or a release electrothermal component can be fabricated and operated without the other component.
It will be understood that various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation—the invention being defined by the claims. | Methods for Implementation of a Switching Function in a Microscale Device and for Fabrication of a Microscale Switch. According to one embodiment, a method is provided for implementing a switching function in a microscale device. The method can include providing a stationary electrode and a stationary contact formed on a substrate. Further, a movable microcomponent suspended above the substrate can be provided. A voltage can be applied between the between a movable electrode of the microcomponent and the stationary electrode to electrostatically couple the movable electrode with the stationary electrode, whereby the movable component is deflected toward the substrate and a movable contact moves into contact with the stationary contact to permit an electrical signal to pass through the movable and stationary contacts. A current can be applied through the first electrothermal component to produce heating for generating force for moving the microcomponent. | 8 |
This application is a continuation of application Ser. No. 09/757,459 filed Jan. 10, 2001, now U.S. Pat. No. 6,399,784 which is a divisional of 09/346,409 filed Jul. 1, 1999 now U.S. Pat. No. 6,245,914 which is a divisional of 09/166,722 filed Oct. 5, 1998 now U.S. Pat. No. 5,962,693 which claims benefit of provisional application No. 60/061,707 filed Oct. 6, 1997.
FIELD OF THE INVENTION
The present invention relates generally to processes for the conversion of cyano groups into amidines for the purpose of producing compounds which are useful as antagonists of the platelet glycoprotein IIb/IIIa fibrinogen receptor complex. These compounds may be used for the inhibition of platelet aggregation, as thrombolytics, and/or for the treatment of thromboembolic disorders.
BACKGROUND
There are several methods to convert cyano groups into amidine groups (S. Patai, Z. Rappoport, The Chemistry of Amidines and Imidates, 1991, John Wiley & Sons Ltd.). One of the most widely used methods for the preparation of amidines is the Pinner synthesis (R. Roger, D. G. Neilson, Chem. Rev. 1961, 61, 179-211), which proceeds in two steps through an imidate intermediate.
Abood et al, in U.S. Pat. No. 5,484,946, discusses formation of the amidine moiety from a nitrile group through an amidoxime intermediate. Jendrall et al, in Tetrahedron 1995, 51, 12047-12068, used a similar process to convert a cyano group into the amidinium functionality. Eloy and Leners, in Chem. Rev., 1962, 62, 155-183, review the preparation of amidoximes from nitriles. Chio and Shine, in J. Heterocyclic Chem., 1989, 26, 125-128, reported that these amidoximes can be transformed into 1,2,4-oxadiazole derivatives. Judkins et al, in Synthetic Commun. 1996, 26, 4351, describe formation of amidine moiety from nitrile through an amidoxime intermediate under acetylation or acylation conditions.
This literature however, does not disclose any regioselectivity between an amidoxime and an isoxazoline. In fact, Mueller et al, Angew. Chem., 1994, 106, 1305-1308, report that hydrogenation with 10% Pd/C will reduce a isoxazoline ring system. There is also no precedent for the transformation of a cyano group into an amidine functionality through a 1,2,4-oxadiazole moiety, and therefore the conversion of a 1,2,4-oxadiazole into amidine directly through catalytic hydrogenation is not taught.
Compounds of generic form (I) are antagonists of the platelet glycoprotein IIb/IIIa fibrinogen receptor complex which are currently being evaluated for the inhibition of platelet aggregation, as thrombolytics, and for the treatment of thromboembolic disorders. Consequently, large quantities of these compounds are needed to support drug development studies.
The preparation of compounds of generic form (I) have been disclosed in U.S. Pat. No. 5,446,056, PCT international publication WO 95/14683, PCT international publication WO 96/38426, pending and commonly owned U.S. application Ser. No. 08/700,906, and in J. Med. Chem., Xue et al, 1997, 40, 2064-2084. The preparation of (X) has been disclosed by Zhang et al in Tetrahedron Lett. 1996, 37, 4455-4458 and J. Org. Chem. 1997, 62, 2466-2470, which describe amidine formation from a nitrile using the Pinner reaction. Although this process has been able to produce compounds of formula (X) on a multikilogram scale, employing the Pinner reaction on a commercial scale poses several disadvantages. The Pinner approach involves the use of an excess of hydrogen chloride gas which is environmentally unfriendly, and removal of the inorganic salts generated during the Pinner process requires extensive purification protocols. It was therefore necessary to develop an efficient, safer process to produce compounds of formula (I) on large scale.
SUMMARY OF THE INVENTION
The present invention relates generally to processes for the conversion of cyano groups into amidines for the purpose of producing compounds, and intermediates therefore, which are useful as antagonists of the platelet glycoprotein IIb/IIIa fibrinogen receptor complex. These compounds may be used for the inhibition of platelet aggregation, as thrombolytics, and/or for the treatment of thromboembolic disorders.
There is provided by this invention a process for the preparation of compounds of formula (I), (III), (IV), (V) and (VI):
wherein:
R 1 is selected from H or NHR 1a ;
R 1a is selected from the group consisting of:
—C(═O)—O—R 1b ,
—C(═O)—R 1b ,
—C(═O)N(R 1b ) 2 ,
—C(═O)NHSO 2 R 1b ,
—C(═O)NHC(═O)R 1b ,
—C(═O)NHC(═O)OR 1b ,
—C(═O)NHSO 2 NHR 1b ,
—C(═S)—NH—R 1b ,
—NH—C(═O)—O—R 1b ,
—NH—C(═O)R 1b ,
—NH—C(═)—NH—R 1b ,
—SO 2 —O—R 1b ,
—SO 2 —R 1b ,
—SO 2 —N(R 1b ) 2 ,
—SO 2 —NHC(═O)OR 1b ,
—P(═S)(OR 1b ) 2 ,
—P(═O)(OR 1b ) 2 ,
—P(═S)(R 1b ) 2 ,
—P(═O)(R 1b ) 2 , and
R 1b is selected from the group consisting of:
C 1 -C 8 alkyl substituted with 0-2 R 1c ,
C 2 -C 8 alkenyl substituted with 0-2 R 1c ,
C 2 -C 8 alkynyl substituted with 0-2 R 1c ,
C 3 -C 8 cycloalkyl substituted with 0-2 R 1c ,
aryl substituted with 0-4 R 1c ,
aryl(C 1 -C 6 alkyl)-substituted with 0-4 R 1c ,
a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c , and
C 1 -C 6 alkyl substituted with a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4R 1c ;
R 1c is H, halogen, CF 3 , CN, NO 2 , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl;
R 2 is selected from H or C 1 -C 10 alkyl;
R 3 and R 4 are independently selected from the group consisting of H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 7 cycloalkyl, and aryl substituted with 0-2 R 3a ;
R 3a is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , NO 2 , and NR 3b R 3c ;
R 3b and R 3c are each independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, aryl, heteroarylcarbonyl, heteroarylsulfonyl, and heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 R 3d ;
R 3d is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ;
R 5 is selected from the group consisting of:
hydroxy, C 1 -C 10 alkyloxy, C 3 -C 11 cycloalkyloxy,
C 6 -C 10 aryloxy, C 7 -C 11 arylalkyloxy,
C 3 -C 10 alkylcarbonyloxyalkyloxy,
C 3 -C 10 alkoxycarbonyloxyalkyloxy,
C 3 -C 10 alkoxycarbonylalkyloxy,
C 5 -C 10 cycloalkylcarbonyloxyalkyloxy,
C 5 -C 10 cycloalkoxycarbonyloxyalkyloxy,
C 5 -C 10 cycloalkoxycarbonylalkyloxy,
C 8 -C 11 aryloxycarbonylalkyloxy,
C 8 -C 12 aryloxycarbonyloxyalkyloxy,
C 8 -C 12 arylcarbonyloxyalkyloxy,
C 5 -C 10 alkoxyalkylcarbonyloxyalkyloxy,
5-(C 5 -C 10 alkyl)-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy,
(5-aryl-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, and
(R 5a )HN-(C 1 -C 10 alkoxy)-;
R 5a is selected from the group consisting of H, C 1 -C 4 alkyl, aryl(C 1 -C 10 alkoxy)carbonyl, C 2 -C 10 alkoxycarbonyl, and C 3 -C 6 alkenyl;
R 6 is selected from the group consisting of H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , C 1 -C 8 alkyl, C 1 -C 8 perfluoroalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, C 7 -C 10 arylalkyloxy, aryloxy and aryl substituted with 0-5 R 6c ;
R 6c is selected from the group consisting of H, halo, CF 3 , CN, NO 2 , NR 6d R 6e , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl;
R 6d and R 6e are independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, aryl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, heteroarylcarbonyl, heteroarylsulfonyl, or heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 substituents selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ;
n is 0-4; and
a is a single or double bond, with the proviso that if a is a double bond, it is not simultaneously substituted with R 3 and R 4 ;
said process comprising one or more of:
(1): contacting a compound of formula (II) with a salt of hydroxyl amine in the presence of a suitable base to form a compound of formula (III);
(2): contacting a compound of formula (III) with an acylating agent of formula R 6 CO—O—COR 6 or R 6 COX, wherein X is fluorine, bromine, chlorine or imidazole, in a suitable solvent to form a compound of formula (IV) or a salt thereof; and
(3): contacting a compound of formula (IV) with hydrogen under a suitable pressure in the presence of a hydrogenation catalyst to form a compound of formula (I) or a pharmaceutically acceptable salt form thereof.
DETAILED DESCRIPTION OF THE INVENTION
In a first embodiment, the present invention provides a process for the preparation of compounds of formula (I):
or a pharmaceutically acceptable salt form thereof; wherein:
R 1 is selected from H or NHR 1a ;
R 1a is selected from the group consisting of:
—C(═O)—O—R 1b ,
—C(═O)—R 1b ,
—C(═O)N(R 1b ) 2 ,
—C(═O) NHSO 2 R 1b ,
—C(═O)NHC(═O)R 1b ,
—C(═O)NHC(═O)OR 1b ,
—C(═O)NHSO 2 NHR 1b ,
—C(═S)—NH—R 1b ,
—NH—C(═O)—O—R 1b ,
—NH—C(═O)R 1b ,
—NH—C(═)—NH—R 1b ,
—SO 2 —O—R 1b ,
—SO 2 —R 1b ,
—SO 2 —N(R 1b ) 2 ,
—SO 2 —NHC(═O) OR 1b ,
—P(═S)(OR 1b ) 2 ,
—P(═O)(OR 1b ) 2 ,
—P(═S)(R 1b ) 2 ,
—P(═O)(R 1b ) 2 , and
R 1b is selected from the group consisting of:
C 1 -C 8 alkyl substituted with 0-2 R 1c ,
C 2 -C 8 alkenyl substituted with 0-2 R 1c ,
C 2 -C 8 alkynyl substituted with 0-2 R 1c ,
C 3 -C 8 cycloalkyl substituted with 0-2 R 1c ,
aryl substituted with 0-4 R 1c ,
aryl(C 1 -C 6 alkyl)-substituted with 0-4 R 1c ,
a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c , and
C 1 -C 6 alkyl substituted with a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4R 1c ;
R 1c is H, halogen, CF 3 , CN, NO 2 , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl;
R 2 is selected from H or C 1 -C 10 alkyl;
R 3 and R 4 are independently selected from the group consisting of H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 7 cycloalkyl, and aryl substituted with 0-2 R 3a ;
R 3a is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , NO 2 , and NR 3b R 3c ;
R 3b and R 3c are each independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, aryl, heteroarylcarbonyl, heteroarylsulfonyl, and heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 R 3d ;
R 3d is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ;
R 5 is selected from the group consisting of:
hydroxy, C 1 -C 10 alkyloxy, C 3 -C 11 cycloalkyloxy,
C 6 -C 10 aryloxy, C 7 -C 11 arylalkyloxy,
C 3 -C 10 alkylcarbonyloxyalkyloxy,
C 3 -C 10 alkoxycarbonyloxyalkyloxy,
C 3 -C 10 alkoxycarbonylalkyloxy,
C 5 -C 10 cycloalkylcarbonyloxyalkyloxy,
C 5 -C 10 cycloalkoxycarbonyloxyalkyloxy,
C 5 -C 10 cycloalkoxycarbonylalkyloxy,
C 8 -C 11 aryloxycarbonylalkyloxy,
C 8 -C 12 aryloxycarbonyloxyalkyloxy,
C 8 -C 12 arylcarbonyloxyalkyloxy,
C 5 -C 10 alkoxyalkylcarbonyloxyalkyloxy,
5-(C 5 -C 10 alkyl)-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy,
(5-aryl-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, and (R 5a )HN-(C 1 -C 10 alkoxy)-;
R 5a is selected from the group consisting of H, C 1 -C 4 alkyl, aryl(C 1 -C 10 alkoxy)carbonyl, C 2 -C 10 alkoxycarbonyl, and C 3 -C 6 alkenyl;
n is 0-4;
a is a single or double bond, with the proviso that if a is a double bond, it is not simultaneously substituted with R 3 and R 4 ;
said process comprising:
contacting a compound of formula (IV):
wherein:
R 6 is selected from the group consisting of H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , C 1 -C 8 alkyl, C 1 -C 8 perfluoroalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, C 7 -C 10 arylalkyloxy, C 1 -C 6 alkyloxy, aryloxy and aryl substituted with 0-5 R 6c ;
R 6c is selected from the group consisting of H, halo, CF 3 , CN, NO 2 , NR 6d R 6e , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl;
R 6d and R 6e are independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, aryl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, heteroarylcarbonyl, heteroarylsulfonyl, or heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 substituents selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ;
with hydrogen under a suitable pressure in the presence of a hydrogenation catalyst to form a compound of formula (I) or a pharmaceutically acceptable salt form thereof.
In a preferred embodiment, the present invention provides a process for the preparation of a compound of formula (I), wherein:
said suitable pressure is up to 100 psi, and
said hydrogenation catalyst is selected from the group consisting of palladium on carbon, palladium hydroxide on carbon, palladium on calcium carbonate and platinum on carbon.
In a more preferred embodiment, the present invention provides a process for the preparation of a compound of formula (I), wherein:
R 1 is selected from H or NHR 1a ;
R 1a is —C(═O)—O—R 1b or —SO 2 —R 1b ;
R 1b is selected from the group consisting of:
C 1 -C 8 alkyl substituted with 0-1 R 1c ,
C 2 -C 8 alkenyl substituted with 0-1 R 1c ,
C 2 -C 8 alkynyl substituted with 0-1 R 1c ,
C 3 -C 8 cycloalkyl substituted with 0-1 R 1c ,
aryl substituted with 0-3 R 1c ,
aryl(C 1 -C 6 alkyl)-substituted with 0-3 R 1c ,
a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c , and
C 1 -C 6 alkyl substituted with a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c ;
R 1c is selected from the group consisting of H, halogen, CF 3 , CN, NO 2 , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy and C 2 -C 5 alkoxycarbonyl;
R 2 is H or C 1 -C 10 alkyl;
R 3 and R 4 are H or C 1 -C 6 alkyl;
R 5 is selected from the group consisting of hydroxy, C 1 -C 10 alkyloxy, C 3 -C 11 cycloalkyloxy, C 6 -C 10 aryloxy and C 7 -C 11 arylalkyloxy;
R 6 is selected from the group consisting of H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 7 cycloalkyl, C 1 -C 8 perfluoroalkyl, C 7 -C 10 arylalkyloxy, C 1 -C 6 alkyloxy, aryloxy, aryl substituted with 0-2 R 6c ;
R 6c is H, halogen, CF 3 , CN, NO 2 , NR 6d R 6e , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl; and
R 6d and R 6e are independently selected from H or C 1 -C 10 alkyl;
n is 1;
a is a single or double bond, with the proviso that if a is a double bond, it is not simultaneously substituted with R 3 and R 4 .
In an even more preferred embodiment, the present invention provides a process for the preparation of a compound of formula (I-a):
or a pharmaceutically acceptable salt form thereof, wherein:
R 1a is —C(═O)OCH 2 (CH 2 ) 2 CH 3 or 3,5-dimethyloxazol-4-yl-sulfonyl;
comprising contacting a compound of formula (IV-a):
wherein R 6 is H, methyl, ethyl, propyl, butyl, pentyl, hexyl C 7 -C 8 arylalkyloxy, C 1 -C 5 alkyloxy, aryloxy or aryl;
with hydrogen under a suitable pressure from about 20 to about 50 psi in the presence of palladium on carbon, in the range of about 1% to about 10% by weight of compound (IV), to form a compound of formula (I) or a pharmaceutically acceptable salt form thereof.
In a second embodiment, the present invention provides a process for the preparation of compounds of formula (IV) or a salt thereof comprising:
contacting a compound of formula (III):
with an acylating agent of formula R 6 CO—O—COR 6 or R 6 COX, wherein X is fluorine, bromine, chlorine or imidazole, in a suitable solvent to form a compound of formula (IV) or a salt thereof.
In a preferred second embodiment, the present invention provides a process for the preparation of a compound of formula (IV), wherein:
X is chlorine;
R 1 is NHR 1a ;
R 1a is —C(═O)OCH 2 (CH 2 ) 2 CH 3 or 3,5-dimethyloxazol-4-yl-sulfonyl;
R 2 is H;
R 3 and R 4 are H;
R 5 is methyl;
R 6 is CH 3 ;
n is 1;
a is a single bond; and
said suitable solvent is acetic acid.
In a third embodiment, the present invention provides a process for the preparation of compounds of formula (III), comprising:
contacting a compound of formula (II):
with a salt of hydroxyl amine in the presence of a suitable base to form a compound of formula (III).
In a preferred third embodiment, the present invention provides a process for the preparation of a compound of formula (III), wherein said salts of hydroxyl amine are hydroxylamine hydrochloride and hydroxylamine sulfate.
In a more preferred third embodiment, the present invention provides a process for the preparation of a compound of formula (III), wherein:
X is chlorine;
R 1 is NHR 1a ;
R 1a is —C(═O)—O—CH 2 (CH 2 ) 2 CH 3 or 3,5-dimethyloxazol-4yl-sulfonyl;
R 2 is H;
R 3 and R 4 are H;
R 5 is methyl;
R 6 is selected from the group consisting of: H, C 1 -C 6 alkyl, C 7 -C 8 arylalkyloxy, C 1 -C 5 alkyloxy,
aryloxy and aryl;
n is 1;
a is a single bond;
said suitable salt of hydroxylamine is hydroxylamine hydrochloride; and
the suitable base is selected from the group consisting of:
triethylamine, diisopropylethylamine and 4-methyl morpholine.
In a fourth embodiment, the present invention provides a process for the preparation of compounds of formula (I):
or a pharmaceutically acceptable salt form thereof,
said process comprising:
(a) heating a compound of the formula (IV):
wherein:
R 1 is selected from H or NHR 1a ;
R 1a is selected from the group consisting of:
—C(═O)—O—R 1b ,
—C(═O)—R 1b ,
—C(═O)N(R 1b ) 2 ,
—C(═O)NHSO 2 R 1b ,
—C(═O)NHC(═O)R 1b ,
—C(═O)NHC(═O)OR 1b ,
—C(═O)NHSO 2 NHR 1b ,
—C(═S)—NH—R 1b ,
—NH—C(═O)—O—R 1b ,
—NH—C(═O)R 1b ,
—NH—C(═)—NH—R 1b ,
—SO 2 —O—R 1b ,
—SO 2 —R 1b ,
—SO 2 —N(R 1b ) 2 ,
—SO 2 —NHC(═O)OR 1b ,
—P(═S)(OR 1b ) 2 ,
—P(═O)(OR 1b ) 2 ,
—P(═S)(R 1b ) 2 ,
—P(═O)(R 1b ) 2 , and
R 1b is selected from the group consisting of:
C 1 -C 8 alkyl substituted with 0-2 R 1c ,
C 2 -C 8 alkenyl substituted with 0-2 R 1c ,
C 2 -C 8 alkynyl substituted with 0-2 R 1c ,
C 3 -C 8 cycloalkyl substituted with 0-2 R 1c ,
aryl substituted with 0-4 R 1c ,
aryl(C 1 -C 6 alkyl)-substituted with 0-4 R 1c ,
a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c , and
C 1 -C 6 alkyl substituted with a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4R 1c ;
R 1c is H, halogen, CF 3 , CN, NO 2 , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl;
R 2 is selected from H or C 1 -C 10 alkyl;
R 3 and R 4 are independently selected from the group consisting of H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 7 cycloalkyl, and aryl substituted with 0-2 R 3a ;
R 3a is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , NO 2 , and NR 3b R 3c ;
R 3b and R 3c are each independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, aryl, heteroarylcarbonyl, heteroarylsulfonyl, and heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 R 3d ;
R 3d is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ;
R 5 is selected from the group consisting of:
hydroxy, C 1 -C 10 alkyloxy, C 3 -C 11 cycloalkyloxy,
C 6 -C 10 aryloxy, C 7 -C 11 arylalkyloxy,
C 3 -C 10 alkylcarbonyloxyalkyloxy,
C 3 -C 10 alkoxycarbonyloxyalkyloxy,
C 3 -C 10 alkoxycarbonylalkyloxy,
C 5 -C 10 cycloalkylcarbonyloxyalkyloxy,
C 5 -C 10 cycloalkoxycarbonyloxyalkyloxy,
C 5 -C 10 cycloalkoxycarbonylalkyloxy,
C 8 -C 11 aryloxycarbonylalkyloxy,
C 8 -C 12 aryloxycarbonyloxyalkyloxy,
C 8 -C 12 arylcarbonyloxyalkyloxy,
C 5 -C 10 alkoxyalkylcarbonyloxyalkyloxy,
5-(C 5 -C 10 alkyl)-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy,
(5-aryl-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, and (R 5a )HN-(C 1 -C 10 alkoxy)-;
R 5a is selected from the group consisting of H, C 1 -C 4 alkyl, aryl(C 1 -C 10 alkoxy)carbonyl, C 2 -C 10 alkoxycarbonyl, and C 3 -C 6 alkenyl;
R 6 is selected from the group consisting of H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , C 1 -C 8 alkyl, C 1 -C 8 perfluoroalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, C 7 -C 10 arylalkyloxy, aryloxy and aryl substituted with 0-5 R 6c ;
R 6c is selected from the group consisting of H, halo, CF 3 , CN, NO 2 , NR 6d R 6e , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl;
R 6d and R 6e are independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, aryl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, heteroarylcarbonyl, heteroarylsulfonyl, or heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 substituents selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ;
n is 0-4;
a is a single or double bond, with the proviso that if a is a double bond, it is not simultaneously substituted with R 3 and R 4 ;
for a time sufficient, and to a temperature sufficient to form a compound of formula (V):
and (b) contacting said compound of formula (V) with hydrogen under a suitable pressure in the presence of a hydrogenation catalyst to form a compound of formula (I) or a salt thereof.
In a preferred fourth embodiment, the present invention provides a process for the preparation of a compound of formula (I), wherein:
said suitable pressure is up to 100 psi;
said hydrogenation catalyst is selected from the group consisting of palladium on carbon, palladium hydroxide on carbon, palladium on calcium carbonate and platinum on carbon;
said sufficient temperature is from about 30° C. to about 120° C.;
said sufficient time is from about 10 minutes to about 24 hours;
wherein an amount of catalyst loaded on carbon is from about 1% to about 10% by weight; and
wherein an amount of a hydrogenation catalyst is from about 1% to about 30% by weight of compound (IV).
In a more preferred fourth embodiment, the present invention provides a process for the preparation of a compound of formula (I), wherein:
R 1 is NHR 1a ;
R 1a is —C(═O)—O—CH 2 (CH 2 ) 2 CH 3 or 3,5-dimethyloxazol-4yl-sulfonyl;
R 2 is H;
R 3 and R 4 are H;
R 5 is methyl;
R 6 is selected from the group consisting of:
H, methyl, ethyl, propyl, butyl, pentyl, hexyl, C 7 -C 8 arylalkyloxy, aryloxy, C 1 -C 5 alkoxy and aryl;
n is 1, and
a is a single bond;
said suitable pressure is from about 20 to about 50 psi;
said sufficient temperature is from about 50° C. to about 120° C.;
said sufficient time is from about 10 minutes to about 3 hours;
said hydrogenation catalyst is palladium on carbon;
wherein an amount of catalyst loaded on carbon is from about 3% to about 5% by weight; and
wherein an amount of palladium on carbon is from about 3% to about 7% by weight of compound (IV).
In a fifth embodiment, the present invention provides a process for the preparation of compounds of the formula (I):
or a pharmaceutically acceptable salt form thereof; wherein:
R 1 is selected from H or NHR 1a ;
R 1a is selected from the group consisting of:
—C(═O)—O—R 1b ,
—C(═O)—R 1b ,
—C(═O)N(R 1b ) 2 ,
—C(═O)NHSO 2 R 1b ,
—C(═O)NHC(═O)R 1b ,
—C(═O)NHC(═O)OR 1b ,
—C(═O)NHSO 2 NHR 1b ,
—C(═S)—NH—R 1b ,
—NH—C(═O)—O—R 1b ,
—NH—C(═O)R 1b ,
—NH—C(═)—NH—R 1b ,
—SO 2 —O—R 1b ,
—SO 2 R 1b ,
—SO 2 —N(R 1b ) 2 ,
—SO 2 —NHC(═O)OR 1b ,
—P(═S)(OR 1b ) 2 ,
—P(═O)(OR 1b ) 2 ,
—P(═S)(R 1b ) 2 ,
—P(═O)(R 1b ) 2 , and
R 1b is selected from the group consisting of:
C 1 -C 8 alkyl substituted with 0-2 R 1c ,
C 2 -C 8 alkenyl substituted with 0-2 R 1c ,
C 2 -C 8 alkynyl substituted with 0-2 R 1c ,
C 3 -C 8 cycloalkyl substituted with 0-2 R 1c ,
aryl substituted with 0-4 R 1c ,
aryl(C 1 -C 6 alkyl)-substituted with 0-4 R 1c ,
a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4 R 1c , and
C 1 -C 6 alkyl substituted-with a 5-10 membered heterocyclic ring system having 1-3 heteroatoms selected independently from O, S, and N, said heterocyclic ring being substituted with 0-4R 1c ;
R 1c is H, halogen, CF 3 , CN, NO 2 , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl;
R 2 is selected from H or C 1 -C 10 alkyl;
R 3 and R 4 are independently selected from the group consisting of H, C 1 -C 6 alkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 7 cycloalkyl, and aryl substituted with 0-2 R 3a ;
R 3a is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , NO 2 , and NR 3b R 3c ;
R 3b and R 3c are each independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, aryl, heteroarylcarbonyl, heteroarylsulfonyl, and heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 R 3d ;
R 3d is selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ;
R 5 is selected from the group consisting of:
hydroxy, C 1 -C 10 alkyloxy, C 3 -C 11 cycloalkyloxy,
C 6 -C 10 aryloxy, C 7 -C 11 arylalkyloxy,
C 3 -C 10 alkylcarbonyloxyalkyloxy,
C 3 -C 10 alkoxycarbonyloxyalkyloxy,
C 3 -C 10 alkoxycarbonylalkyloxy,
C 5 -C 10 cycloalkylcarbonyloxyalkyloxy,
C 5 -C 10 cycloalkoxycarbonyloxyalkyloxy,
C 5 -C 10 cycloalkoxycarbonylalkyloxy,
C 8 -C 11 aryloxycarbonylalkyloxy,
C 8 -C 12 aryloxycarbonyloxyalkyloxy,
C 8 -C 12 arylcarbonyloxyalkyloxy,
C 5 -C 10 alkoxyalkylcarbonyloxyalkyloxy,
5-(C 5 -C 10 alkyl)-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy,
(5-aryl-1,3-dioxa-cyclopenten-2-one-yl)-methyloxy, and (R 5a )HN-(C 1 -C 10 alkoxy)-;
R 5a is selected from the group consisting of H, C 1 -C 4 alkyl, aryl(C 1 -C 10 alkoxy)carbonyl, C 2 -C 10 alkoxycarbonyl, and C 3 -C 6 alkenyl;
n is 0-4;
a is a single or double bond, with the proviso that if a is a double bond, it is not simultaneously substituted with R 3 and R 4 ;
said process comprising:
contacting a compound of formula (VI):
wherein:
Z is selected from R 6 SO 2 - or (R 7 ) 3 Si-;
R 6 is selected from the group consisting of H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , C 1 -C 8 alkyl, C 1 -C 8 perfluoroalkyl, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, C 7 -C 10 arylalkyloxy, aryloxy and aryl substituted with 0-5 R 6c ;
R 6c is selected from the group consisting of H, halo, CF 3 , CN, NO 2 , NR 6d R 6e , C 1 -C 8 alkyl, C 2 -C 6 alkenyl, C 3 -C 11 cycloalkyl, C 4 -C 11 cycloalkylalkyl, aryl, aryl(C 1 -C 6 alkyl)-, C 1 -C 6 alkoxy, and C 2 -C 5 alkoxycarbonyl;
R 6d and R 6e are independently selected from the group consisting of H, C 1 -C 10 alkyl, C 2 -C 10 alkoxycarbonyl, C 2 -C 10 alkylcarbonyl, C 1 -C 10 alkylsulfonyl, aryl, aryl(C 1 -C 10 alkyl)sulfonyl, arylsulfonyl, heteroaryl(C 1 -C 4 alkyl)sulfonyl, heteroarylcarbonyl, heteroarylsulfonyl, or heteroarylalkylcarbonyl, wherein said aryl and heteroaryl are optionally substituted with 0-3 substituents selected from the group consisting of C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, CF 3 , and NO 2 ;
R 7 is selected independently from C 1 -C 10 alkyl or aryl substituted 0-3 R 7a ; and
R 7a is C 1 -C 10 alkyl;
with hydrogen under a suitable pressure in the presence of a hydrogenation catalyst to form a compound of formula (I) or a pharmaceutically acceptable salt form thereof.
In a sixth embodiment, the present invention provides a process for the preparation of compounds of formula (VI):
comprising: contacting a compound of formula (III):
with an agent of formula Z-X, wherein:
X is fluorine, bromine or chlorine;
Z is R 6 SO 2 - or (R 7 ) 3 Si-;
R 7 is selected independently from C 1 -C 10 alkyl or aryl substituted 0-3 R 7a ; and
R 7 a is C 1 -C 10 alkyl;
in the presence of a suitable acid scavenger in a suitable solvent to form a compound of formula (IV) or a salt thereof.
In a seventh embodiment, the present invention provides a compound of formula (III-i):
and salt forms thereof.
In a eighth embodiment, the present invention provides a compound of formula (IV-i):
and salt forms thereof.
In a ninth embodiment, the present invention provides a compound of formula (V-i):
and salt forms thereof.
DEFINITIONS
The reactions of the synthetic methods claimed herein are carried out in suitable solvents which may be readily selected by one of skill in the art of organic synthesis, said suitable solvents generally being any solvent which is substantially nonreactive with the starting materials (reactants), the intermediates, or products at the temperatures at which the reactions are carried out, i.e., temperatures which may range from the solvent's freezing temperature to the solvent's boiling temperature. A given reaction may be carried out in one solvent or a mixture of more than one solvent. Depending on the particular reaction step, suitable solvents for a particular reaction step may be selected.
Suitable halogenated solvents include: carbon tetrachloride, bromodichloromethane, dibromochloromethane, bromoform, chloroform, bromochloromethane, dibromomethane, butyl chloride, dichloromethane, tetrachloroethylene, trichloroethylene, 1,1,1-trichloroethane, 1,1,2-trichloroethane, 1,1-dichloroethane, 2-chloropropane, hexafluorobenzene, 1,2,4-trichlorobenzene, o-dichlorobenzene, chlorobenzene, fluorobenzene, fluorotrichloromethane, chlorotrifluoromethane, bromotrifluoromethane, carbon tetrafluoride, dichlorofluoromethane, chlorodifluoromethane, trifluoromethane, 1,2-dichlorotetrafluorethane and hexafluoroethane.
Suitable ether solvents include: dimethoxymethane, tetrahydrofuran, 1,3-dioxane, 1,4-dioxane, furan, diethyl ether, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, diethylene glycol dimethyl ether, diethylene glycol diethyl ether, triethylene glycol dimethyl ether, anisole, or t-butyl methyl ether.
Suitable protic solvents may include, by way of example and without limitation, water, methanol, ethanol, 2-nitroethanol, 2-fluoroethanol, 2,2,2-trifluoroethanol, ethylene glycol, 1-propanol, 2-propanol, 2-methoxyethanol, 1-butanol, 2-butanol, i-butyl alcohol, t-butyl alcohol, 2-ethoxyethanol, diethylene glycol, 1-, 2-, or 3-pentanol, neo-pentyl alcohol, t-pentyl alcohol, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, cyclohexanol, benzyl alcohol, phenol, or glycerol.
Suitable aprotic solvents may include, by way of example and without limitation, tetrahydrofuran (THF), dimethylformamide (DMF), dimethylacetamide (DMAC), 1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)-pyrimidinone (DMPU), 1,3-dimethyl-2-imidazolidinone (DMI), N-methylpyrrolidinone (NMP), formamide, N-methylacetamide, N-methylformamide, acetonitrile, dimethyl sulfoxide, propionitrile, ethyl formate, methyl acetate, hexachloroacetone, acetone, ethyl methyl ketone, ethyl acetate, sulfolane, N,N-dimethylpropionamide, tetramethylurea, nitromethane, nitrobenzene, or hexamethylphosphoramide.
Suitable hydrocarbon solvents include: benzene, cyclohexane, pentane, hexane, toluene, cycloheptane, methylcyclohexane, heptane, ethylbenzene, m-, o-, or p-xylene, octane, indane, nonane, or naphthalene.
Suitable carboxylic acid solvents include acetic acid, trifluoroacetic acid, ethanoic acid, propionic acid, propiolic acid, butyric acid, 2-butynoic acid, vinyl acetic acid, pentanoic acid, hexanoic acid, heptanoic acid, octanoic acid, nonanoic acid and decanoic acid.
Suitable pressures range from atmospheric to any pressure obtainable in a laboratory or industrial plant.
Suitable hydrogenation catalysts are those which facilitate the delivery of hydrogen to the N—O bond of an N-acylated hydroxylamine. Such hydrogenation catalysts by way of example and without limitation are palladium on carbon, palladium hydroxide on carbon, palladium on calcium carbonate poisoned with lead and platinum on carbon.
As used herein, suitable acid scavengers include those compounds capable of accepting a proton from a hydroxyamidine during either an acylation, sulfonation or silation reaction without reacting with the agent reacting with the oxygen of the hydroxyamidine. Examples include, but are not limited to tertiary bases such as N,N-diisopropylethylamine, 2,3-, 2,4-, 2,5-, 2,6-, 3,4-, 3,5-lutidine, triethylamine, 2-, 3-, or 4-picoline, pyrrole, pyrrolidine, N-methyl morpholine, pyridine and pyrimidine.
As used herein, suitable bases include those soluble in the reaction solvent and capable of free-basing hydroxylamine. Examples include, but are not limited to: lithium hydroxide, sodium hydroxide, potassium hydroxide, lithium carbonate, sodium carbonate, potassium carbonate, imidazole, ethylene diamine, N,N-diisopropylethylamine, 2,3-, 2,4-, 2,5-, 2,6-, 3,4-, 3,5-lutidine, triethylamine, 2-, 3-, or 4-picoline, pyrrole, pyrrolidine, N-methyl morpholine, pyridine, pyrimidine or piperidine.
As used herein, acylating agent refers to an acid halide or anhydride, which, when reacted with a hydroxyamidine results in O-acylation of the hydroxyl amidine. Such acylating agents by way of example and without limitation are of the general structure R 6 COX or R 6 CO—O—COR 6 , as defined above in the specification. By way of further example, and without limitation, where X is fluorine, chlorine, bromine or imidazole, R 6 is H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , methyl, ethyl, propyl, butyl, ethenyl, allyl, ethynyl, cyclopropyl, phenyl, benzyl, C 7 -C 10 arylalkyloxy, C 1 -C 10 alkyloxy or aryloxy.
As used herein, agent refers to a compound of the formula Z-X, which, when reacted with a hydroxyamidine results in placement of the Z group on the oxygen of the hydroxyamidine. By way of further example, and without limitation, where X is fluorine, chlorine, bromine or imidazole, Z is either R 6 SO 2 — or (R 7 ) 3 Si—, R 6 is H, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , methyl, ethyl, propyl, butyl, ethenyl, allyl, ethynyl, cyclopropyl, phenyl, benzyl, C 7 -C 10 arylalkyloxy, or aryloxy, and R 7 is independently selected from C 1 -C 10 alkyl or aryl substituted with 0-3 R 7a , and R 7a is C 1 -C 10 alkyl.
The compounds described herein may have asymmetric centers. Unless otherwise indicated, all chiral, diastereomeric and racemic forms are included in the present invention. Many geometric isomers of olefins, C═N double bonds, and the like can also be present in the compounds described herein, and all such stable isomers are contemplated in the present invention. It will be appreciated that compounds of the present invention that contain asymmetrically substituted carbon atoms may be isolated in optically active or racemic forms. Methods on how to prepare optically active forms from optically active starting materials are known in the art, such as by resolution of racemic forms or by synthesis. All chiral, diastereomeric, racemic forms and all geometric isomeric forms of a structure are intended.
When any variable (for example but not limited to R 1b , R 1c , R 3a , R 3b , R 3c , R 6c , etc.) occurs more than one time in any constituent or in any formula, its definition on each occurrence is independent of its definition at every other occurrence. Thus, for example, if a group is shown to be substituted with 0-2 R 3a , then said group may optionally be substituted with up to two R 3a and R 3a at each occurrence is selected independently from the defined list of possible R 3a .
Combinations of substituents and/or variables are permissible only if such combinations result in stable compounds. By stable compound or stable structure it is meant herein a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture, and formulation into an efficacious therapeutic agent.
The term “substituted”, as used herein, means that any one or more hydrogen on the designated atom is replaced with a selection from the indicated group, provided that the designated atom's normal valency is not exceeded, and that the substitution results in a stable compound.
As used herein, “alkyl” is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms; for example, C 1 -C 4 alkyl includes methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, s-butyl, and t-butyl; for example C 1 -C 10 alkyl includes C 1 -C 4 alkyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomer thereof.
As used herein, any carbon range such as “C x -C y ” is intended to mean a minimum of “x” carbons and a maximum of “y” carbons representing the total number of carbons in the substituent to which it refers. For example, “C 3 -C 10 alkylcarbonyloxyalkyloxy” could contain one carbon for “alkyl”, one carbon for “carbonyloxy” and one carbon for “alkyloxy” giving a total of three carbons, or a larger number of carbons for each alkyl group not to exceed a total of ten carbons.
“Alkenyl” is intended to include hydrocarbon chains of either a straight or branched configuration and one or more unsaturated carbon-carbon bonds which may occur in any stable point along the chain, such as ethenyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, 3-butenyl, 1,3-butadienyl and the like. “Alkynyl” is intended to include hydrocarbon chains of either a straight or branched configuration and one or more triple carbon-carbon bonds which may occur in any stable point along the chain, such as ethynyl, propynyl, butynyl and the like. “Aryl” is intended to mean phenyl or naphthyl. The term “arylalkyl” represents an aryl group attached through an alkyl bridge; for example aryl(C 1 -C 2 )alkyl is intended to mean benzyl, phenylethyl and the like.
As used herein, “cycloalkyl” is intended to include saturated ring groups, including mono-, bi-, or poly-cyclic ring systems, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, and adamantyl.
As used herein, “alkyloxy” or “alkoxy” represents an alkyl group of indicated number of carbon atoms attached through an oxygen bridge, for example methoxy, ethoxy, propoxy, i-propoxy, butoxy, i-butoxy, s-butoxy and t-butoxy. The term “aryloxy” is intended to mean phenyl or naphthyl attached through an oxygen bridge;
As used herein, “carbonyl” means a carbon double bonded to oxygen and additionally substituted with two groups through single bonds; “carbonyloxy” means a carbon double bonded to oxygen and additionally bonded through a single bonds to two groups, one of which is an oxygen. As used herein, “sulfonyl” is intended to mean a sulfur bonded through double bonds to two oxygens and bonded to two additional groups through single bonds. As used herein, “hydroxy” means a group consisting of an oxygen and a hydrogen bonded to another group through the oxygen.
“Halo” or “halogen” as used herein refers to fluoro, chloro, bromo and iodo.
As used herein, the term “heterocycle” or “heterocyclic” is intended to mean a stable 5- to 10-membered monocyclic or bicyclic or 5- to 10-membered bicyclic heterocyclic ring which may be saturated, partially unsaturated, or aromatic, and which consists of carbon atoms and from 1 to 3 heteroatoms independently selected from the group consisting of N, O and S and wherein the nitrogen and sulfur heteroatoms may optionally be oxidized, and the nitrogen may optionally be quaternized, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached to its pendant group at any heteroatom or carbon atom which results in a stable structure. The heterocyclic rings described herein may be substituted on carbon or on a nitrogen atom if the resulting compound is stable. Examples of such heterocycles include, but are not limited to, pyridyl (pyridinyl), pyrimidinyl, furanyl (furyl), thiazolyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, tetrazolyl, benzofuranyl, benzothiophenyl, indolyl, indolenyl, isoxazolinyl, quinolinyl, isoquinolinyl, benzimidazolyl, piperidinyl, 4-piperidonyl, pyrrolidinyl, 2-pyrrolidonyl, pyrrolinyl, tetrahydrofuranyl, tetrahydroquinolinyl, tetrahydroisoquinolinyl, decahydroquinolinyl or octahydroisoquinolinyl, azocinyl, triazinyl, 6H-1,2,5-thiadiazinyl, 2H, 6H-1,5,2-dithiazinyl, thianthrenyl, pyranyl, isobenzofuranyl, chromenyl, xanthenyl, phenoxathiinyl, 2H-pyrrolyl, pyrrolyl, imidazolyl, pyrazolyl, isothiazolyl, isoxazolyl, oxazolyl, pyrazinyl, pyridazinyl, indolizinyl, isoindolyl, 3H-indolyl, 1H-indazolyl, purinyl, 4H-quinolizinyl, phthalazinyl, naphthyridinyl, quinoxalinyl, quinazolinyl, cinnolinyl, pteridinyl, 4aH-carbazole, carbazole, β-carbolinyl, phenanthridinyl, acridinyl, perimidinyl, phenanthrolinyl, phenazinyl, phenarsazinyl, phenothiazinyl, furazanyl, phenoxazinyl, isochromanyl, chromanyl, imidazolidinyl, imidazolinyl, pyrazolidinyl, pyrazolinyl, piperazinyl, indolinyl, isoindolinyl, quinuclidinyl, morpholinyl or oxazolidinyl. Also included are fused ring and spiro compounds containing, for example, the above heterocycles.
As used herein, the term “heteroaryl” refers to aromatic heterocyclic groups. Such heteroaryl groups are preferably 5-6 membered monocylic groups or 8-10 membered fused bicyclic groups. Examples of such heteroaryl groups include, but are not limited to pyridyl (pyridinyl), pyrimidinyl, furanyl (furyl), thiazolyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, indolyl, isoxazolyl, oxazolyl, pyrazinyl, pyridazinyl, benzofuranyl, benzothienyl, benzimidazolyl, quinolinyl, or isoquinolinyl.
As used herein, “pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the intermediates or final compound are modified by making acid or base salts of the intermediates or final compounds. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids; and the like.
The pharmaceutically acceptable salts of the intermediates or final compounds include the conventional non-toxic salts or the quaternary ammonium salts from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include those derived from inorganic acids such as hydrochloric, hydrobromic, sulfuric, sulfamic, phosphoric, nitric and the like; and the salts prepared from organic acids such as acetic, propionic, succinic, glycolic, stearic, lactic, malic, tartaric, citric, ascorbic, pamoic, maleic, hydroxymaleic, phenylacetic, glutamic, benzoic, salicylic, sulfanilic, 2-acetoxybenzoic, fumaric, toluenesulfonic, methanesulfonic, ethane disulfonic, oxalic, isethionic, and the like.
The pharmaceutically acceptable salts are generally prepared by reacting the free base or acid with stoichiometric amounts or with an excess of the desired salt-forming inorganic or organic acid or base in a suitable solvent or various combinations of solvents.
The pharmaceutically acceptable salts of the acids of the intermediates or final compounds are prepared by combination with an appropriate amount of a base, such as an alkali or alkaline earth metal hydroxide e.g. sodium, potassium, lithium, calcium, or magnesium, or an organic base such as an amine, e.g., dibenzylethylenediamine, trimethylamine, piperidine, pyrrolidine, benzylamine and the like, or a quaternary ammonium hydroxide such as tetramethylammoinum hydroxide and the like.
As discussed above, pharmaceutically acceptable salts of the compounds of the invention can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid, respectively, in water or in an organic solvent, or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol, or acetonitrile are preferred. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton, Pa., 1985, p. 1418, the disclosure of which is hereby incorporated by reference. The present invention is contemplated to be practiced on at least a multigram scale, kilogram scale, multikilogram scale, or industrial scale. Multigram scale, as used herein, is preferably the scale wherein at least one starting material is present in 10 grams or more, more preferably at least 50 grams or more, even more preferably at least 100 grams or more. Multikilogram scale, as used herein, is intended to mean the scale wherein more than one kilogram of at least one starting material is used. Industrial scale as used herein is intended to mean a scale which is other than a laboratory scale and which is sufficient to supply product sufficient for either clinical tests or distribution to consumers.
The methods of the present invention, by way of example and without limitation, may be further understood by reference to Scheme 1. Scheme 1 details the general synthetic method for synthesis of compounds of formula (I). Compound (II) can be prepared by methods described in J. Org. Chem. 1997, 62, 2466-2470, and Tetrahedron Lett. 1996, 37, 4455-4458. It is understood to one skilled in the art that the anhydride or acid chlorides used in the acylation step can be prepared by conversion of carboxylic acid derivatives as described in Advanced Organic Chemistry, March, 4th edition, John Wiley and Sons, Inc., 1992, p. 401-402 and p. 437-438.
In reaction 1, a compound of formula (II) is dissolved in about 10 liters of suitable solvent per kilogram of compound (II). A suitable salt of hydroxyl amine is added. While a wide range of solvents such as halogenated, protic, aprotic, hydrocarbon, or ethers can be used, protic solvents such as methanol, ethanol and isopropanol are preferred, of which methanol is most preferred. Suitable salts of hydroxyl amine include phosphate, sulfate, nitrate and hydrochloride salts; a most preferred salt is hydroxyl amine hydrochloride. The hydroxyl amine salt is free-based with about 1.0 to about 2.0 equivalents of an appropriate base. Preferrable bases are tertiary amines; most preferred is triethyl amine. The reaction mixture can then be heated for a time sufficent to form a compound of form (III). By way of general guidance, compound (II) may be contacted with free-based hydroxyl amine at about 40° C. to about 65° C. for about 1 to about 5 hours to produce compound (III). Preferred temperatures are from about 55° C. to about 65° C. Preferred reaction times are from about 2 to about 4 hours. The product precipitates as a white solid during the course of the reaction. The solids can then be filtered and the cake washed with a solvent, the choice of which is readily understood by one skilled in the art. The product is dried to afford pure compound (III).
In reaction 2, a vessel is charged with compound (III). The solids are dissolved in a suitable solvent followed by the slow charging of the vessel with a second solution made by dissolving a suitable acylating agent in the solvent being used for the reaction. Preferably, the addition of the acylating agent solution should be done over a period of about 15 minutes to about one hour. While a wide range of reaction solvents such as halogenated, aprotic, hydrocarbon, ether, or organic acids are possible, preferred solvents are acetic acid, trifluoroacetic acid, pyridine, chloroform, dichloromethane, dichlorobenzene, acetonitrile, and tetrahydrofuran. Most preferred are carboxylic acids which are structural derivatives of the acylating agent being used. By way of general example, acetic acid would preferably be used as the solvent when acetic anhydride is the acylating agent, whereas triflouroacetic acid would be preferably used when trifluoroacetic anhydride is the acylating agent. Certain solvents such as aprotic, ether, halogenated and hydrocarbon solvents may require the addition of an acid scavenger. Preferred acid scavengers include tertiary bases such as triethyl amine, diisopropyl ethylamine, N-methyl morpholine and pyridine. Most preferred is triethyl amine. Solvents capable of reacting with the acylating agent, such as alcohols, water and the like are not preferred as is readily understood by one skilled in the art. Preferred acylating agents are anhydrides. Most preferred is acetic anhydride. Further, the acylating agent (and preferable solvent) can be strategically chosen to form the desired salt of the reaction product. By way of general example, acetic anhydride would be selected as the acylating agent if the acetate salt of the product is desired. The choice of acylating agent and solvent in this regard is readily understood by one skilled in the art.
After the addition of the acylating agent, the reaction progression can be monitored by HPLC analysis performed on an aliquot of the reaction solution. The acylation reaction is considered finished when compound (III) is completely consumed. Typical reaction times are in the range of about 5 minutes to about 24 hours. Preferred reaction times are about 5 minutes to about 3 hours. The product can be isolated by the removal of the solvent via distillation and precipitation of the product through the addition of a suitable aprotic solvent. Preferred aprotic solvents are ethers. The choice of precipition solvent and the methods of isolation are readily understood by one skilled in the art. Preferably, the product is carried forward without isolation.
Reaction 3, comprises the hydrogenation of the O-substituted hydroxyamidine. This reaction can be carried out without isolation of compound (IV), by the addition of a slurry of a suitable hydrogenation catalyst in the solvent used in the preceding reaction. If compound (IV) is isolated, the hydrogenation can be carried out in protic, aprotic, hydrocarbon, ether, or organic acid solvents. The preferred solvents are methanol, ethanol, 2-propanol, dimethylformamide, ethyl acetate, anisole, acetic acid and trifluoroacetic acid. Most preferred is a mixture of methanol and acetic acid. While numerous hydrogenation catalysts are possible, palladium on carbon is most preferred. The amount of catalyst loaded on the carbon ranges from about 0.5% to about 30%. The preferred amount of catalyst on carbon is about 1% to about 10%. Most preferred is about 3% to 5%. The total weight of the catalyst and carbon per gram of starting material is preferably about 1% to about 10%. Most preferred is about 3% to 7%. The total weight of catalyst and carbon is based on the weight of the O-alkylated hydroxyamidine. The reaction solution is then subjected to a hydrogen atmosphere under a suitable pressure. Preferred pressures range from about 1 psi to 100 psi. Most preferred is 20 psi to 50 psi. The reaction time of the hydrogenation is dependent on cumulative factors, including the amount of catalyst present, the reaction temperature and the hydrogen pressure. By way of general example, an acetylation reaction containing 10.0 kilograms of compound (III) required the use of 0.5 kilograms of 3% palladium on carbon, under 5 psi of hydrogen at room temperature to reach completion in about 5 hours. Varying any one of these conditions will effect reaction time which is readily understood by one skilled in the art.
Reaction completion can be monitored by HPLC analysis performed on aliquots of the reaction mixture. The reaction is considered complete when compound (IV) has been completely consumed. After the reaction is judged complete, the catalyst is filtered off and washed with reaction solvent. The filtrate is concentrated, and the product precipitated by the addition of a suitable aprotic solvent. The most preferred solvent for precipitation is acetone. The choice of precipition solvent and the methods of isolation are readily understood by one skilled in the art. The product is then filtered and dried to give pure compound (I).
In reaction 4, the resultant reaction solution of Step 2 is heated to form compound (V). The heating range is from about 30° C. to the reflux temperature of the solvent. Preferred temperatures are from about 30° C. to about 120° C. Preferred solvents for the cyclization are acetic acid, trifluoroacetic acid, pyridine, chloroform, dichloromethane, dichlorobenzene, acetonitrile, and tetrahydrofuran. The most preferred solvent for the cyclization is acetic acid. The preferred time of reflux is solvent dependent due to the limitations of boiling points. By way of general example, the use of acetic acid as the solvent required a heating time of about 3 hours. The product can be isolated by the removal of the solvent via distillation followed by the drying of the solids. Preferably, compound (V) is carried forward without isolation.
In reaction 4, compound (V) is hydrogenated under the identical conditions of Reaction 3 to give compound (I). The present invention may be further exemplified without limitation by reference to Scheme 2.
The following examples are meant to be illustrative of the present invention. These examples are presented to exemplify the invention and are not to be construed as limiting the inventors scope.
EXAMPLE 1
(R)-Methyl-3-[[[3[4[amino(hydroxyimino)methyl]phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N(butoxy-carbonyl)-L-alanine: Compound (III-i)
A 100 gal stainless steel reactor was charged with methanol (87 Kg), compound (II-i) (11 Kg), hydroxylamine hydrochloride (3.6 Kg), and triethylamine (5.2 Kg). The reaction mixture was heated at 60° C. for 3 h and a large amount of solid precipitated during the reaction. After cooling to 0-5° C., the solid was filtered through a Nutsche filter and the cake was washed with a mixture of methanol and water (made from 20 Kg of methanol and 25 Kg of water). After dried the cake, the product (11.8 Kg) was obtained.
EXAMPLE 2
(R)-Methyl-3-[[[3-[4-(aminoiminomethyl)phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N(butoxycarbonyl)-L-alanine monoacetate: Compound (I-i)
A 50 gal stainless steel reactor was charged with acetic acid(63 Kg) and (R)-Methyl-3[[[3[4[amino(hydroxyimino)methyl]phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N(butoxy-carbonyl)-L-alanine (Batch 1: 10.0 Kg; Batch 2: 10.0 Kg.) A solution of acetic anhydride (Batch 1: 2205 g; Batch 2: 1983 g) in acetic acid (21 Kg) was charged into the reactor slowly over 30 min from a pressure cylinder using nitrogen pressure at rt (22° C.). Additional 5.3 Kg of acetic acid was then used to rinse the cylinder. After stirring at 22° C. for 30 min or until a clear solution was attained, a small sample was taken for HPLC analysis. After the reaction was complete as determined by HPLC. A slurry of Pd/C(Batch 1: 3% Pd/C, 0.5 Kg; Batch 2: 5% Pd/C, 0.4 Kg) in acetic acid (5 L) was added and the resulting mixture was hydrogenated under 5 psi hydrogen pressure for 4-5 h. After the reaction was complete as determined by HPLC, the catalyst was filtered off and washed with acetic acid (21 Kg) to give a solution of the product. Anisole (80 Kg) was then added to the filtrate and the resulting mixture was concentrated at about 70° C. under vacuum (40 mm Hg or lower) in a 100 gal reactor. The distillation was stopped until that the distillate was about 148 L or the solid became visible in the batch. Cooled the reactor to 40° C., 72 Kg of acetone was added over 30-90 min. The slurry was stirred at ambient temperature for 1 h and the 0-5° C. for another 1 h. The solid was collected on a Rosenmund filter/dryer and the cake was washed with 10% methanol in acetone (made from 6 Kg of methanol and 57 Kg of acetone). The solid cake was dried until LOD<1%. A hot (80° C.) mixture of acetonitrile (27 Kg) and acetic acid (18 Kg) was charged into the filter to dissolve the cake and the hot solution was then transfer back to 100 gal reactor. The transfer line was washed with a mixture of acetic acid (0.9 Kg) and acetonitrile (1.4 Kg). After the solution was cooled to 40-45° C., acetone (65 Kg) was added within 10 min. The resulting slurry was stirred gently at 25° C. for 1 h and then 0-5° C. for another 1 h. The solid was filtered by the Rosenmund filter/dryer and the cake was washed with 10% methanol in acetone (prepared from 5.5 Kg methanol and 50 Kg of acetone). After drying the cake until LOD<0.1%, the product was obtained (Batch 1: 6.3 Kg. Batch 2: 6.8 Kg). Heels from both batches in the Rosenmund filter/dryer were dissolved in acetonitrile and acetic acid and combined, which was crystallized in the Kilo lab to give additional 2.86 Kg of product.
EXAMPLE 3
(R)-methyl-3-[[[3-[4-[(acetyloxyimino)aminomethyl]phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N-(butoxycarbonyl)-L-alanine: Compound (IV-i)
To a suspension of (R)-Methyl-3-[[[3-[4-[amino(hydroxyimino)methyl]phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N-(butoxycarbonyl)-L-alanine (11.76 g) in acetic acid (50 mL) was added acetic anhydride (3.6 g) dropwise. After the completion of addition, the reaction mixture was stirred at room temperature 15 min. The reaction mass became clear. Ether (200 mL) was added slowly and a thick slurry formed. The resulting mixture was then stirred for another 1.5 h at room temperature and the solid was filtered. The cake was washed with ether (50 mL) and dried to give (R)-methyl-3-[[[3-[4-[(acetyloxyimino)aminomethyl]phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N-(butoxycarbonyl)-L-alanine (12.3 g).
EXAMPLE 4
(R)-methyl-N-(butoxycarbonyl)-3-[[[4,5-dihydro-3-[4-(5-methyl-1,2,4-oxadiazol-3-yl)phenyl]-5-isoxazolyl]acetyl]amino]-L-alanine: Compound (V-i)
To a suspension of (R)-Methyl-3-[[[3-[4-[amino(hydroxyimino)methyl]phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N-(butoxycarbonyl)-L-alanine (1.05 g) in acetic acid (7 mL) was added acetic anhydride (0.35 g) dropwise. After the completion of addition, the reaction mixture was refluxed for 3 h. The solvent was distilled under vacuum and the solid was dried to give (R)-methyl-N-(butoxycarbonyl)-3-[[[4,5-dihydro-3-[4-(5-methyl-1,2,4-oxadiazol-3-yl)phenyl]-5-isoxazolyl]acetyl]amino]-L-alanine (1.05 g).
EXAMPLE 5
(R)-Methyl-3-[[[3-[4-(aminoiminomethyl)phenyl]-4,5-dihydro-5-isoxazolyl]acetyl]amino]-N-(butoxycarbonyl)-L-alanine monoacetate: Compound (I-i) Method B:
A mixture of (R)-methyl-N-(butoxycarbonyl)-3-[[[4,5-dihydro-3-[4-(5-methyl-1,2,4-oxadiazol-3-yl)phenyl]-5-isoxazolyl]acetyl]amino]-L-alanine (70 mg) and 3% Pd/C(30 mg) in methanol (3 mL) and acetic acid (0.5 mL) was stirred under hydrogen atmosphere for 3 h. The catalyst was filtered off and washed with methanol (4 mL). The combined filtrate and wash was concentrated to small volume. Acetone (2 mL) was added slowly and a slurry was formed. After stirred for 30 min, the solid was filtered and the cake was washed with 10% methanol in acetone (4 mL) and dried to give the product (25 mg).
HPLC CONDITIONS
Column:
Eclipse XDB-C8 4.6 × 250 mm
Mobile Phase:
A: 0.1% trifluoroacetic acid/0.1%
triethylamine in HPLC grade water
B: tetrahydrofuran (unstabilized-suitable
for liquid chromatography)/0.1%
trifluoroacetic acid
Gradient:
t = 0 min
85% A 15% B
t = 10 min
85% A 15% B
t = 32 min
50% A 50% B
t = 40 min
50% A 50% B
Flow Rate:
1.5 mL/min
Injection Volume:
10 microliters
Stop Time:
40 minutes
Post Time:
10 minutes
Oven Temp.:
40° C.
Detector:
UV (280 nm, 230 nm, 260 nm)
Sample Prep.:
Dissolve approximately 0.5 mg of sample (dry
solids weight) per mL in 50% tetrahydrofuran
49.9% H 2 O/0.1% acetic acid. Filter any
undissolved solids through an Acrodisc 0.45
micron Nylon filter. | The present invention relates to processes for the conversion of nitriles to amidines in the preparation of compounds which are antagonists of the platelet glycoprotein IIb/IIIa fibrinogen receptor complex. The compounds described herein are potent thrombolytics and useful for the inhibition of platelet aggregation in the treatment of thromboembolic disorders. | 2 |
This application is a continuation of Ser. No. 09/884,412, filed Jun. 19, 2001, which is a a divisional application of Ser. No. 09/488,629, filed Jan. 20, 2000, now U.S. Pat. No. 6,274,171, which is a continuation-in-part of Application Ser. No. 08/964,328, filed Nov. 5, 1997, now abandoned, which is a continuation-in part of Application No. 08/821,137, filed Mar. 20, 1997, now abandoned, which claims priority from Provisional Application No. 60/014,006 filed Mar. 25, 1996.
BACKGROUND OF THE INVENTION
Extended release drug formulations are conventionally produced as compressed tablets by hydrogel tablet technology. To produce these sustained release tablet drug dosage forms, the active ingredient is conventionally compounded with cellulose ethers such as methyl cellulose, ethyl cellulose or hydroxypropylmethylcellulose with or without other excipients and the resulting mixture is pressed into tablets. When the tablets are orally administered, the cellulose ethers in the tablets swell upon hydration from moisture in the digestive system, thereby limiting exposure of the active ingredient to moisture. As the cellulose ethers are gradually leached away by moisture, water more deeply penetrates the gel matrix and the active ingredient slowly dissolves and diffuses through the gel, making it available for absorption by the body. An example of such a sustained release dosage form of the analgesic/anti-inflammatory drug etodolac (Lodin) appears in U.S. Pat. No. 4,966,768. U.S. Pat. No. 4,389,393 discloses sustained release therapeutic compressed solid unit dose forms of an active ingredient plus a carrier base comprised of a high molecular weight hydroxypropylmethylcellulose, methyl cellulose, sodium carboxymethylcellulose and or other cellulose ether.
Where the production of tablets is not feasible, it is conventional in the drug industry to prepare encapsulated drug formulations which provide extended or sustained release properties. In this situation, the extended release capsule dosage forms may be formulated by mixing the drug with one or more binding agents to form a uniform mixture which is then moistened with water or a solvent such as ethanol to form an extrudable plastic mass from which small diameter, typically 1 mm, cylinders of drug/matrix are extruded, broken into appropriate lengths and transformed into spheroids using standard spheronization equipment. The spheroids, after drying, may then be thin-coated to retard dissolution. The fin-coated spheroids may then be placed in pharmaceutically acceptable capsules, such as starch or gelatin capsules, in the quantity needed to obtain the desired therapeutic effect. Spheroids releasing the drug at different rates may be combined in a capsule to obtain desired release rates and blood levels. U.S. Pat. No. 4,138,475 discloses a sustained release pharmaceutical composition consisting of a hard gelatin capsule filled with film-coated spheroids comprised of propanolol in admixture with microcrystalline cellulose wherein the film coating is composed of ethyl cellulose, optionally, with hydroxypropylmethylcellulose and/or a plasticizer.
Venlafaxine, 1-[2-(dimethylamino)-1-(4methoxyphenyl)ethyl]cyclohexanol, is an important drug in the neuropharmacological arsenal used for treatment of depression. Venlafaxine and the acid addition salts thereof are disclosed in U.S. Pat. No. 4,535,186. Venlafaxine hydrochloride is presently administered to adults in compressed tablet form in doses ranging from 75 to 350 mg/day, in divided doses two or three times a day. In therapeutic dosing with venlafaxine hydrochloride tablets, rapid dissolution results in a rapid increase in blood plasma levels of the active compound shortly after administration followed by a decrease in blood plasma levels over several hours as the active compound is eliminated or metabolized, until sub-therapeutic plasma levels are approached after about twelve hours following administration, thus requiring additional dosing with the drug. With the plural daily dosing regimen the most common side effect is nausea, experienced by about forty five percent of patients under treatment with venlafaxine hydrochloride. Vomiting also occurs in about seventeen percent of the patients.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with this invention, there is provided an extended release (ER), encapsulated formulation containing venlafaxine hydrochloride as the active drug component, which provides in a single dose, a therapeutic blood serum level over a twenty four hour period.
Through administration of the venlafaxine formulation of this invention, there is provided a method for obtaining a flattened drug plasma concentration to time profile, thereby affording a tighter plasma therapeutic range control than can be obtained with multiple daily dosing. In other words, this invention provides a method for eliminating the sharp peaks and troughs hills and valleys) in blood plasma drug levels induced by multiple daily dosing with conventional immediate release venlafaxine hydrochloride tablets. In essence, the plasma levels of venlafaxine hydrochloride rise, after administration of the extended release formulations of this invention, for between about five to about eight hours (optimally about six hours) and then begin to fall through a protracted, substantially linear decrease from the peak plasma level for the remainder of the twenty four hour period, maintaining at least a threshold therapeutic level of the drug during the entire twenty-four period. In contrast, the conventional immediate release venlafaxine hydrochloride tablets give peak blood plasma levels in 2 to 4 hours. Hence, in accordance with the use aspect of this invention, there is provided a method for moderating the -plural blood plasma peaks and valleys attending the pharmacokinetic utilization of multiple daily tablet dosing with venlafaxine hydrochloride which comprises administering to a patient in need of treatment with venlafaxine hydrochloride, a one-a-day, extended release formulation of venlafaxine hydrochloride.
The use of the one-a-day venlafaxine hydrochloride formulations of this invention reduces by adaptation, the level of nausea and incidence of emesis that attend the administration of multiple daily dosing. In clinical trials of venlafaxine hydrochloride ER, the probability of developing nausea in the course of the trials was greatly reduced after the first week. Venlafaxine ER showed a statistically significant improvement over conventional venlafaxine hydrochloride tablets in two eight-week and one 12 week clinical studies. Thus, in accordance with this use aspect of the invention there is provided a method for reducing the level of nausea and incidence of emesis attending the administration of venlafaxine hydrochloride which comprises dosing a patient in need of treatment with venlafaxine hydrochloride with an extended release formulation of venlafaxine hydrochloride once a day in a therapeutically effective amount.
The formulations of this invention comprise an extended release formulation of venlafaxine hydrochloride comprising a therapeutically effective amount of venlafaxine hydrochloride in spheroids comprised of venlafaxine hydrochloride, microcrystalline cellulose and, optionally, hydroxypropylmethylcellulose coated with a mixture of ethyl cellulose and hydroxypropylmethylcellulose. Unless otherwise noted, the percentage compositions mentioned herein refer to percentages of the total weight of the final composition or formulation.
More particularly, the extended release formulations of this invention are those above wherein the spheroids are comprised of from about 6% to about 40% venlafaxine hydrochloride by weight, about 50% to about 95% microcrystalline cellulose, NF, by weight, and, optionally, from about 0.25% to about 1% by weight of hydroxypropylmethylcellulose, USP, and coated with from about 2% to about 12% of total weight of film coating comprised of from about 80% to about 90% by weight of film coating of ethyl cellulose, NF, and from about 10% to about 20% by weight of film coating of hydroxypropylmethylcellulose, USP.
A preferred embodiment of this invention are formulations wherein the spheroids are comprised of about 30% to about 40% venlafaxine hydrochloride by weight, about 50% to about 70% microcrystalline cellulose, NT, by weight, and, optionally, from about 0.25% to about 1% by weight of hydroxypropylmethylcellulose, USP, and coated with from about 2% to about 12% of total weight of film coating comprised of from about 80% to about 90% by weight of film coating of ethyl cellulose, NF, and from about 10% to about 20% by weight of film coating of hydroxypropylmethylcellulose, USP.
Another preferred lower dose formulation of this invention are those wherein the spheroids are comprised less than 30% venlafaxine hydrochloride. These formulations comprise spheroids of from about 6% to about 30% venlafaxine hydrochloride by weight, about 70% to about 94% microcrystalline cellulose, NF, by weight, and, optionally, from about 0.25% to about 1% by weight of hydroxypropylmethylcellulose, USP, and coated with from about 2% to about 12% of total weight of film coating comprised of from about 80% to about 90% by weight of film coating of ethyl cellulose, NF, and from about 10% to about 20% by weight of film coating of hydroxypropylmethylcellulose, USP.
Within this subgroup of lower dose formulations are formulations in which the spheroids are comprised of from about 6% to about 25% venlafaxine hydrochloride and from about 94% to about 75% microcrystalline cellulose, with an optional amount of from 0.25% to about 1% by weight of hydroxypropylmethylcellulose. Another preferred subgroup of spheroids in these formulations comprises from about 6% to about 25% venlafaxine hydrochloride and from about 94% to about 75% microcrystalline cellulose, with an optional amount of from 0.25% to about 1% by weight of hydroxypropylmethylcellulose. A ether preferred subgroup of spheroids in these formulations comprises from about 6% to about 20% venlafaxine hydrochloride and from about 94% to about 80% microcrystalline cellulose, with an optional amount of from 0.25% to about 1% by weight of hydroxypropylmethylcellulose. Within each of these subgroups is understood to be formulations in which the spheroids are comprised of venlafaxine HCT and microcrystalline cellulose in the amounts indicated, with no hydroxypropylmethylcellulose present. Each of these formulations is also preferably contained in a gelatin capsule, preferably a bard gelatin capsule.
DETAILED DESCRIPTION OF THE INVENTION
1-[2-(dimethylamino)-1-(4methoxyphenyl)ethyl]cyclohexanol hydrochloride is polymorphic. Of the forms isolated and characterized to date, Form I is considered to be the kinetic product of crystallization which can be converted to Form II upon heating in the crystallization solvent. Forms I and II cannot be distinguished by their melting points but do exhibit some differences in their infrared spectra and X-ray diffraction patterns. Any of the polymorphic forms such as Form I or Form II may be used in the formulations of the present invention.
The extended release formulations of this invention are comprised of 1-[2-(dimethylamino)-1-(4-methoxyphenyl)ethyl]cyclohexanol hydrochloride in admixture with microcrystalline cellulose and hydroxypropylmethylcellulose. Formed as beads or spheroids, the drug containing formulation is coated with a mixture of ethyl cellulose and hydroxypropylmethyl cellulose to provide, the desired level of coating, generally from about two to about twelve percent on a weight/weight basis of final product or more preferably from about five to about ten percent (w/w), with best results obtained at from about 6 to about 8 percent (w/w). More specifically, the extended release spheroid formulations of this invention comprise from about 30 to 40 percent venlafaxine hydrochloride, from about 50 to about 70 percent microcrystalline cellulose, NF, from about 0.25 to about 1 percent hydroxypropylmethylcellulose, USP, and from about 5 to about 10 percent film coating, all on a weight/weight basis. And preferably, the spheroid formulations contain about 35 percent venlafaxine hydrochloride, about 55 to 60 percent microcrystalline cellulose NF (Avicel® PH101), about one half percent hydroxypropylmethylcellulose 2208 USP (K3, Dow, which has a viscosity of 3 cps for 2% aqueous solutions, a methoxy content of 19-24% and a hydroxypropoxy content of 4-13%), and from about 6 to 8 percent film coating.
The film coating is comprised of 80 to 90 percent of ethyl cellulose, NF and 10 to 20 percent hydroxypropylmethylcellulose (2910), USP on a weight/weight basis. Preferably the ethyl cellulose has a ethoxy content of 44.0-51% and a viscosity of 50 cps for a 5% aqueous solution and the hydroxypropylmethylcellulose is USP 2910 having a viscosity of 6 cps at 2% aqueous solution with a methoxy content of 28-30% and a hydroxypropoxy content of 7-12%. The ethyl cellulose used herein is Aqualon HG 2834.
Other equivalents of the hydroxypropylmethylcelluloses 2208 and 2910 USP and ethyl cellulose, NF, having the same chemical and physical characteristics as the proprietary products named above may be substituted in the formulation without changing the inventive concept. Important characteristics of suitable hydroxypropylmethylcelluloses include a low viscosity, preferably less than 10 cps and more preferably 2-5 cps, and a gel temperature above that of the temperature of the extrudate during extrusion. As explained below, these and other characteristics which enable the extrudate to remain moist and soft (pliable) are preferred for the hydroxypropylmethylcellulose. In the examples below, the extrudate temperature was generally 50-55° C.
It was completely unexpected that an extended release formulation containing venlafaxine hydrochloride could be obtained because the hydrochloride of venlafaxine proved to be extremely water soluble. Numerous attempts to produce extended release tablets by hydrogel technology proved to be fruitless because the compressed tablets were either physically unstable (poor compressibility or capping problems) or dissolved too rapidly in dissolution studies. Typically, the tablets prepared as hydrogel sustained release formulations gave 40-50% dissolution at 2 brs, 60-70% dissolution at 4 hrs and 85-100% dissolution at 8 hrs.
Numerous spheroid formulations were prepared using different grades of microcrystalline cellulose and hydroxypropylmethylcellulose, different ratios of venlafaxine hydrochloride and filler, different binders such as polyinylpyrrolidone, methylcellulose, water, and polyethylene glycol of different molecular weight ranges in order to find a formulation which would provide a suitable granulation mix which could be extruded properly. In the extrusion process, heat buildup occurred which dried out the extrudate so much that it was difficult to convert the extruded cylinders into spheroids. Addition of hydroxypropylmethylcellulose 2208 -to the venlafaxine hydrochloride-microcrystalline cellulose mix made production of spheroids practical.
The encapsulated formulations of this invention may be produced in a uniform dosage for a specified dissolution profile upon oral administration by techniques understood in the art. For instance, the spheroid components may be blended for uniformity with a desired concentration of active ingredient, then spheronized and dried. The resulting spheroids can then be sifted through a mesh of appropriate pore size to obtain a spheroid batch of uniform and prescribed size.
The resulting spheroids can be coated and resifted to remove any agglomerates produced in the coating steps. During the coating process samples of the coated spheroids may be tested for their distribution profile. If the dissolution occurs too rapidly, additional coating may be applied until the spheroids present a desired dissolution rate.
The following examples are presented to illustrate applicant's solution to the problem of preparation of the extended release drug containing formulations of this invention.
EXAMPLE NO. 1
Venlafaxine Hydrochloride Extended Release Capsules
A mixture of 44.8 parts ( 88.4% free base) of venlafaxine hydrochloride, 74.6 parts of the microcrystalline cellulose, NF, and 0.60 parts of hydroxypropylmethyl cellulose 2208, USP, are blended with the addition of 41.0 parts water. The plastic mass of material is extruded, spheronized and dried to provide uncoated drug containing spheroids.
Stir 38.25 parts of ethyl cellulose, NF, HG2834 and 6.75 parts of hydroxypropylmethylcellulose 2910, USP in a 1:1 v/v mixture of methylene chloride and anhydrous methanol until solution of the film coating material is complete.
To a fluidized bed of the uncoated spheroids is applied 0.667 parts of coating solution per part of uncoated spheroids to obtain extended release, film coated spheroids having a coating level of 3%.
The spheroids are sieved to retain the coated spheroids of a particle size between 0.85 mm to 1.76 mm diameter. These selected film coated spheroids are filled into pharmaceutically acceptable capsules conventionally, such as starch or gelatin capsules.
EXAMPLE NO. 2
Same as for Example 1 except that 1.11 parts of the film coating solution per part of uncoated spheroids is applied to obtain a coating level of 5%.
EXAMPLE NO. 3
Same as for Example 1 except that 1.33 parts of the film coating solution is applied to 1 part of uncoated spheroids to obtain a coating level of 6%.
EXAMPLE NO. 4
Same as for Example 1 except that 1.55 parts of the film coating solution is applied to 1 part of uncoated spheroids to obtain a coating level of 7%.
In the foregoing failed experiments and in Examples 1-4, the extrusion was carried out on an Alexanderwerk extruder. Subsequent experiments carried out on Hutt and Nica extruders surprisingly demonstrated that acceptable, and even improved, spheroids could be made without the use of an hydroxypropylmethylcellulose.
In such fierier experiments the applicability of the invention was extended to formulations wherein the weight percentage of venlafaxine hydrochloride is 6% to 40%, preferably 8% to 35%. Thus, the extended release spheroid formulations of this invention comprise from about 6 to about 40 percent venlafaxine hydrochloride, from about 50 to about 94 percent microcrystalline cellulose, NF, optionally, from about 0.25 to about 1 percent hydroxypropylmethylcellulose, and from about 2 to about 12 percent, preferably about 3 to 9 percent, film coating.
Spheroids of the invention were produced having 8.25% (w/w) venlafaxine hydrochloride and the remainder (91.75%, w/w) being microcrystalline cellulose, with a coating of from 3 to 5% (w/w), preferably 4%, of the total weight. The spheroids with 8.25% venlafaxine hydrochloride and 4% coating were filled into No. 2 white opaque shells with a target fill weight of 236 mg.
Further spheroids of the invention were produced having 16.5% (w/w) venlafaxine hydrochloride and the remainder (83.5%,w/w) being microcrystalline cellulose, with a coating of from 4 to 6% (w/w), preferably 5%, of the total weight. The spheroids 16.5% venlafaxine hydrochloride and 5% coating were filled into No. 2 white opaque shells with a target fill weight of 122 mg.
The test for acceptability of the coating level is determined by analysis of the dissolution rate of the finished coated spheroids prior the encapsulation. The dissolution procedure followed uses USP Apparatus 1 (basket) at 100 rpm in purified water at 37° C.
Conformance with the dissolution rate given in Table 1 provides the twenty-four hour therapeutic blood levels for the drug component of the extended release capsules of this invention in capsule form. Where a given batch of coated spheroids releases drug too slowly to comply with the desired dissolution rate study, a portion of uncoated spheroids or spheroids with a lower coating level may be added to the batch to provide, after thorough mixing, a loading dose for rapid increase of blood drug levels. A batch of coated spheroids that releases the drug too rapidly can receive additional film-coating to give the desired dissolution profile.
TABLE 1
Acceptable Coated Spheroid Dissolution Rates
Time (hours)
Average % Venlafaxine HCl released
2
<30
4
30-55
8
55-80
12
65-90
24
>30
Batches of the coated venlafaxine hydrochloride containing spheroids which have a dissolution rate corresponding to that of Table 1 are filled into pharmaceutically acceptable capsules in an amount needed to provide the unit dosage level desired. The standard unit dosage immediate release (IR) tablet used presently provides amounts of venlafaxine hydrochloride equivalent to 25 mg, 37.5 mg, 50 mg, 75 mg and 100 mg venlafaxine. The capsules of this invention are filled to provide an amount of venlafaxine hydrochloride equivalent to that presently used in tablet form and also up to about 150 mg venlafaxine hydrochloride.
Dissolution of the venlafaxine hydrochloride ER capsules is determined as directed in the U.S. Pharmacopoeia (JSP) using apparatus 1 at 100 rpm on 0.9 L of water. A filtered sample of the dissolution medium is taken at the times specified. The absorbance of the clear solution is determined from 240 to 450 nanometers (nm) against the dissolution medium. A baseline is drawn from 450 am through 400 nm and extended to 240 nm. The absorbance at the wavelength of maximum absorbance (about 274 mm) is determined with respect to this baseline. Six hard gelatin capsules are filled with the theoretical amount of venlafaxine hydrochloride spheroids and measured for dissolution. Standard samples consist of venlafaxine hydrochloride standard solutions plus a gelatin capsule correction solution.
The percentage of venlafaxine released is determined from the equation % Venlafaxine hydrochloride released = ( As ) ( Wr ) ( S ) ( V1 ) ( 0.888 ) ( 100 ) ( Ar ) ( V2 ) ( C )
where As is absorbance of sample preparation, Wr is weight of reference standard, mg; S is strength of the reference standard, decimal; V1 is the volume of dissolution medium used to dissolve the dosage form, mL; 0.884 is the percent free base, Ar is the absorbance of the standard preparation, V2 is the volume of reference standard solution, mL; and C is the capsule claim in mg.
Table 2 shows the plasma level of venlafaxine versus time for one 75 mg conventional Immediate Release (IR) tablet administered every 12 hours, two 75 mg extended release (ER) capsules administered simultaneously every 24 hours, and one 150 mg extended release (ER) capsule administered once every 24 hours in human male subjects. The subjects were already receiving venlafaxine hydrochloride according to the dosage protocol, thus the plasma blood level at zero time when dosages were administered is not zero.
TABLE 2
Plasma venlafaxine level (ng/mL) versus time, conventional tablet
(not extended release) versus ER causule
75 mg
2 × 75 mg
1 × 150 mg
(IR) tablet
(ER) capsules
(ER) capsules
Time (hours)
(q 12 h)
(q 24 hr)
(q 24 h)
0
62.3
55.0
55.8
0.5
76.3
1
135.6
53.3
53.2
2
212.1
69.8
70.9
4
162.0
138.6
133.3
6
114.6
149.0
143.5
8
86.7
129.3
129.5
10
118.4
114.4
12
51.9
105.1
105.8
12.5
74.7
13
127.5
14
161.3
90.5
91.3
16
134.6
78.2
78.5
18
106.2
20
83.6
62.7
63.3
24
57.6
56.0
57.3
Table 2 shows that the plasma levels of two 75 mg/capsule venlafaxine hydrochloride ER capsules and one 150 mg/capsule venlafaxine hydrochloride ER capsule provide very similar blood levels. The data also show that the plasma level after 24 hours for either extended release regimen is very similar to that provided by two immediate release 75 mg tablets of venlafaxine hydrochloride administered at 12 hour intervals.
Further, the plasma levels of venlafaxine obtained with the extended release formulation do not increase to the peak levels obtained with the conventional immediate release tablets given 12 hours apart. The peak level of venlafaxine from (ER), somewhat below 150 ng/ml, is reached in about six hours, plus or minus two hours, based upon this specific dose when administered to patients presently under treatment with venlafaxine hydrochloride (IR). The peak plasma level of venlafaxine, somewhat over 200 ng/ml, following administration of (IR) is reached in two hours and falls rapidly thereafter.
Table 3 shows venlafaxine blood plasma levels in male human subjects having a zero initial blood plasma level. Again, a peak blood plasma concentration of venlafaxine is seen at about 6 hours after dosing with venlafaxine hydrochloride extended release capsules in the quantities indicated The subjects receiving the single 50 mg immediate release tablet showed a peak plasma level occurring at about 4 hours. For comparative purposes, the plasma levels of venlafaxine for subjects receiving the conventional formulated tablet can be multiplied by a factor of three to approximate the plasma levels expected for a single dose of 150 mg. conventional formulation.
TABLE 3
Plasma Blood Levels in Human Males Having No Prior
Venlafaxine Blood Level
Time
1 × 50 mg
2 × 75 mg
1 × 150 mg
(Hours)
IR tablet
ER capsules
ER capsule
0
0
0
0
1
27.87
1.3
0
1.5
44.12
6.0
2.2
2
54.83
20.6
12.8
4
66.38
77.0
81.0
6
49.36
96.5
94.4
8
30.06
93.3
86.9
10
21.84
73.2
72.8
12
15.91
61.3
61.4
14
13.73
52.9
51.9
16
10.67
47.5
41.1
20
5.52
35.2
34.0
24
3.56
29.3
28.5
28
2.53
23.4
22.9
36
1.44
11.9
13.5
48
0.66
5.8
5.2
The blood plasma levels of venlafaxine were measured according to the following procedure. Blood samples from the subjects were collected in heparinized evacuated blood tubes and the tubes were inverted gently several times. As quickly as possible, the tubes were centrifuged at 2500 rpm for 15 minutes. The plasma was pipetted into plastic tubes and stored at −20° C. until analysis could be completed.
To 1 mL of each plasma sample in a plastic tube was added 150 μL of a stock internal standard solution (150 μg/ml). Saturated sodium borate (0.2 mL) solution was added to each tube and vortexed. Five mL of ethyl ether was added to each tube which were then capped and shaken for 10 minutes at high speed. The tubes were centrifuged at 3000 rpm for 5 minutes. The aqueous layer was frozen in dry ice and the organic layer transferred to a clean screw cap tube. A 0.3 ml portion of 0.01 N HCl solution was added to each tube and shaken for 10 minutes at high speed. The aqueous layer was frozen and the organic layer removed and discarded. A 50 μL portion of the mobile phase (23:77 acetonitrile:0.1M monobasic ammonium phosphate buffer, pH 4.4) was added to each tube, vortexed, and 50 μL samples were injected on a Superco Supercoil LC-8-DB, 5 cm×4.6 mm, 5 μ column in a high pressure liquid chromatography apparatus equipped with a Waters Lambda Max 481 detector or equivalent at 229 nm. Solutions of venlafaxine hydrochloride at various concentrations were used as standards.
EXAMPLE NO. 5
Manufactured by the techniques described herein, another preferred formulation of this invention comprises spheroids of from about 30% to about 35% venlafaxine hydrochloride and from about 0.3% to about 0.6% hydroxypropylmethylcellulose. These spheroids are then coated with a film coating, as described above, to a coating level of from about 5% to about 9%, preferably from about 6% to about 8%. A specific formulation of this type comprises spheroids of about 33% venlafaxine hydrochloride and about 0.5% hydroxypropylmethylcellulose, with a film coating of about 7%.
Lower dosage compositions or formulations of this invention may also be produced by the techniques described herein. These lower dosage forms may be administered alone for initial titration or initiation of treatment, prior to a dosage increase. They may also be used for an overall low-dose administration regimen or in combination with higher dosage compositions, such as capsule formulations, to optimize individual dosage regimens.
These lower dose compositions may be used to create encapsulated formulations, such as those containing doses of venlafaxine hydrochloride from about 5 mg to about 50 mg per capsule. Particular final encapsulated dosage forms may include, but are not limited to, individual doses of 7.5 mg, 12.5 mg, 18.75 mg, or 28.125 mg of venlafaxine HCl per capsule.
The spheroids useful in these lower dose formulations may comprise from about 5% to about 29.99% venlafaxine HCl, preferably from about 5% to about 25%, from about 75% to about 95% microcrystalline cellulose, and, optionally from about 0.25% to about 1.0% hydroxypropylmethylcellulose. The spheroids may be coated as described above, preferably with a film coating of from about 5% to about 10% by weight. In some preferred formulations, the spheroids comprise the cited venlafaxine HCl and microcrystalline cellulose, with no hydroxypropylmethyl cellulose.
EXAMPLE NO. 6
Spheroids comprising 16.5% venlafaxine HCl and 83.5% microcrystalline cellulose were mixed with approximately 50% water (w/w) to granulate in a Littleford Blender Model FM-50E/1Z (Littleford Day Inc., P.O. Box 128, Florence, Kent. 41022-0218, U.S.A.) at a fixed speed of 180 rpm. The blended material was extruded through a 1.25 mm screen using a Nica extruder/spheronization machine (Aeromatic-Fielder Division, Niro Inc., 9165 Rumsey Rd., Columbia, Md. 21045, U.S.A.) for a 12/20 mesh cut after drying. Two portions of the resulting spheroids were coated with a 5% and 7% coating level, respectively, by techniques described above using the coating formulation:
Ingredient
% (w/w)
Methylene Chloride
60.000
Methanol Anhydrous
35.500
Ethylcellulose, NF, HG 2834, 50 cps
3.825
Hydroxypropyl Methylcelluose, 2910 USP,
0.675
6 cps
The 5% and 7% coated lots were tested for dissolution on a Hewlett Packard automated dissolution system over a 24 hour period, resulting in the following dissolution patterns:
% Dissoluded
% Dissolved
Time/hr
16.5%/5%
16.5%/7%
2
12.4
5.6
4
42.8
25.4
8
70.7
60.4
12
82.2
75.4
24
94.3
92.7
EXAMPLE NO. 7
A formulation of spheroids containing 8.25% venlafaxine HCl and 91.75% microcrystalline cellulose was prepared according to the techniques of Example No. 6 and coated with a 5% film coating. In the Hewlett Packard automated dissolution system these spheroids provided the following dissolution profile:
% Dissolved
Time/hr
8.25%/5%
2
4.4
4
24.2
8
62.9
12
77.8
24
93.5
Thus, the desired dissolution rates of sustained release dosage forms of venlafaxine hydrochloride, impossible to achieve with hydrogel tablet technology, has been achieved with the film-coated spheroid compositions of this invention. | This invention relates to a 24 hour extended release dosage formulation and unit dosage form thereof of venlafaxine hydrochloride, an antidepressant, which provides better control of blood plasma levels than conventional tablet formulations which must be administered two or more times a day and fiber provides a lower incidence of nausea and vomiting than the conventional tablets. More particularly, the invention comprises an extended release formulation of venlafaxine hydrochloride comprising a therapeutically effective amount of venlafaxine hydrochloride in spheroids comprised of venlafaxine hydrochloride, microcrystalline cellulose and, optionally, hydroxypropylmethylcellulose coated with a mixture of ethyl cellulose and hydroxypropylmethylcellulose. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a fire detector and a fire alarm system employing the same, and more particularly to a fire detector and a fire alarm system wherein a plurality of fire detectors are connected across a pair of lines leading to a signal station and which is capable of detecting, at the signal station, removal of a detector head or heads of the associated detector or detectors and yet capable of keeping the system operative so that the signal station may receive a possible fire alarm signal even after removal of the detector head or heads.
2. Description of Prior Art
In general, a fire alarm system (hereinafter referred to as "alarm system") has a plurality of fire detectors (hereinafter referred to as "detector") sequentially connected in parallel to a line and a signal station adapted to receive a fire alarm signal from the respective detectors to give an alarm.
Since the alarm system is not actuated in a normal condition and works only at an exceptional, abnormal time when a fire breaks out, it should be fully prepared against emergencies and have high reliability so that it can give an accurate alarm when a fire starts. To assure high reliability of the system, not only the detectors but also the line per se should have a sufficient reliability. To this end, it is required to immediately detect possible breaking of the line and alarm such breaking so as to enable quick repair of the breaking.
Therefore, it has been proposed to provide a fire alarm system equipped with a breaking detecting means at a signal station and capable of monitoring line conditions. In this system, a small current for monitoring flows constantly or periodically through the line via a terminating element. The breaking detecting means detects possible breaking of the line from a phenomenon of shut-off of the current due to the breaking. The breaking detecting means is formed, for example, of a semiconductor.
Each of the detectors employed in the fire alarm system is comprised, as illustrated in FIG. 1, of a socket 2 fixed to a ceiling etc. of a building and connected to the line leading to the signal station and a detector head 3 including a detecting means for detecting smoke, heat, etc. The detector head 3 is attached to the socket 2 by engaging a contact blade 5 of the head 3 with a holder member 4 having a holding resilient member 4b provided on the socket 2. Thus, the detector head 3 is formed detachable from the socket 2. This is very convenient for installation of the detector, maintenance check, exchange, etc. of the detectors and improves efficiency of these operations. However, due to this removable formation of the detector head, the detector head is unfortunately sometimes removed by intruders or thoughtless persons. A problem is that the signal station cannot detect the removal of the detector head because a plurality of detectors are connected in parallel with each other in the fire alarm system.
To solve this problem and assure high reliability of the system, it has been proposed to detect removal of the detector head, utilizing the aforesaid breaking detecting means. More specifically, in this improved system, the line is put into a breaking condition when any one of the detector heads is removed from the associated sockets and the signal station is adapted to detect the breaking of the line.
For instance, as illustrated in FIG. 2, a line 7 leading to a signal station 6 is connected, through a contact means 9 which is provided in each of detectors 1 and adapted to conduct when the detector head 3 is fitted to the socket 2, to a succeeding detector 1 and a terminating element 8 comprised of a resistor 8a etc. is connected at the end of the line 7 so that the signal station 6 may detect removal of the detector head. As illustrated in FIGS. 1, 3A and 3B, the contact means 9 of the detector 1 is comprised of a holder member 4, a resilient member 11 provided adjacently to the holder member 4 and the contact blade member 5, and the contact blade member 5 is interposed between and in contact with the holder member 4 and the resilient member 11 when the detector head 3 is attached to the socket 2 to conduct the line 7 for supplying a power source to a detecting portion 10. On the other hand, when the head 3 is removed, the holder member 4 is isolated from the resilient member 11, rendering the contact means 9 non-conducting to disconnect the line 7. Thus, removal of the detector head 3 is detected.
However, this detector and the fire alarm system employing the same have such a disadvantage in practical use that when any one of the detector heads 3 is removed, the line 7 is put into a breaking condition and all the detectors succeeding the detector whose detector head has been removed become inoperative. This system is too much adapted for detection of removal of the detector head to perform a fire detecting function which is essential to a fire alarm system. Thus, this system has a fatal defect as a fire alarm system.
Further, there has been proposed a detector having a contact means on a socket which is kept in a non-conducting state when a detector head is attached to the socket and adapted to conduct a short-circuit a line when the head is removed. This detector, however, has a disadvantage that a signal for indicating removal of the detector head cannot be distinguished from a fire alarm signal because both the signals are caused by short-circuiting of the line. In addition, this detector lacks reliability of the system and is not practicable because removal of one detector head hinders alarming operating of other detectors.
Where a fire alarm system has a special testing signal line for testing operations of detectors, either of the preceding two proposals may be carried out for detecting removal of a detector head. However, this system cannot be applied to a fire alarm system having no test signal line. Therefore, a special line must be provided at a time of installation of a fire alarm system, which increases an installation cost. Thus, this system is not always desirable and it is unpractical, in especial, when an area to be covered by the system is considerably large.
As described above, none of the foregoing fire alarm systems can effect detection of removal of the detector head, utilizing disconnection or short-circuiting of the line without causing hindrance to alarm operations of other detectors. Thus, a detector and a fire alarm system which is capable of solving the problems involved in the conventional detectors and systems and capable of detecting removal of the detector head with high reliability has not been proposed.
The present invention has been made in view of these facts and achieved based on a finding that such a short time, as several micro-seconds to several seconds, will suffice to detect disconnection of a line. Such a momentary time required for detection of the disconnection is negligible for reliability of the system because there is substantially no chance that a fire will break out during such a momentary time. More specifically, the present invention is so formed as to detect removal of the detector head by momentarily disconnecting the line during a time required for the detecting in the course of or after removal of the detector head. Thus, the invention provides a novel fire detector and fire alarm system which can markedly enhance reliability of the system without causing hindrance to the succeeding detectors.
OBJECTS OF THE INVENTION
A primary object of the present invention is to provide a fire detector which is capable of detecting removal of a detector head without causing disconnection or short-circuiting of the line for a substantial length of time and therefore without causing any hindrance to operations of succeeding detectors.
A second object of the present invention is to provide a fire detector which is widely applicable to a general fire alarm system without requiring provision of a special signal line.
A third object of the present invention to provide a fire detector which is capable of detecting removal of a detector head, distinguishing it from breaking of a line.
A fourth object of the present invention is to provide a fire alarm system suited for the detector which can attain the objects of the invention as described above.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a fire detector comprised of a detector head and a socket, connected across a pair of lines leading to a signal station and connecting, through said detector, one of the pair of lines to a succeeding fire detector formed and connected identically with said fire detector, which detector is characterized by a means for disconnecting said line temporarily when said detector head is being removed from said socket or periodically after said detector head has been removed from said socket.
Further in accordance with the present invention, there is provided a fire alarm system wherein a plurality of fire detectors each comprised of a detector head and a socket are sequentially connected across a pair of lines leading to a signal station, a terminating element is provided at the end of the line to form a closed loop of the line and said line is connected through the respective fire detectors to the respectively succeeding detectors, which system is characterized in that each of said fire detectors includes a means for disconnecting the line connected therethrough to the succeeding detector and temporarily signal station during removal of said detector head from said socket or periodically after said detector head has been removed from said socket and said signal station includes a means for detecting the temporary or periodical disconnection of the line by said fire detector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a detector employable in a conventional alarm system;
FIG. 2 is a connection diagram of a conventional fire alarm system, also illustrating conventional fire detectors employed therein;
FIGS. 3A and 3B are a side elevational and a top plan view of a holder member, a resilient member and a contact blade member employed in the conventional detector as illustrated in FIG. 1, showing an engaging relation therebetween;
FIG. 4 is a connection diagram of one form of a fire detector and a fire alarm system employing the same in accordance with the present invention;
FIGS. 5A to 5C, FIGS. 6 and 7 are side elevational and top plan views of various forms of contact means employable in the fire alarm system as illustrated in FIG. 4;
FIGS. 8A and 8B and FIGS. 9, 10A, 10B, 11 and 12 are side elevational and top plan views of various forms of actuating means employable in the fire alarm system as illustrated in FIG. 4;
FIG. 13 is a top plan view of a detector head, illustrating positions of the actuating means;
FIGS. 14 and 15 are side elevational views of contact means and actuating means for use in a plug-in type detector;
FIG. 16 is a circuit diagram of still another form of contact means;
FIG. 17 is a circuit diagram of a signal station employable in the alarm system of the present invention;
FIG. 18 is a connection diagram of another form of a fire detector and a fire alarm system according to the present invention;
FIGS. 19 to 21 are circuit diagrams of various forms of detectors employable in the fire alarm system as illustrated in FIG. 18;
FIG. 22 is a circuit diagram of a still another form of detector according to the present invention;
FIGS. 23 and 24 are circuit diagrams of further forms of fire alarm system according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 4 is a connection plan of a fire alarm system employing a fire detector in accordance with the present invention. In FIG. 4, a plurality of detectors 1 are connected in parallel to a line 7 which forms a closed loop in cooperation with a signal station 6 and a terminating element 8. Each of the detectors 1 has a normally conducting contact means 12 for sequentially connecting the line 7 therethrough to a succeeding detector. The detector 1 further has an actuating means 15 for temporarily rendering the contact means 12 non-conducting when a detector head 3 of the detector 1 is being detached.
The contact means 12 is connected between contacts 7a and 7b of each of the detectors 1 and normally conducting, irrespective of the state of the detector head 3, namely, whether the detector head 3 is attached or removed, to connect the line 7 therethrough to the succeeding detector 1. As the contact means 12, there may be used a holder member 4 for holding the detector head 3 in an attached position or may be employed a special member provided solely therefor. The former case is as illustrated in FIGS. 5A and 5B wherein the contact means 12 is formed of the holder member 4 and a resilient member 11 provided on a socket 2 so as to oppose to the holder member 4 (as in FIG. 3). The resilient member 11 is made of a material selected from metals having resiliency and electric conductivity and fixed so as to confront a face 4a of the holder member 4 which is contactable with a contact blade member 5. A tip end 11a of the resilient member 11 is pressed against the face 4a by the resiliency thereof. Thus, the resilient member 11 forms the normally conducting contact means in combination with the holder member 4.
A contact means 12 as illustrated in FIG. 5C is formed, like the contact means 12 as described above, of a holder member 4 and a resilient member 11, but in the contact means 12 of FIG. 5C, the resilient member 11 is offset relative to the holder member 4 to facilitate pressing of the resilient member 11 by means of a projection 17 as will be described in detail later.
FIGS. 6 and 7 illustrate a contact means 12 of the latter case, wherein a normally conducting pressure switch such as a microswitch 13 and a normally conducting magnetic switch such as a reed switch 14 are employed, respectively. These microswitch 13 and reed switch 14 are provided separately from the holder member 4 and mounted on the socket 2. In this case a holder member (not shown in FIGS. 6 and 7) and a contact blade member (not shown in the figures) do not form the contact means and function as a holding means for a detector head 3 and an input and output terminals of a detecting portion 10. The pressure switch may be alternatively formed of a movable contact and a fixed contact provided on a socket 2 or formed of a piezo-electric element. As the magnetic switch, there can be mentioned, besides the reed switch 14, a Hall element switch, a magnetoresistive element switch, etc. The mounting positions of these switches are determined in relation with an actuating means 15 as will be described in detail below.
The actuating means 15 is generally provided on the detector head 3 and acts to temporarily render the contact means 12 non-conducting to temporarily disconnect the line 7 during removal of the detector head 3. The construction of the actuating means 15 is varied depending on the formation of the contact means 12. The actuating means 15 may be so formed that it can per se act as an input/output terminal to the detecting portion 10 as indicated by A in FIG. 4 or so formed that it cannot act as the input/output terminal as indicated by B in FIG. 4.
Actuating means 15 as illustrated in FIGS. 8A and 8B and FIG. 9 are adapted for the contact means comprised of the holder member 4 and the resilient member 11 as illustrated in FIGS. 5A and 5B and act as input/output terminals to the detecting portion 10. More specifically, each of the actuating means 15 of FIGS. 8A and 8B is comprised of the contact blade member 5 and an insulating member 16 fixed to the contact blade member 5 and mounted at a part of a portion 5a of the contact blade member 5 contactable with and slidable on the holder member 4 and/or resilient member 11 so as to insulate the holder member 4 from the resilient member 11 in the course of disengaging the contact blade member 5 from the holder member 4. The insulating member 16 is fixed to the contact blade member 5 by embedding the insulating member 16 in a -shaped groove formed at a part of the face 5a of the contact blade member 5 as illustrated in FIG. 8A or by inserting the insulating member 16 through an opening formed at a part of the portion 5a of the contact blade member 5 with the ends of the insulating member projected from the portion 5a as illustrated in FIG. 8B. The insulating member 16 may alternatively be fixed in other suitable ways not illustrated in the drawings. With these arrangements of the insulating member 16, the tip end portion 11a of the resilient member 11 will be necessarily brought into contact with the insulating member 16 when the tip end 11a slides on the slide face 5a of the contact blade member 5 during removal of the detector head 3. Thus, when the tip end 11a is in contact with the insulating member 16, the holder member 4 is temporarily insulated from the resilient member 11.
The actuating means 15 as illustrated in FIG. 9 is comprised of the contact blade member 5 and the insulating member 16 fixed to the resilient member 11, and the insulating member 16 is fixed on the resilient member 11 at a position facing the holder member 4 and kept from the holder member 4 but projected so that it may be raised by the contact blade member 5 to displace the resilient member 11 away from the holding member 4 when the contact blade member 5 is being disengaged from the holding member 4. The insulating member 16 is kept from being pressed against the contact blade member 5 when the contact blade member 5 is engaged with the holding member 4 and it is pushed up by the contact blade member 5 only when the resilient member 11 slides on the contact blade member 5.
An actuating means 15 as illustrated in FIGS. 10A and 10B is also adapted for the contact means 12 comprised of the holding member 4 and the resilient member 11 and suitably employed in combination with the contact means 12 of FIG. 5C. This actuating means 15 is formed of a projection 17 provided on the detector head 3 adjacently to the contact blade member 5. This projection will raise the resilient member 11 when the detector head 3 is being detached, to keep the resilient member 11 away from the holding member 4. The projection 17 is provided at a position, e.g. a position as indicated by C in FIG. 13, where its face 17a for pushing the resilient member 11 does not prevent contact between the resilient member 11 and the contact blade member 5 when the detector head 3 is fitted to the socket 2 and it pushes the resilient member 11 upwardly when the head 3 is being disengaged from the socket 2.
Actuating means 15 as illustrated in FIGS. 11 and 12 are adapted for the contact means 12 formed of the pressure switch and the magnetic switch as illustrated in FIGS. 6 and 7, respectively. These actuating means do not act as input/output terminals to the detecting portion 10. More particularly, in FIG. 11, the actuating means 15 is formed of a projection 17 provided on the detector head 3 so as to oppose to the microswitch 13 and adapted to push a pressure sensitive portion 13a of the microswitch 13 by the projection 17 when the head 3 is being detached, to render the microswitch 13 non-conductive. The actuating means 15 of FIG. 12 is formed of a magnet 18 provided on the detector head 3 so as to confront the reed switch 14, and adapted to approach the reed switch 14 when the head 3 is being removed, to open reeds 14a and 14b of the reed switch 14. These actuating means 15 are provided at positions, e.g. positions indicated by D in FIG. 13, where they are brought into contact with the microswitch 13 or drawn near the reed switch 14.
FIG. 14 illustrates a case where a contact means 12 and an actuating means 15 are adapted for a plug-in type detector. In the figure, the contact means 12 is comprised of two resilient members 11 each having tip ends opposed to each other and pressed against each other, and the actuating member 15 is formed of an insulating member 16 fixed to a tip end of a plug-in member 19. A pressure switch and a magnetic switch may also be employed in the plug-in type detector. For instance, as illustrated in FIG. 15, a microswitch 13 is provided on an inner sidewall of a -shaped socket 2 and a projection 17 is provided on a face of a detector head 3 at a position confronting the microswitch 13, so that the projection 17 depresses the microswitch 13 to temporarily open the contact means 12 when the detector head 3 is drawn out of the socket 2.
In the embodiments as described above, the contact means 12 is directly rendered non-conductive by the action of the actuating means 15, but as illustrated in FIG. 16, for example, a contact means 12 employs a normally non-conducting reed switch 14 and is so formed that it renders the line 7 non-conducting when the reed switch 14 becomes conductive. More specifically, the embodiment of FIG. 16 is comprised of the normally non-conducting reed switch 14, a monostable multivibrator 20 coupled, at a trigger input terminal thereof, to one end of the reed switch 14 and a relay 21 with a coil 21a coupled in series to the multivibrator 20 and contacts 21b coupled between the junction terminals 7a and 7b. In this embodiment, when a magnet (not shown in FIG. 16) approaches the reed switch 14 to make the same conducting during removal of the detector head 3, the monostable multivibrator 20 is triggered to output a mono pulse having a given width so that the relay 21 is energized and the contacts 21b are temporarily opened.
A fire alarm system in accordance with the invention will now be described. In this fire alarm system, a plurality of detectors selected from the various forms of the detectors 1 as described above are successively connected in parallel to the line 7 leading to the signal station 6 and the terminating element 8 is provided at an end of the line 7 to form a closed loop. The line 7 is connected through the respective detectors 1 to the respectively succeeding detectors 1.
The signal station 6 includes a fire alarm signal detecting circuit 22, a temporary disconnection detecting circuit 25 and a power source 30, and acts to supply a power source to the respective detectors 1 through the line 7 and detect a fire alarm signal from the respective detectors 1 and removal of a detector heads.
FIG. 17 is a circuit diagram of a specific example of the signal station 6. In the figure, a fire alarm signal detecting circuit 22 is comprised of a relay 23 having a coil 23a connected in series to a line 7 and contacts 23b connected in parallel to the line 7 and an alarm means 24. The contacts 23b constitute a make contact means and are adapted to conduct when the coil 23a is energized by the fire alarm signal formed of a short-circuited current to actuate the alarm means 24. The alarm means 24 is formed of an indicator lamp and/or buzzer etc. and informs occurrence of a fire by light and/or sound, etc. Although the fire alarm signal detecting circuit 22 is adapted to detect the fire alarm signal by the relay 23 in this embodiment, a transistor circuit may alternatively be employed to detect the fire alarm signal as illustrated in FIGS. 23 and 24.
The temporary disconnection detecting circuit 25 is comprised, for example, of relays 26 and 27 and an alarm means 29 for detecting temporary disconnection of the line 7 and alarming removal of the detector head. The relay 26 has a coil 26a connected in series to the line 7 and contacts 26b connected in parallel to the line 7, while the relay 27 has a coil 27a connected in series to the contacts 26b, contacts 27b connected in parallel to the contacts 26b and contacts 27c connected in parallel to the line 7. The alarm means 29 is connected in series to the contacts 27c. The contacts 26b constitute a break contact means and the contacts 27b and 27c constitute make contact means, respectively. Therefore, the contacts 26b are non-conductive when a current flows through the line 7 and become conductive to energize the coil 27a when the line 7 is disconnected by removal of the detector head, to shut off the current flowing through the line 7. As a result, the contact 27c conducts to actuate the alarm means 29. At the same time, the contacts 27b become conductive to hold the coil 27a in an energized state. Thus, the momentary disconnection of the line 7 generally for one second or less due to the contact means 12 and the actuating means 15 can be detected.
This temporary disconnection detecting circuit 25 may be employed in a conventional signal station. This enables application of the detectors of the present invention to the existing fire alarm system. This temporary disconnection 25 may be utilized for detecting breaking of the line 7. In this case, the temporary disconnection of the line and the breaking of the line can be distinguished based on the fact that when the self-holding of the relay 27 is released, the relay 27 is not re-energized in the former case while the relay 27 is re-energized in the latter case. This distinguishing may be effected automatically as will be described in detail later.
The terminating element 8 is formed for example of a resistor 8a to make a closed loop of the line 7. The element 8 also acts to flow, through the line 7, a monitoring current so weak that it cannot actuate the fire alarm signal detecting circuit 22.
The connection of the detectors 1 and the signal station 6 are made in the following manner. The socket 2 is connected to the line 7 fixedly while the detector head 3 is connected to the socket 2 removably. The socket 2 is connected to the line 7 by connecting the sockets 2 of the respective detectors 1 in parallel to the line 7 and connecting the line 7 through contacts 7a and 7b of the respective sockets to the contacts 7a and 7b of the respectively succeeding sockets. In these connections, attention is to be paid to the polarity of an output end of the signal station and the polarities of the respective detectors. The manners of these connections are similar in other embodiments as will be described later.
The operation for detecting removal of the detector head of the above-described detector in the fire alarm system according to the foregoing embodiment will now be described. In FIG. 4, when the detector heads 3 of the detectors 1 connected to the line 7 are all fitted to the respective sockets 2, the line 7 is connected through the contact means 12 of the respective detectors 1 to the succeeding detectors 1 so that a current from the power source of the signal station 6 flows through the line 7 via the terminal element 8 and the temporary disconnection detecting circuit 25 is not actuated.
On the other hand, when the detector head 3 of any of the detectors 1 is removed from the socket 2, the associated contact means 12 is temporarily rendered non-conducting by the actuating means 15 so that the line 7 is temporarily disconnected. However, the detector head 3 is fully removed from the socket 2, the contact means 12 becomes conductive again, so that there is caused no problem for fire alarming by the succeeding detectors 1.
FIG. 18 is a connection diagram of another form of fire alarm system embodying the present invention. In the figure, the detector 1 is comprised of a contact means 9 which conducts when the detector head 3 is fitted to the socket 2 to connect the line 7 therethrough to another detector 1 and a periodical conducting circuit 31 which is adapted to be periodically conductive and non-conductive to periodically connect and disconnect the line 7 connected through the contact means to another detector 1 when the detector head 3 is being removed from the socket 2.
The contact means 9 functions not only to connect the line 7 therethrough to another detector 1 but as a switch for restraining the operation of the periodically conducting circuit 31 by forming a shunt by the contact means. As the contact means 9, a conventional contact means used in the old detector may also be employed. Alternatively, the contact means 9 may be formed of a pressure switch, a magnetic switch, etc. provided separately from the holding member 4 etc. In the latter case, the switches are so formed that it is in a conductive state when the detector head 3 is fitted to the socket 2 and becomes non-conductive when the head 3 is removed.
As illustrated in FIG. 19, the periodical conducting circuit 31 is comprised, for example, of an oscillation circuit 32 and a switch circuit 33 connected between the terminals 7a and 7b of the socket 2. The oscillation circuit 32 includes a Schmitt trigger circuit 32a, a capacitor 32b, resistors 32c and 32e, a diode 32d and a capacitor 32f for power supply, and adapted to be actuated to oscillate, when the shunt formed by the contact means 9 is released, for periodically driving the switch circuit 33. The capacitor 32f for power supply is provided to drive the oscillation circuit 32 and is adapted to be charged during a period when the line 7 is disconnected by the switch circuit 33 as will be described later and to discharge when the line 7 is conductive, to supply a power source for driving the oscillation circuit 32. The diode 32d is provided to render the conducting time and the non-conducting time unsymmetrical. The ratio of these times can be varied by varying the resistance value of the resistor 32e.
The switch circuit 33 is formed of a field effect transistor and driven by an output from the oscillation circuit 32 to periodically connect and disconnect the line between the terminals 7a and 7b. This switch circuit 33 may be formed of an ordinary bipolar transistor etc. instead of using the field effect transistor. Furthermore, when there is a problem with a current capacitance of the switch circuit 33, the switch circuit 33 is so formed that it may periodically energize a relay 34 (a coil 34a and contacts 34b) to carry out periodical connection and disconnection of the line to be relayed as illustrated in FIG. 20.
In an embodiment as illustrated in FIG. 21, a contact means 35 has a transfer structure for switching contacts upon removal of the detector head 3. A periodical conducting circuit 31 is comprised of an oscillating circuit 32 adapted to be connected to the line 7 for oscillation by the contact switching of the contact means 35 and a switch circuit 33 connected in parallel to the contacts of the contact means 35 for connecting the line 7 therethrough and driven by an output from the oscillation circuit 32 to be periodically conducted. According to this embodiment, since the oscillation circuit 32 is connected in parallel to the line 7 through the contact means 35, power source supply is obtained during a time when the line 7 is disconnected. Thus, in this embodiment, the capacitor 32f for power supply is not needed. In this embodiment, the line 7 may be connected and disconnected by energizing a relay through the switch circuit 33 as in the embodiment of FIG. 20. The contact means 35 is formed of the holding member 4, the contact blade member 5 and the resilient member 11. Alternatively, the contact means 35 may be formed of a pressure switch, a magnetic switch, etc. In this case, two pressure switches or magnetic switches, one of which is normally conductive and another of which is normally non-conductive, may be employed in combination.
The fire alarm system of the present invention as illustrated in FIG. 18 will be described. This fire alarm system is comprised of a plurality of detectors 1 each connected to the line 7 leading to the signal station and having a periodically conducting circuit 31 and the signal station 6 including a fire alarm signal detecting circuit 36 and a circuit 39 for detecting a periodical disconnection of the line 7.
The fire alarm signal detecting circuit 36 includes, for example, a transistor 37 for detecting short-circuiting of the line 7 and a relay 38 adapted to be energized by the transistor 37 as illustrated in FIG. 24. Alternatively, the fire alarm signal detecting circuit 22 as illustrated in FIG. 17 may be employed in this fire alarm system.
The periodic disconnection detecting circuit 39 is formed, for example, similarly to the temporary disconnection detecting circuit 25 as illustrated in FIG. 17. In this case, first occurrence of disconnection of the periodical disconnection is detected. The periodical disconnection detecting circuit 39 may alternatively be formed, for example, as illustrated in FIG. 24, of a current variation detecting circuit 45 for detecting a variation in a current through the line 7, an integration circuit 58 for integrating the detection signal and an alarm circuit 59 for estimating the level of the integration value from the integration circuit 58 so as to alarm removal of the detector head when the level reaches a preset reference value. The alarm circuit 59 is comprised of a comparator 60 having a reference value which is a value corresponding to or lower than a value obtained by integrating, for a predetermined time, the detection signal intermittently outputted from the detecting circuit upon periodical disconnection of the line 7, a relay 62 adapted to be energized by a transistor 61 in response to an output from the comparator 60 and an alarm means 29 connected to make-and-break contacts 62b.
Further alternatively, the periodical disconnection detecting circuit 39 may be so formed that it periodically light or sound an alarm means directly by a relay (not shown) having no self-holding function or through a suitable demultiplier circuit (not shown).
The operations of the detectors and the fire alarm system employing the same as illustrated in FIG. 18 will be described. In this fire alarm system, if the detector head 3 of any of the detectors 1 is removed from the associated socket 2, the short-circuiting of the contact means 9 of the associated detector 1 is released and the oscillation circuit 32 is actuated to oscillate for driving the switch circuit 33. As a result, the line 7 to be relayed by the detector 1 is periodically disconnected and connected in response to the oscillation of the oscillation circuit 32. The periodical disconnection detecting circuit 39 detects this periodical disconnection of the line 7. Thus, the removal of the detector head 3 can be detected. In this embodiment, since the line 7 periodically conducts when the detector head 3 is removed, no problem is caused to the succeeding detectors.
FIG. 22 illustrates a still another form of fire detector. This detector 1 has contact means 9 adapted to conduct when the detector head 3 is fitted to the socket 2 for connecting the line 7 therethrough to a succeeding detector and a delay switch circuit 40 connected in parallel to the contact means 9 and adapted to be kept inoperative temporarily due to a shunt formed by the contact means 9 when the detector head 3 is attached to the socket 2 and become conductive after a given time of delay when the head 3 is removed.
The delay switch circuit 40 is comprised of a thyristor 41 connected in parallel with the contact means 9, a Zener diode 42 providing a trigger circuit for the thyristor 41, a capacitor 43 and resistors 44a and 44b. Upon removal of the detector head 3, the contact means 9 is opened to release its short-circuiting. Then, the thyristor 41 is turned on after a time of delay determined by a time constant determined by the capacitor 43 and the resistor 44a and a threshold voltage of the Zener diode 42, to again conduct the line 7 which has been disconnected due to the opening of the contact means 9. In this embodiment, the delay in the delay switch circuit 40 provides a temporary disconnection of the line 7. However, since a charging current to the capacitor 43 continues to flow, such disconnection is not complete one. The detectors 1 in accordance with this embodiment may be used in combination with the signal station 6 as illustrated in FIG. 17 to constitute a fire alarm system of the present invention. This embodiment is advantageous especially in that an irregular, temporary disconnection of the line 7 can be rendered uniform by the fixed delay time of the delay switch circuit 40.
FIGS. 23 and 24 illustrate other forms of fire alarm system in accordance with the present invention, which is capable of detecting removal of the detector head and breaking of the line per se, automatically distinguishing the former from the latter.
The fire alarm system of FIG. 23 has a signal station 6 which includes a current variation detecting circuit 45 for detecting a current variation in the line 7, a level estimating circuit 46 for estimating a level of the detected current variation to output an estimation signal, a removal alarm circuit 47 for comparing the estimation signal and a preset reference signal to detect temporary disconnection of the line 7 and alarm the removal of the detector head, and a breaking alarm circuit 53 for integrating the estimation signal to alarm the breaking of the line when the integration value exceeds a predetermined level. More particularly, in this fire alarm system, the current variation detecting circuit 45, the level estimating circuit 46 and the removal alarm circuit 47 provides a temporary disconnection detecting circuit as denoted by numeral 25 in FIG. 4, while the current variation detecting circuit 45, the level estimating circuit 46 and the breaking alarm circuit 53 provides a breaking detecting circuit.
The current variation detecting circuit 45 includes a transistor 45a which is so connected as to conduct when a current through the line 7 decreases, for outputting a detection signal by dividing a voltage appearing at the emitter of the transistor 45a with a suitable resistor. The level estimating circuit 46 includes a comparator 46a for comparing the detection signal with a reference value and is adapted to output an estimation signal by estimating decrease of the current through the line 7 to below the reference value as disconnection or breaking of the line 7.
The removal alarm circuit 47 is comprised of a reference time setting circuit 48 adapted to be actuated upon receipt of the estimation signal as a trigger for outputting a reference signal of a preset time, a comparing gate 49 for comparing the reference signal with the estimation signal, a memory 50 for storing an output from the comparing gate 49, a transistor 51 which is turned on or turned off according to an output from the memory 50, and a relay 52 adapted to be energized by the transistor 51 for driving the alarm means 29. The reference time setting circuit 48 is formed, for example, of a monostable multivibrator for outputting the reference signal lasting for the preset time which is determined by a time required for removal of the detector head 3 (for instance, several seconds). In this embodiment, the reference signal is outputted in the inverted form. The comparing gate 49 is formed, for example, of a NOR gate circuit and adapted to receive, as inputs, the inverted reference signal and the estimation signal. The comparing gate 49 opens when the estimation signal terminates within a time the reference signal is kept to be inputted to detect temporary disconnection of the line 7. The memory 50 is formed, for example, of a flip-flop circuit for holding an output from the comparing gate 49 and conducting the transistor 51 to energize the relay 52 and drive the alarm means 29.
The breaking alarm circuit 53 is comprised of an integration circuit 54 for integrating an output of the level estimating circuit 46, a transistor 55 which conducts when the integration value of the integration circuit 46 exceeds a preset value, a relay 56 adapted to be energized by the transistor 55 and an alarm means 57 adapted to be driven by the relay 56. The integration circuit 54 has a time constant longer than the lasting time of the reference signal outputted from the reference time setting circuit 48 and detects breaking of the line 7 in such a manner that the breaking is distinguished from temporary disconnection of the line 7.
The fire alarm system as illustrated in FIG. 24 has a signal station 6 which includes a current variation detecting circuit 45 for detecting a current change in the line 7, an integration circuit 58 for integrating the detection signal, an alarm means 59 for estimating a level of the integration value of the integration circuit 58 to alarm removal of the detector head when the level reaches a first reference value and a breaking alarm circuit 63 for estimating the level of the integration value of the integration circuit 58 to alarm breaking of the line 7 when the level reaches a second reference value. The first reference value is selected to be lower than a value obtained by integrating, for a predetermined time, the detection signal intermittently provided by periodical disconnection of the line 7, while the second reference value is selected to be lower than a value obtained by integrating, for a predetermined time, the detection signal constantly provided upon breaking of the line but higher than the first reference value. More specifically, in the fire alarm system of the present embodiment, a periodical disconnection detecting circuit 39 is formed of the current variation detecting circuit 45, the integrating circuit 58 and the removal alarm circuit 59, and a breaking detecting circuit is formed of the current variation detecting circuit 45, the integrating circuit 58 and the breaking alarm circuit 63, as in the embodiment of FIG. 18.
The breaking alarm circuit 63 includes a comparator 64 for comparing the integration value of the integration circuit 58 having the reference value, a transistor 65 which is turned on or turned off depending on an output from the comparator 64, a relay 66 adapted to be energized by the transistor 65 and an alarm means 57 adapted to be driven by the relay 66. In the comparator 64, the second reference value is preliminarily set as a value lower than a value obtained by integrating, for a predetermined time, the detection signal constantly outputted from the current variation detecting circuit 45 due to breaking of the line 7 but higher than the first reference value set in the comparator 60. The comparator 64 outputs the estimation signal when the integration value of the integration circuit 58 reaches this second reference value. This conducts the transistor 65 to energize the relay 66 and drive the alarm means 57 through make-and-break contacts 66c. At this time, the relay 66 is self-held through assistance of the contacts 66c and opens make-and-break contacts 66d to deenergize the relay 62 in the removal alarm circuit 59.
As described above, the present invention enables the detection of removal of the detector head without causing any hindrance to the succeeding fire alarm detectors and without providing any special signal line for such detection. | A fire detector and a fire alarm system wherein a plurality of fire detectors are connected across a pair of lines leading to a signal station and which is capable of detecting, at the signal station, removal of a detector head or heads from an associated socket or sockets of any one or more detectors and yet capable of keeping the succeeding fire detectors operative to send a possible fire alarm signal even after removal of the head or heads. Each of said fire detectors comprises a means for disconnecting the line connected therethrough to the succeeding detector, temporarily in the course of removal of the detector head or heads from the associated socket or sockets or periodically after the detector or detectors has or have been removed from the associated socket or sockets. The signal station comprises a means for detecting the temporary or periodical disconnection of the line. | 6 |
TECHNICAL FIELD
[0001] This invention concerns a facility for grinding inorganic matter, intended in particular to be installed in a concrete mixing plant.
BRIEF DESCRIPTION OF RELATED ART
[0002] The manufacture of concrete includes various steps, each of which consumes a significant amount of energy. These steps include, in particular, two grinding steps, one at the beginning, the other at the end of the manufacturing process. These steps are energy-intensive. The first grinding step is the grinding of the raw material, representing 20-30% of the total electrical power consumption of the manufacture of concrete. It also carries out the mixing and drying of this matter, known as raw meal, before cooking it at a temperature of approximately 1450° C. The second grinding step is carried out on the product resulting from the cooking: the clinker. It represents 30-50% of the total electrical power consumption of the manufacture of concrete, and is an essential step in the production of concrete. In fact, this is the step that, by adding gypsum and additives, determines the composition and granulometry of the final product, and thus the technical characteristics of the cement. This invention, more specifically, concerns this second grinding step, that of the clinker, but can also concern the first grinding step in which the raw meal is obtained.
[0003] In the constant desire to reduce the operating costs and environmental impact of the manufacture of concrete, the facilities used in the grinding steps, in particular that of the clinker, have developed over the past roughly twenty years. Thus, until the 1980s, this type of facility used ball mills according to a grinding method consisting of passing the matter to be ground through a horizontal rotating tube that contains metal discs. This means of grinding the matter has very low energy efficiency. Later, grinding facilities developed progressively in the direction of pressing the matter, which provides better energy efficiency. This initially took the form of using roller mills, either vertical or horizontal. The substantial increase in energy efficiency that accompanied these technologies is cancelled out by the increased complexity of the facility, and, in the case of vertical roller mills, the need to wet the matter to be ground, which entails an additional step of drying, in which a great deal of heat energy is expended.
[0004] Simultaneously, both metallurgical improvements and improved granulometric separation methods for the matter allowed for the development of roller press grinding. This type of mill, which also presses the matter, uses gravity for the intake of the matter, reduces energy consumption, and simplifies the grinding facility.
[0005] Thus, the current grinding facilities, which comprise a roller press, generally comprise a static separator, usually cascade-type, serving to remove and dry the raw material, and to break and remove the agglomerated material (or discs) resulting from press-grinding, a roller press allowing for reduction of the granulometry of the matter, and a dynamic separator to select the particles having the desired granulometry. The connection of the cascade-type static separator to the roller press in this type of facility allows for recycling of material having excessive granulometry even following a first pass through the roller press. This type of facility, though perfectly suited to ensure adequate granulometry of the final product, still consumes a substantial amount of energy, due in particular to the recycling in the roller press of low-granulometry matter which should have gone to the final product.
BRIEF SUMMARY
[0006] The disclosure provides a facility for grinding inorganic matter having a roller press, which both has the grinding and drying characteristics of the current facilities, and requires a reduced amount of energy per dedicated tonnage of inorganic matter to be processed.
[0007] To this end, the invention concerns a facility for grinding inorganic matter having a roller press, including a first static separator having an intake for raw material, comprising two outputs, the first for low-granulometry matter and the second for matter with larger granulometry, whereby the latter is connected to a roller press, and the first output of the first static separator is connected to the intake of a dynamic separator comprising two outputs, a first output for particles having the desired granulometry and the second for matter with larger granulometry, connected to the intake of the roller press, in which a ventilation circuit is provided through the first static separator and the dynamic separator in order to participate in the separation, drying, and transport of the low-granulometry particles, which facility comprises a second static separator having an intake that is solely connected to the output of the roller press, and at least one of the outputs of which, for low-granulometry particles, is connected to the dynamic separator, which first static separator is fed only with raw material and through which the ventilation circuit passes.
[0008] The use of a second static separator dedicated to the output of the roller press allows for better distribution of the load between the two static separators, with the first static separator dedicated solely to receiving the raw material. This results not only in improved drying of the raw material and the ground matter, but also in better disintegration and separation of the particles of the discs resulting from the grinding in the roller press, and thus better performance of the facility (reduced amount of low-granulometry particles returning to the press). This improvement in the performance of the press and reduction in the load borne by each separator, which results in reduced differential pressure needed by the ventilation circuit, allows for a reduction in energy consumption per ton of inorganic matter processed.
[0009] Advantageously, the facility comprises a deballasting circuit.
[0010] When the roller press is started or adjusted, such a circuit allows for deballasting of the matter that has passed through the press, and, which, due to constrains related to the roller press grinding technology, has only been very slightly ground. This reduces the load borne by the press in the essential start-up and adjustment periods, thus allowing for increased useful life of the press and the dynamic separator.
[0011] Preferably, the deballasting circuit comprises a hopper, the intake of which can be temporarily connected to the output of the roller press, and the output of which is connected to the first static separator.
[0012] Thus, upon starting the press, the matter coarsely ground by the press can be stored in the hopper and gradually reintroduced with the raw material, thus limiting the load borne by the press at start-up.
[0013] According to an alternative embodiment, the deballasting circuit comprises a hopper, the intake of which can be temporarily connected to the second output of the second static separator, that of the high-granulometry matter.
[0014] Such an alternative allows during the deballasting phase for recovery of the low-granulometry particles arising from this partial grinding, whilst ensuring that the high-granulometry matter is not reintroduced into the dynamic separator, but stored in the deballasting hopper. Once the normal operation of the press has been attained, the coarsely ground matter is reintroduced gradually with the raw material.
[0015] Advantageously, at least one of the static separators is of the cascade type.
[0016] Such separators, by design, are robust, and can process coarse material, and have high disintegration and drying capacity. This type of separator is thus ideal both for processing the raw material and carrying out an initial sorting of the material once it has been ground.
[0017] The raw feed of the first static separator comprises several hoppers, a means of weighted dosing associated with each hopper, and a means for conveying the matter into the first static separator.
[0018] Feeding the first static separator, and thus the grinding facility, in this manner allows for the desired mixture constituting the final product, i.e. the concrete or raw meal (for a facility adapted for the first grinding step of the manufacture of cement) to be determined in the grinding stage by the operation of various hoppers containing different components and using means of dosing.
[0019] Preferably, the facility comprises means for detecting metallic matter, which means cause the rejection of such matter via a reject circuit.
[0020] The existence of means for detecting metallic matter coupled with a reject circuit for such matter allows for the elimination of the risk of damage to the grinding facility, which may arise from the presence of this type of matter, thus guaranteeing better composition of the finished product.
[0021] Advantageously, the first output of the dynamic separator is connected to a filtration device that allows for separation of the low-granulometry particles from the air of the ventilation circuit, and the filtration device is connected to a system for transporting the granular product.
[0022] The use of such a filtration device coupled with a transportation system allow for recovery of particles having the desired granulometry and the transportation of these particles to a storage area, or directly to the conditioning step for the final product.
[0023] Preferably, the intake of the roller press is equipped with a feed hopper.
[0024] This hopper ensures both continuous supply and control of the quantity of the matter fed into the press.
[0025] Advantageously, the second static separator comprises two outputs, one for the low-granulometry particles and one for the high-granulometry matter, the output for high-granulometry matter being connected to the dynamic separator.
[0026] Such a coupling allows for the dynamic separator to be supplied with the ground matter that has already passed through the second static separator, and has thus been acceptably disintegrated. This sequence ensures good separation of low-granulometry particles and high-granulometry matter, and thus allows for the press to be supplied with a reduced amount of matter with high granulometry (fewer low-granulometry particles in the matter reintroduced into the press), thus reducing the load on the press, which allows for an increased raw material load. This results in a significant increase in the performance of the facility as a whole for an equivalent quantity of energy. In fact, the performance to be applied for the separation of the pressed matter is that of the dynamic separator (85-90%) and not that of the first static separator (40-50%).
[0027] According to an alternative embodiment, the second static separator comprises two outputs, one for low-granulometry particles and one for the high-granulometry matter, the output for high-granulometry matter being connected to the intake of the first static separator.
[0028] Such a coupling of the second output of the second static separator with the intake of the first separator allows for the ground matter to pass through two separators, and thus for an optimization of the disintegration of the discs arising from the grinding, and optimal recovery of low-granulometry particles after each grinding.
[0029] According to another embodiment, the second static separator comprises two outputs, one for low-granulometry particles and one for the high-granulometry matter, the output for high-granulometry matter being directly connected to the roller press.
[0030] Advantageously, at least one intake and/or output of at least one separator is equipped with sealing.
[0031] Such a sealing allows for limitation of “false air” that may arise at the level of the separators.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The invention will be better understood using the following description, which refers to the attached schematic, showing three exemplary embodiments of this facility for grinding inorganic matter.
[0033] FIG. 1 is a schematic representation of a known-art grinding facility;
[0034] FIG. 2 is a schematic representation of a first embodiment of a grinding facility according to the invention;
[0035] FIG. 3 is a schematic representation of a second embodiment of a grinding facility according to the invention;
DETAILED DESCRIPTION
[0036] FIG. 1 shows a facility for grinding inorganic raw material having a roller press according to the state of the art.
[0037] Such a facility comprises a means of supplying raw material 1 , means of detecting metallic matter 2 , coupled with a reject circuit 3 , a static separator 4 , a roller press 5 , a dynamic separator 6 , a ventilation circuit 7 , and a circulation circuit 8 for the finished product.
[0038] During operation, the inorganic matter, e.g., clinker, gypsum, and additives such as blast furnace slag or ash, is injected into the circuit of the facility. This is carried out by means of several hoppers 9 , each containing one of the components necessary for the manufacture of the concrete. Each hopper is associated with a weighted dosing means 10 so as to obtain a mixture having the given composition, e.g., for CEMI concrete, 95% clinker and 5% gypsum, when the various components are introduced into the circuit of the facility.
[0039] This raw material is then transported by a conveyor 11 such as a conveyor belt, a bucket elevator, or a chain conveyor. This conveyor, in the schematic representation of FIG. 1 , is a conveyor belt 11 . During this transport, the raw material passes through a metallic particle detection system 2 , which redirects the matter to a reject circuit 3 if the raw material contains such particles. The reject circuit 3 , following a filtration procedure to selectively recover the metallic particles in a reject hopper 12 , allows the sorted raw material to be redirected to the conveyor 11 , which transports it, with the rest of the raw material, to the intake 13 of a static separator 4 .
[0040] This static separator 4 , usually of cascade type, is connected to the ventilation circuit 7 . This circuit 7 , either open or recirculating, allows for adjustment of the temperature of the air passing through this circuit. This adjustment is made by combining an air heater such as a hot gas generator or the heat connected to the equipment of the concrete factory such as the exhaust gases of a kiln or a cooler, and means of cooling such as the injection of outside air. Thus, according to the mode of operation of the cascade separator, i.e., the matter falling, cascade-fashion, onto several inclined walls around which the air flow of the ventilation circuit 7 circulates, the material is disintegrated by means of the collision with the inclined walls, and the low-granulometry particles that detach themselves are carried off by the air flow. The low-granulometry particles are directed by the air flow to a first output 14 of the cascade separator 4 , whilst the rest of the matter is directed to the second output 15 , connected to a feed hopper 16 for the roller press 5 . The passage of the high-granulometry matter through this hopper 16 allows for the supply to the roller press 5 to be regulated. The high-granulometry matter is then ground by the roller press 5 , and exits in a mixture of fine particles and discs of agglomerated matter. The matter thus ground is then reintroduced by means of the conveyor 18 , generally a bucket elevator, into the static separator 4 at the output 17 of the press 5 .
[0041] During this second passage, the discs, mixed with the raw material, are disintegrated, allowing for partial release of the low-granulometry particles, which are transported by the air flow to the first output 14 of the static separator 4 . This first output 14 is connected to the intake 19 of a second, dynamic, separator 6 . This separator 6 , which is preferably a third-generation vertical-axle squirrel cage, allows for the selection of the particles having the required size, which are carried by the air flow to a first output 20 . The rest of the matter is sent through a second output 21 and a conveyor 22 , generally a conveyor belt, to the feed hopper 16 of the press 5 reduce its granulometry. The particles selected, which thus pass through the first output of the dynamic separator, are transported by the ventilation circuit 7 to a filtration device 23 , which allows for collection of the finished product having the required composition and granulometry. This product is then transported by a transportation system 24 for granular products, such as an air chute 24 , to be stored in storage silos before being packaged for sale or sent to the kiln following homogenization (for a facility adapted to obtain raw meal).
[0042] FIG. 2 shows a first embodiment of a grinding facility according to the invention. Such a grinding facility differs from a prior-art facility in that the output of the press can be connected by a conveyor system 25 either to a deballasting circuit 26 , or to a second static separator 27 , also of cascade type, having two outputs 28 , 29 connected to the dynamic separator 6 .
[0043] Thus, when the facility is started up, the feed hoppers 9 supply the facility with inorganic matter. As with the facility shown in FIG. 1 , this raw material is sent by a conveyor system 11 to the first cascade separator 4 , which carries out a first sorting of the raw material; the high-granulometry matter is sent to the press 5 through the intake hopper 16 of the press 5 . When the press 5 is started up or being adjusted, the raw material, upon passing through the roller press 5 , is only slightly ground. Thus, in order not to overload the press 5 , the raw material, with this very slightly ground matter, is transported by the conveyor 25 to a deballasting circuit 26 comprising a deballasting hopper 30 and a means of weighted dosing 31 connected to the first cascade separator 4 . The matter is then stored in the deballasting hopper 30 whilst the roller press 5 is reaching its specific rated grinding power value, e.g., a value on the order of 2 kWh/t. Once this level has been attained, the slightly ground matter stored in the deballasting hopper 30 is gradually mixed with the raw material via the first static separator 4 . It thus passes again through the roller press 5 to be properly ground.
[0044] The mixture of raw material and partially ground matter, after passing through the roller press 5 , is then sent in a steady state of operation to the second static separator 27 . This second separator 27 , in the case of this properly ground matter, allows both for disintegration and drying of the discs formed during the grinding by the roller press 5 . The matter thus obtained, a mixture of coarse matter and fine particles, is sent through the two outputs 28 , 29 of the second separator to the dynamic separator 6 . The low-granulometry particles having been separate from the rest of the matter, the separator 6 , due to its high selectivity, carries out a selective sorting, as a result of which the fine particles having the desired granulometry exit through a first output 20 , and the higher-granulometry matter exists through a second output 21 . The latter matter is sent back to the press 5 for another grinding, disintegration, and sorting cycle, until the desired granulometry is achieved. Particles having the desired granulometry, i.e., of a size lower than a few microns, are transported by the ventilation circuit 7 from the first output 20 of the dynamic separator 6 to a filtration device 23 . This filtration device allows for the finished product with the required composition and granulometry to be collected. This product is then transported by a transportation system 24 for granular products, such as an air chute 24 , to be stored in storage silos before being packaged for sale or sent to the kiln following homogenization (for a facility adapted to obtain raw meal).
[0045] A facility for grinding inorganic matter according to this embodiment, by increasing the amount of low-granulometry matter recovered after each grinding and thus increasing the performance of the entire facility, allows for a reduction in consumption per ton of ground matter of more than 16%, and a reduction by half of the capacity of the feed hopper 16 , as well as the transport system 25 .
[0046] FIG. 3 shows a second embodiment of a grinding facility according to the invention. Such a grinding facility differs from the first embodiment in that an output 29 of the second static separator 27 , the high-granulometry matter output, is connected to a conveyor 32 to the feed hopper 16 of the roller press 5 .
[0047] During operation, the feed circuit 9 , 10 , 11 , 13 of the press and the deballasting circuit 25 , 26 operate identically to the first embodiment. The change related to this second embodiment only occurs after the material has passed through the second, static, separator 27 . When it does so, the high-granulometry matter, which passes through the second output 29 of the second static separator 27 , is not sent to the dynamic separator 6 , but directly to the feed hopper 16 of the press 5 , by means of a conveyor 32 . Thus, the matter rich in course materials is ground again in order to reduce its granulometry, whilst only the low-granulometry particles originating from the first outputs 24 , 28 of the two static separators 4 , 27 pass through the dynamic separator 6 . The particles selected, as in the first embodiment, are transported by the ventilation circuit 7 to a filtration device 23 , which allows for collection of the finished product having the required composition and granulometry. This product is then transported by a transportation system 24 for granular products, such as an air chute 24 , to be stored in storage silos before being packaged for sale or sent to the kiln following homogenization (for a facility adapted to obtain raw meal).
[0048] A third embodiment, not shown here, comprises, for a facility similar to the first embodiment, of connecting the second output 29 of the second cascade separator 27 , corresponding to the high-granulometry matter, to the conveyor 11 supplying the facility. This allows the ground matter to pass through two static separators 2 , 27 , thus, allowing for optimal recovery of the low-granulometry particles at each grinding by means of optimizing the disintegration of the discs arising from the grinding.
[0049] In the three embodiments shown, the deballasting circuit 26 is connected to the output of the press 17 during the deballasting phase. A possible alternative is to supply the deballasting circuit 26 during this deballasting phase from the second output 29 of the second static separator 27 , which output 29 corresponds to the high-granulometry matter. In this configuration, the output 17 of the roller press 5 is directly connected, as during steady-state operation, to the intake of the second static separator 27 . During this deballasting phase, this alternative allows for recovery of the low-granulometry particles arising from the partial grinding despite the low performance of the press 5 .
[0050] In any embodiment of the invention, as shown by FIGS. 2 and 3 , sealings 33 can be placed on the intakes 13 , 34 , 29 for matter and the outputs 15 , 29 , 21 for high-granulometry particles of the various separators 4 , 27 , 6 . For example, the second separator has a sealing 33 on its intake 34 . These sealings 33 are installed in order to limit the “false air” that may enter at the level of these separators ( 4 , 27 , 6 ).
[0051] Obviously, the invention is not limited to these embodiments of the grinding facility for inorganic matter described above by way of example; rather, it encompasses all possible embodiments. In particular, it can be adapted to be used to grind the raw material before cooking. | The invention relates to a facility for grinding inorganic material comprising: a means ( 1 ) for supplying raw material; a means ( 2 ) for detecting metal material coupled to a discharge circuit ( 3 ); a first static separator ( 4 ); a roller press ( 5 ); a dynamic separator ( 6 ); a ventilation circuit ( 7 ); and a circuit ( 8 ) for circulating the finished product. The press is connectable by means of a conveyance system ( 25 ) having a diverting circuit ( 26 ) or a second static separator ( 27 ), at least one of the outlets ( 28 ) of which is connected to the dynamic separator ( 6 ). | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/368,295, filed Mar. 28, 2002, which application is incorporated herewith in its entirety.
TECHNICAL FIELD
The present invention relates to methods of synthesizing heteroatom-substituted porphyrins, and further relates to novel heteroatom-substituted porphyrins.
Abbreviations
Ac
acetyl
Bu
butyl
calc'd
calculated
dba
dibenzylidieneacetone
DPEphos
bis(2-diphenylphosphinophenyl)
ether
DMSO
dimethyl sulfoxide
Et
ethyl
KOBut
potassium butoxide
Me
methyl
OTf
trifluoromethanesulfonate
Ph
phenyl
Pr
propyl
rt
room temperature
TFA
trifluoroacetate
THF
tetrahydrofuran
TLC
thin layer chromatography
vis
visible
BACKGROUND ART
Synthetic porphyrins and metalloporphyrins have become increasingly important in numerous and diverse technical fields. Their several practical applications include their use as sensitizers in photodynamic therapy (PDT) (Mody, (2000) J. Porphyrins Phthalocyanines 4: 362); in electron transfer (Lippard and Berg, (1994) Principles of Bioinorganic Chemistry , University Science Book: Mill Valley, Calif.); in DNA strand cleavage (Bennett et al., (2000) Proc. Natl. Acad. Sci . 97: 9476; Hashimoto et al., (1983) Tetrahedron letters , 24: 1523); as carriers of cytotoxic anticancer drugs such as platinum (Song et al., (2002) Inorganic Biochemistry 83: 83; and Lottner et al. (2002) J. Med. Chem ., 45, 2064); as components of synthetic receptors (Jain and Hamilton, (2002) Org. Lett . 2: 1721); and as oxidation catalysts (Guo et al. (2001) J. Mol. Catal. A Chem . 170: 43). Additionally, functionalized porphyrins have become important leads in current drug discovery techniques (See Mody, supra, and Priola et al., (2002) Science 287: 1503). Accordingly, the development of new methodologies and strategies to improve the synthesis of functionalized porphyrins has become highly desirable.
Numerous methods for the synthesis of porphyrins are known. The classical methods for porphyrin synthesis typically require harsh reaction conditions and can provide disappointingly low yields (Rothemund, (1935) J. Am. Chem. Soc ., 57: 2010; Adler et al., (1967) J. Org. Chem . 32: 476). Newer methodologies, such as those developed by Lindsey and colleagues, have resolved certain issues regarding reaction conditions and yields (Lindsey et al., (1987) J. Org. Chem . 52: 827). More recently, transition metal-catalyzed organic synthesis methodologies (e.g., Suzuki coupling and Heck-type coupling), have been successfully employed with porphyrin systems, providing versatile and general synthetic approaches for the preparation of a variety of functionalized porphyrins and porphyrin analogs. See, e.g., DiMagno et al., (1993) J. Org. Chem ., 58: 5983; DiMagno, et al. (1993) J. Org. Chem . 115: 2513; Chan, et al., (1995) Tetrahedron 51: 3129; Zhou et al., (1996) J. Org. Chem . 61: 3590; Risch and Rainer, (1997) Tetrahedron Letters 38: 223; Hyslop et al., (1998) Am. Chem. Soc . 120: 12676; Boyle and Shi, (2002) J. Chem. Soc. Pekin Trans ., 1: 1397; and Pereira, et al., (2002) J. Chem. Soc. Pekin Trans ., 2: 1583. See also, Suzuki, (1998) Metal - Catalyzed Cross - Coupling Reactions , pp. 49-97, Wiley-VCH, Weinheim, Germany; U.S. Pat. No. 5,550,236 and U.S. Pat. No. 5,756,804, which references are incorporated herein by reference.
However, each of these foregoing methods possesses undesirable aspects that should be mitigated, including incompatibilities between catalysts and reaction compounds, low turnover number (TON) and low turnover frequency (TOF). Thus, despite recent advances in porphyrin chemistry, a need still exists for facile and general syntheses for, in particular, heteroatom-substituted porphyrins and metalloporphyrins.
SUMMARY OF THE INVENTION
Novel heteroatom-substituted porphyrin compounds are one aspect of the present invention. Novel compounds of the present invention have the structure of Formula I, as follows:
In Formula I, M is H 2 or a transition metal; each R 1 , R 2 , R 3 , R 4 , R 5 and R 6 are each independently selected from the group consisting of Y, H, alkyl, substituted alkyl, arylalkyl, aryl, and substituted aryl; Y is a heteroatom-containing moiety; and at least one of R 1 , R 2 , R 3 , R 4 , R 5 and R 6 is Y. In one preferred embodiment of the invention, M is selected from the group consisting of H 2 , Fe, Zn and Ni, although numerous other transition metals are useful in the invention. In one embodiment of the invention, Y is a heteroatom-containing moiety selected from the group consisting of NR 7 R 8 , NR 10 , OR 10 , PR 7 R 8 , SR 10 , SiR 7 R 8 R 9 , BR 7 R 8 , GeR 7 R 8 R 9 , SnR 7 R 8 R 9 and SeR 10 , wherein R 7 , R 8 , R 9 , and R 10 are each independently selected from the group consisting of H, alkyl, substituted alkyl, arylalkyl, aryl, and substituted aryl. In another embodiment of the invention, Y is a selected from the group consisting of amino, substituted amino, imino, substituted imino, and phenoxy groups.
Another aspect of the present invention is a method of synthesizing a heteroatom-substituted porphyrin compound, whereby a porphyrin precursor and a heteroatom reagent is reacted in the presence of a ligand, a metal compound, and a base in order to yield the substituted porphyrin. In one embodiment of the invention, the porphyrin precursor has the same general structure of Formula I, wherein M is H 2 or a transition metal; each R 1 , R 2 , R 3 , R 4 , R 5 and R 6 are each independently selected from the group consisting of X, H, alkyl, substituted alkyls, arylalkyls, aryls, and substituted aryls, and X is selected from the group consisting of halogen, trifluoromethanesulfonate (OTf), haloaryl and haloalkyl. In this embodiment of the invention, at least one of R 1 , R 2 , R 3 , R 4 , R 5 and R 6 is X. In a preferred embodiment, M is selected from the group consisting of H 2 , Zn, Fe and Ni. Preferred heteroatom reagents comprise moieties in which the heteroatom is selected from the group consisting of N, O, P, S, Si, B, Ge, Sn, and Se, with N and O being particularly preferred.
Accordingly, it is an object of the present invention to provide a novel heteroatom-substituted porphyrin compound and a novel method of synthesizing a heteroatom-substituted porphyrin compound. This object is achieved in whole or in part by the present invention.
Some of the objects and aspects of the invention having been stated herein above, other objects will be evident as the description proceeds, when taken in connection with the accompanying examples, drawings, and descriptions set forth hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates several schemes by which heteroatom substituents (e.g., nitrogen, oxygen, etc.) may be substituted into porphyrins by metal/ligand-catalyzed cross-coupling or amination reactions. In FIG. 1 , “M” represents H 2 , or a transition metal; “X” represents a reactive group such as, for example a halide, trifluoromethanesulfonate (OTf), haloalkyl or haloaryl; and “Y” is heteroatom moiety such as, for example, NR 7 R 8 , NR 10 , OR 10 , PR 7 R 8 , SR 10 , SiR 7 R 8 R 9 , BR 7 R 8 , GeR 7 R 8 R 9 , SnR 7 R 8 R 9 and SeR 10 , where R 7 , R 8 , R 9 , and R 10 are each independently, for example, H, alkyl, substituted alkyl, arylalkyl, aryl, or substituted aryl.
FIG. 2 illustrates the chemical structures of eleven compounds that are representative, although not inclusive, of phosphine ligands useful in the present invention.
FIGS. 3A and 3B are schemes of particular embodiments of the present invention. FIG. 3A shows two generalized schemes of palladium-catalyzed amination reactions of meso-monobromoporphyrins (left-hand scheme) and meso-dibromoporphyrins (right-hand scheme). FIG. 3B shows the same two amination reactions with specific reaction components and conditions indicated. In FIG. 3B , the upper reaction scheme represents the amination of a meso-monobromoporphyrin, while the lower scheme represents the amination of a meso-dibromoporphyrin.
FIG. 4 illustrates the chemical structures of several compounds of the present invention, which compounds are synthesized by methods of the present invention. The compound numbers shown in FIG. 4 (e.g., 3a, 3b, 4a, 4b, etc.) correspond to the compound numbers indicated in Table 1, below.
FIGS. 5A-5D are schemes of particular embodiments of the present invention. FIG. 5A is a general scheme of the synthesis of aminophenylporphyrins by a palladium-catalyzed amination reaction of p-bromophenyl porphyrin and its zinc complex. FIG. 5B illustrates a particular embodiment of the general scheme of FIG. 5A , wherein specific reaction conditions and components are indicated. FIG. 5C illustrates yet another particular embodiment of the general reaction shown in FIG. 5A , wherein specific reaction conditions and components are indicated. FIG. 5D illustrates a generalized scheme of a palladium-catalyzed reaction of a tetrakis-p-bromophenyl porphyrin that yields a tetrakis-aminophenyl porphyrin.
FIG. 6 illustrates a general reaction scheme whereby [5-bromo-10,20-diphenylporphyrino]zinc(II) (indicated in the Figure as compound 1) and [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) (indicated in the Figure as Compound 2) undergo a palladium-catalyzed cross-coupling reaction to yield the corresponding meso-substituted phenoxyporphyrins (indicated in the Figure as compounds 3 and 4, respectively).
FIG. 7 shows the chemical structures of several heteroatom-substituted phenoxyporphyrin compounds of the present invention, which compounds are synthesized via the methods described herein.
DETAILED DESCRIPTION OF THE INVENTION
Throughout the specification and claims, a given chemical formula or name shall encompass all stereoisomers.
The term “independently selected” is used herein to indicate that the R groups, e.g., R 1 , R 2 , R 3 or R 4 , can be identical or different (e.g., R 1 , R 2 and R 3 may all be substituted alkyls, or R 1 and R 4 may be a substituted alkyl and R 3 may be an aryl, etc.). Moreover, “independently selected” means that in a multiplicity of R groups with the same name, each group may be identical to or different from each other (e.g., one R 1 may be an alkyl, while another R 1 group in the same compound may be aryl; one R 2 group may be H, while another R 2 group in the same compound may be alkyl, etc.).
A named R group will generally have the structure that is recognized in the art as corresponding to R groups having that name. For the purposes of illustration, representative R groups as enumerated above are defined herein. These definitions are intended to supplement and illustrate, not preclude, the definitions known to those of skill in the art.
As used herein, the term “alkyl” means C 1-20 inclusive, linear, branched, or cyclic, saturated or unsaturated (i.e., alkenyl and alkynyl) hydrocarbon chains, including for example, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, pentyl, hexyl, octyl, ethenyl, propenyl, butenyl, pentenyl, hexenyl, octenyl, butadienyl, propynyl, butynyl, pentynyl, hexynyl, heptynyl, and allenyl groups.
The alkyl group can be optionally substituted with one or more alkyl group substituents which can be the same or different, where “alkyl group substituent” includes alkyl, halo, arylamino, acyl, hydroxy, aryloxy, alkoxyl, alkylthio, arylthio, aralkyloxy, aralkylthio, carboxy, alkoxycarbonyl, oxo and cycloalkyl. Suitable substituted alkyls include, for example, benzyl, trifluoromethyl and the like. There can be optionally inserted along the alkyl chain one or more oxygen, sulfur or substituted or unsubstituted nitrogen atoms, wherein the nitrogen substituent is hydrogen, alkyl (also referred to herein as “alkylaminoalkyl”), or aryl. “Branched” refers to an alkyl group in which an alkyl group, such as methyl, ethyl or propyl, is attached to a linear alkyl chain.
The term “aryl” is used herein to refer to an aromatic substituent which may be a single aromatic ring or multiple aromatic rings which are fused together, linked covalently, or linked to a common group such as a methylene or ethylene moiety. The common linking group may also be a carbonyl as in benzophenone or oxygen as in diphenylether or nitrogen in diphenylamine. The aromatic ring(s) may include phenyl, naphthyl, biphenyl, diphenylether, diphenylamine and benzophenone among others. In particular embodiments, the term “aryl” means a cyclic aromatic comprising about 5 to about 10 carbon atoms, including 5 and 6-membered hydrocarbon and heterocyclic aromatic rings.
The aryl group can be optionally substituted with one or more aryl group substituents which can be the same or different, where “aryl group substituent” includes alkyl, aryl, aralkyl, hydroxy, alkoxyl, aryloxy, aralkoxyl, carboxy, acyl, halo, nitro, alkoxycarbonyl, aryloxycarbonyl, aralkoxycarbonyl, acyloxyl, acylamino, aroylamino, carbamoyl, alkylcarbamoyl, dialkylcarbamoyl, arylthio, alkylthio, alkylene and —NR′R″, where R′ and R″ can be each independently hydrogen, alkyl, aryl and aralkyl.
Specific examples of aryl groups include but are not limited to cyclopentadienyl, phenyl, furan, thiophene, pyrrole, pyran, pyridine, imidazole, isothiazole, isoxazole, pyrazole, pyrazine, pyrimidine, and the like.
The term “alkoxy” is used herein to refer to the —OZ 1 radical, where Z 1 is selected from the group consisting of alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, silyl groups and combinations thereof as described herein. Suitable alkoxy radicals include, for example, methoxy, ethoxy, benzyloxy, t-butoxy, etc. A related term is “aryloxy” where Z 1 is selected from the group consisting of aryl, substituted aryl, heteroaryl, substituted heteroaryl, and combinations thereof. Examples of suitable aryloxy radicals include phenoxy, substituted phenoxy, 2-pyridinoxy, 8-quinalinoxy and the like.
The term “amino” is used herein to refer to the group —NZ 1 Z 2 , where each of Z 1 and Z 2 is independently selected from the group consisting of hydrogen; alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl and combinations thereof. Additionally, the amino group may be represented as N + Z 1 Z 2 Z 3 , with the previous definitions applying and Z 3 being either H or alkyl.
A “heteroatom,” as used herein, is an atom other than carbon. Preferred heteroatoms are heteroatoms selected from the group consisting of N, O, P, S, Si, B, Ge, Sn, and Se. In the present invention, the heteroatoms N and O are particularly preferred. “Halide” or “halo” is defined as being selected from the group consisting of Br, Cl, I and F. In the present invention, the halo groups Br and I are particularly preferred.
Heteroatom-substituted porphyrins of the present invention are synthesized by reacting a porphyrin precursor and a heteroatom reagent in the presence of a metal compound, ligand and a base. Although applicants do not wish to be bound to any particular theory of the invention, it appears that the metal and ligand together (e.g., as a metal-ligand complex, or metal/ligand composition) function as a catalyst for the reaction, by which a heteroatom-substituted porphyrin is produced.
Depending on the heteroatom reagent, reactions of the present invention may be, for example, cross-coupling reactions, amination reactions, or arylamination reactions. For example, in one embodiment, the metal compound and ligand together (in the configuration of a metal complex) catalyze the cross coupling reaction between the porphyrin precursor and the heteroatom reagent to yield the heteroatom-substituted porphyrin. Representative methods of the present invention are generally illustrated in the several schemes shown in FIG. 1 .
Porphyrin precursors of the present invention have the structure of Formula I:
wherein:
M is H 2 or a transitional metal; each R 1 , R 2 , R 3 , R 4 , R 5 and R 6 are each independently selected from the group consisting of X, H, alkyl, substituted alkyls, arylalkyls, aryls and substituted aryls; X is selected from the group consisting of halogen, trifluoromethanesulfonate (OTf), haloaryl and haloalkyl, and at least one of R 1 , R 2 , R 3 , R 4 , R 5 and R 6 is X.
Transitional metals of the present invention include any of the 30 metals in the 3d, 4d and 5d transition metal series of the Periodic Table of the Elements, including the 3d series that includes Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, and Zn; the 4d series that includes Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag and Cd; and the 5d series that includes Lu, Hf, Ta, W, Re, Os, Ir, Pt, Au and Hg. In a preferred embodiment, M is H 2 or a transition metal from the 3d series. In a particularly preferred embodiment, M is selected from the group consisting of H 2 , Zn, Fe, and Ni. In an even more preferred embodiment, M is selected from the group consisting of H 2 and Zn.
In a preferred embodiment, the porphyrin precursor compound is halogenated, that is, at least one of R 1 , R 2 , R 3 , R 4 , R 5 and R 6 is halogen. In a more preferred embodiment, at least one meso-position of the porphyrin precursor compound is halogenated. In another preferred embodiment, more than one meso-position of the porphyrin precursor compound is halogenated. When a porphyrin precursor compound of the present invention is halogenated, one preferred halogen group is Br, although other halogen groups are also useful in the practice of the invention.
In a preferred embodiment of the invention, the heteroatom reagent has the chemical structure Y—H, where Y is heteroatom-containing moiety comprising at least one of N, O, P, S, Si, B, Ge, Sn, and Se. Exemplary heteroatom-containing moieties include, but are not limited to, NR 7 R 8 , NR 10 , OR 10 , PR 7 R 8 , SR 10 , SiR 7 R 8 R 9 , BR 7 R 8 , GeR 7 R 8 R 9 , SnR 7 R 8 R 9 and SeR 10 , wherein R 7 , R 8 , R 9 , and R 10 are each independently selected from the group consisting of H, alkyl, substituted alkyl, arylalkyl, aryl, and substituted aryl. In a preferred embodiment, the heteroatom-containing moiety comprises one of N or O.
In one preferred embodiment, the heteroatom reagent comprises at least one amino group. Suitable amino groups include, but are not limited to, primary amines, secondary amines, anilines, substituted aniline derivatives, aromatic amines, primary aliphatic amines, secondary aliphatic amines and cycloaliphatic amines. Specific amino groups useful in the present invention include, but are not limited to, aniline, 4-nitroaniline, N-methylaniline, 4-trifluoromethylaniline, p-anisidine, 3,5-di-tert-butylaniline, n-hexylamine, benzylamine, diphenylamine, n-butylamine, 4-aminomethylpyridine, and o-toluidine. In an alternative preferred embodiment, the heteroatom reagent comprises an imino group. Suitable imino groups include but are not limited to benzophenone imino groups.
In yet another preferred embodiment, the heteroatom reagent comprises an aryl or aryl halide group, which groups are sometimes referred to herein as phenol or substituted phenol groups. Suitable aryl groups include phenol, 4-methoxyphenol, 4-t-butylphenol, 4-fluorophenol, 2-isopropylphenol, 3-cresol, 4-cresol, and 4-methoxyphenol.
Reactions of the present invention involve a catalyst, which catalyst generally has the form of a metal complex. The metal complex comprises a metal compound of the present invention complexed with a ligand, preferably a phosphine ligand, of the present invention. Metal compounds of the present invention may optionally be provided as metal precursors. Thus, as used herein, a “metal compound” may also be referred to as a “metal precursor,” a “metal precursor compound,” a “metal salt,” or a “metal ion.”
The metal precursor compounds may be characterized by the general formula M′(L) n (also referred to as M′L n or M′—L n ) where M′ is a metal selected from the group consisting of Groups 5, 6, 7, 8, 9 and 10 of the Periodic Table of Elements, L is independently each occurrence, a neutral or charged ligand, and n is a number 0, 1, 2, 3, 4, or 5, depending on M′. In more specific embodiments, M′ is selected from the group consisting of Ni, Pd, Fe, Pt, Ru, Rh, Co and Ir. In preferred embodiments, M′ is selected from the group consisting of Pd, Ni, Cu or Pt; in a more preferred embodiment, M′ is Pd. L is a compound chosen from the group consisting of halide, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, hydroxy, boryl, silyl, hydrido, thio, seleno, phosphino, amino, and combinations thereof. When L is charged, L is selected from the group consisting of hydrogen, halogens, alkyl, substituted alkyl, cycloalkyl, substituted cycloalkyl, heteroalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, boryl, phosphino, amino, thio, seleno, and combinations thereof. When L is neutral, L may be selected from the group consisting of carbon monoxide, isocyanide, nitrous oxide, PA 3 , NA 3 , OA 2 , SA 2 , SeA 2 , and combinations thereof, wherein each A is independently selected from a group consisting of alkyl, substituted alkyl, heteroalkyl, cycloalkyl, substituted cycloalkyl, heterocycloalkyl, substituted heterocycloalkyl, aryl, substituted aryl, heteroaryl, substituted heteroaryl, alkoxy, aryloxy, silyl, and amino.
Specific examples of suitable metal precursor compounds include Pd(dba) 2 , Pd 2 (dba) 3 , Pd(OAc) 2 , PdCl 2 , Pd(TFA) 2 , (CH 3 CN) 2 PdCl 2 , and the like. Particularly preferred metal precursor compounds of the present invention include Pd(OAc) 2 and Pd 2 (dba) 3 , where “Ac” means acetyl and. “dba” means dibenzylidieneacetone.
In the practice of the present invention, ligands of the invention may be combined with such a metal compound in order to provide a catalyst for the heteroatom-substitution reaction. For example, the ligand may be added to a reaction vessel at the same time as metal precursor compound along with the reactants. In other applications, the ligand will be mixed with a suitable metal precursor compound prior to or simultaneous with allowing the mixture to be contacted to the reactants. When the ligand is mixed with the metal precursor compound, a metal-ligand complex may be formed, which may be a catalyst.
Generally, the ligands useful in this invention may be purchased or prepared by methods known to those of skill in the art. The ligand is preferably a phosphine ligand. Suitable phosphine ligand-metal complexes are disclosed in U.S. Pat. No. 6,268,513 to Guram et al., which patent is incorporated herein. Phosphine ligands may comprise dicycloalkylphenyl phosphine ligand or dialkylphenyl phosphine ligand, which may be in the form of a metal-ligand complex or a metal precursor/ligand composition. In an alternative embodiment, the phosphine ligands useful in this invention comprises a cyclopentadienyl ring. Specific ligands that are useful in the practice of the present invention include, but are not limited to, those whose structures are shown in FIG. 2 . Particularly preferred ligands include DPEphos ( FIG. 2 , Ligand 6), BINAP ( FIG. 2 , Ligand 9) and 2-(Di-t-butylphosphino)-1,1-binaphthyl ( FIG. 2 , Ligand 8).
To carry out the process of this invention for one type of reaction, the porphyrin precursor, the heteroatom reagent, a base, a catalytic amount of metal precursor compound and a catalytic amount of the ligand are added to an inert solvent or inert solvent mixture. In a batch methodology, this mixture is stirred at a temperature of from 0° C. to 200° C., preferably at from 30° C. to 170° C., particularly preferably at from 50° C. to 150° C., and more particularly preferably at from 60° C. to 120° C., with 68° C. being most particularly preferred. The mixture is stirred for a period of from 5 minutes to 100 hours, preferably from 15 minutes to 70 hours, particularly preferably from ½ hour to 50 hours, most particularly preferably from 1 hour to 30 hours. After the reaction is complete, the catalyst may be obtained as solid and separated off by filtration. The crude product is freed of the solvent or the solvents and is subsequently purified by methods known to those skilled in the art and matched to the respective product, e.g. by recrystallization, distillation, sublimation, zone melting, melt crystallization or chromatography.
Solvents suitable for the process of the invention are, for example, ethers (e.g., diethyl ether, dimethoxymethane, diethylene glycol, dimethyl ether, tetrahydrofuran (THF), dioxane, diisopropyl ether, tert-butyl methyl ether), hydrocarbons (e.g., hexane, iso-hexane, heptane, cyclohexane, benzene, toluene, xylene), alcohols (e.g., methanol, ethanol, 1-propanol, 2-propanol, ethylene glycol, 1-butanol, 2-butanol, tert-butanol), ketones (e.g., acetone, ethyl methyl ketone, iso-butyl methyl ketone), amides (e.g., dimethylformamide, dimethylacetamide, N-methylpyrrolidone), nitriles (e.g., acetonitrile, propionitrile, butyronitrile), water and mixtures thereof. Particularly preferred solvents are ethers (e.g., dimethoxyethane, THF), and hydrocarbons (e.g., cyclohexane, benzene, toluene, xylene). Most particularly preferred are toluene and THF.
Bases which are useful in the process of the invention are alkali metal and alkaline earth metal hydroxides, alkali metal and alkaline earth metal carbonates, alkali metal hydrogen carbonates, alkali metal and alkaline earth metal acetates, alkali metal and alkaline earth metal alkoxides, alkali metal and alkaline earth metal phosphates, primary, secondary and tertiary amines, alkali metal and alkaline earth fluorides, and ammonium fluorides. Preferred bases include but are not limited to n-BuLi, LDA, NaNH 2 , NaOH, Et 3 N, NaOAc, KOt-Bu, NaOt-Bu, Cs 2 CO 3 , K 2 CO 3 , K 3 PO 4 , carbonate-containing compounds, and phosphate-containing compounds. Particularly preferred bases include, but are not limited to, Cs 2 CO 3 and NaOt-Bu. The base is preferably used in the process of the invention in an amount of from about 0.1 to about 100 equivalents, particularly preferably from about 0.5 to about 50 equivalents, very particularly preferably from about 1.0 to about 10 equivalents, and most particularly from about 1.0 to about 1.5 equivalents.
The metal precursor compound used in this reaction is as described above and may be added to the process along with the other reactants. The metal portion of the catalyst (i.e., the metal precursor compound) is used in the process of this invention in a proportion of from about 0.01 to about 100 mol %, preferably from about 0.1 to about 50 mol %, particularly preferably from about 0.5 to about 10 mol %, and most particularly preferably from about 1 to about 5 mol %. The ligand component of the catalyst, which may or may not be complexed to the metal precursor compound, is used in the reaction in a proportion of from about 0.01 to about 100 mol %, preferably from 0.1 to about 50 mol %, particularly preferably from about 0.5 to about 10 mol %, and most particularly preferably from about 1 to about 5 mol %. These amounts may be combined to give metal precursor to ligand ratios useful in the process. It is also possible, if desired, to use mixtures of two or more different ligands.
In preferred embodiments of the invention, at least one meso-position of the synthesized heteroatom-substituted porphyrin is substituted; that is, the heteroatom-substituted porphyrin is a meso-substituted porphyrin. In one embodiment of the invention, amino-substituted porphyrins are obtained from halogenated porphyrin precursors via palladium-catalyzed amination. Specifically, meso-arylamino- and alkylamino-substituted porphyrins are efficiently synthesized by reacting meso-halogenated porphyrins with amines via palladium-catalyzed amination. A general schematic of this embodiment is illustrated in FIG. 3 A. FIG. 3B illustrates two particular embodiments of the invention. In the schematic on the left side of the figure, the porphyrin precursors 5-bromo-10,20-diphenylporphyrine and its corresponding zinc complex [5-bromo-10,20-diphenyl porphyrino]zinc(II) are each reacted with an amino group to yield the illustrated amino-substituted porphyrin. In the schematic on the right side of the picture, [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) and its corresponding zinc complex [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) are each reacted with an amino group to provide the indicated amino-substituted porphyrin. The precursors and amine reagents are reacted in the presence of palladium acetate and the commercially available phosphine ligand bis(2-diphenylphosphinophenyl) ether, or “DPEphos”.
In other embodiments of the invention, a variety of different amines are efficiently coupled with the meso-brominated 10,20-diphenylporphyrins 5-bromo-10,20-diphenylporphyrine and 5,15-dibromo-10,20-diphenylporphyrine (compounds 1b and 2b in Table 1) as well as their corresponding zinc complexes [5-bromo-10,20-diphenylporphyrino]zinc(II) and [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) (compounds 1a and 2a in Table 1). The meso-arylamino- and alkylamino-substituted porphyrins that are obtained are summarized in Table 1, below, with the structures of the resulting compound being shown in FIG. 4 . Specifically, both the primary aniline (Table 1, entry 1) and the secondary N-methylaniline (Table 1, entry 3) can be effectively coupled with 1a to give monoamino-substituted porphyrins 3a and 4a, respectively. When 2a is used, the corresponding diamino-substituted porphyrins 8a (Table 1, entry 10) and 9a (Table 1, entry 12) are synthesized via double amination reactions. Substituted aniline derivatives such as 4-trifluoromethylaniline (Table 1, entry 17), p-anisidine (Table 1, entry 18) and 3,5-di-tert-butylaniline (Table 1, entry 19) also give high yields of double amination products when reacted with 2a. Primary aliphatic amines can also be well-coupled, as demonstrated in the case of n-hexylamine with 1a (Table 1, entry 9).
In addition to primary and secondary amines, imines are also suitable coupling partners under similar reaction conditions. When benzophenone imine was employed, monoimino-substituted porphyrin 5a (Table 1, entry 5) and diimino-substituted porphyrin 10a (Table 1, entry 14) are obtained from its reactions with 1a and 2a, respectively.
TABLE 1
Palladium-Catalyzed Amination of meso-bromoporphyrins with amines
time
entry
reactant b
amine
(h) c
product d
yield (%) e
1
1a
PhNH 2
13
3a
95
2
1b
PhNH 2
19
3b
98
3
1a
Ph(Me)NH
13
4a
99
4
1b
Ph(Me)NH
16
4b
94
5
1a
Ph 2 C = NH
22
5a
94
6
1b
Ph 2 C = NH
24
5b
84
7
1a
Ph 2 NH
25
6a
61 f
8
1b
Ph 2 NH
40
6b
66
9
1a
n-HexNH 2
50
7a
80
10
2a
PhNH 2
13
8a
82
11
2b
PhNH 2
20
8b
65
12
2a
Ph(Me)NH
17
9a
82
13
2b
Ph(Me)NH
15
9b
71
14
2a
Ph 2 C = NH
16
10a
84
15
2b
Ph 2 C = NH
15
10b
95
16
2a
Ph 2 NH
50
11a
30
17
2a
(4-CF 3 Ph)NH 2
17
12a
90
18
2a
(4-CH 3 OPh)NH 2
16
13a
94
19
2a
(3,5-di-t-BUPh) NH 2
62
14a
95
Reactions were carried out at 68° C. in THF under N 2 with 1.0 equiv of bromoporphyrin, 3.6 equiv of amine for 1b and 2b or 4.8 equiv of amine for 1a and 2a, 5 mol % Pd(OAc) 2 and 7.5 mol % DPEphos in the presence of 1.4 equiv of Cs 2 CO 3 per Br. Concentration: 0.05 mmol bromoporphyrin/5 mL THF. Yields represent isolated yields of > 95% purity as determined by 1 H NMR. The reaction was conducted using 10 mol % Pd(OAc) 2 and 15 mol
# % DPEphos in the presence of 2.8 equiv of NaOt-Bu.
In another embodiment of the invention, the methods of the present invention are carried out to produce aminophenylporphyrins. In one such embodiment, the porphyrin precursors are p-bromophenyl porphyrin and its zinc complex, and the amination reaction is catalyzed by palladium. Schemes for this reaction are illustrated in FIGS. 5A-5D , with exemplary aminophenylporphyrins obtained in this invention being described in Tables 2 and 3, below.
TABLE 2
5,15-di-aminophenylporphyrin and zinc complex
synthesized via Pd catalyzed amination reaction
Ligand
Base
Isolated yield (%)
Amine
(10%)
(8.0)
A
B
Entry
(8.0 equiv)
equiv
equiv
Solvent
Time
M = 2H
M = Zn (II)
1
9
Cs 2 CO 3
Toluene
48
h
70
66
9
NaOtBu
Toluene
48
h
88
—
9
NaOtBu
THF
24
h
95
—
9
NaOtBu
THF
13
h
83
—
9
Cs 2 CO 3
THF
48
h
92
—
9
Cs 2 CO 3
THF
48
h
85 a
—
9
NaOtBu
THF
48
h
92
—
9
NaOtBu
THF
48
h
—
—
2
9
Cs 2 CO 3
Toluene
48
h
76
—
3
3
NaOtBu
THF
48
h
93
68
4
3
NaOtBu
THF
48
h
—
83
5
9
NaOtBu
THF
48
h
88
—
8
NaOtBu
THF
48
h
80
—
9
Cs 2 CO 3
Toluene
66.5
h
45
—
6
3
NaOtBu
THF
48
h
87
73
7
8
NaOtBu
THF
48
h
83
93
8
NaOtBu
THF
24
h
63
—
8
NaOtBu
THF
13
h
76
—
8
NaOtBu
THF
48
h
69 a
—
1
Cs 2 CO 3
THF
48
h
79
—
2
NaOtBu
THF
48
h
66 b
—
2
NaOtBu
THF
48
h
99
—
3
NaOtBu
THF
48
h
92
—
3
NaOtBu
THF
48
h
93
—
8
3
NaOtBu
THF
48
h
90
53 c
9
3
NaOtBu
THF
48
h
88
73
10
3
NaOtBu
THF
48
h
81
57
9
NaOtBu
THF
48
h
57
—
11
1
NaOtBu
THF
48
h
52
—
12
8
Cs 2 CO 3
THF
48
h
76
—
8
NaOtBu
THF
48
h
79
—
Note:
a , 4.0 equiv aniline; b , Pd(OAc) 2 /Ligand = 10%/20%, c , ligand 7
TABLE 3
Tetrakis-aminophenylporphyrins synthesized from
tetrakis-p-bromophenylporphyrin through
Pd catalyzed amination reaction
Amine
Pd
Ligand
Base
16.0
(5%)
(10%)
(16.0)
Isolated
Entry
equiv
equiv
equiv
Solvent
° C.
Time
yield
1
Pd(OAc) 2
9
NaOtBu
THF
100
72
h
91%
2
Pd(OAc) 2
8
NaOtBu
THF
100
72
h
86%
3
Pd(OAc) 2
9
NaOtBu
THF
100
72
h
82%
4
Pd(OAc) 2
9
NaOtBu
THF
100
72
h
81%
In still a third embodiment of the invention, monobromo-porphyrin [5-bromo-10,20-diphenylporphyrino]zinc(II) and the dibromoporphyrin [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) may undergo efficient cross-coupling reactions with various phenols under mild conditions to yield desired phenoxy- and diphenoxy-substituted porphyrins. FIG. 6 illustrates the etheration of monobromo-porphyrin [5-bromo-10,20-diphenylporphyrino]zinc(II) and the dibromoporphyrin [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) using a combination of Pd(OAc) 2 or Pd 2 (dba) 3 and a phosphine ligand as the catalyst. FIG. 7 illustrates the chemical structures a variety of phenoxy- and diphenoxy-substituted porphyrins that are obtained in the practice of the present invention.
LABORATORY EXAMPLES
The following Laboratory Examples have been included to illustrate preferred modes of the invention. Certain aspects of the following Laboratory Examples are described in terms of techniques and procedures found or contemplated by the present co-inventors to work well in the practice of the invention. These Laboratory Examples are exemplified through the use of standard laboratory practices of the co-inventors. In light of the present disclosure and the general level of skill in the art, those of skill will appreciate that the following Laboratory Examples are intended to be exemplary only, and that numerous changes, modifications and alterations can be employed without departing from the spirit and scope of the invention.
Examples 1-21 relate to methods of the present invention whereby substituted porphyrins with directly appended arylamino or alkylamino groups are synthesized using palladium catalyzed amination.
Example 1
General Considerations
All reactions were carried out under a nitrogen atmosphere in oven-dried glassware using standard Schlenk techniques. Tetrahydrofuran was distilled under nitrogen from sodium benzophenone ketyl. 5-Bromo-10,20-diphenylporphyrine and 5,15-dibromo-10,20-diphenylporphyrine as well as their corresponding zinc complexes [5-bromo-10,20-diphenylporphyrino]zinc(II) and [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) were synthesized by literature methods. Bis(2-diphenylphosphinophenyl)ether (DPEphos), palladium(II) acetate and tris(dibenzylideneacetone) dipalladium(0) were purchased from Strem Chemical Co. Cesium carbonate was obtained as a gift from Chemetall Chemical Products, Inc. Proton and carbon nuclear magnetic resonance spectra ( 1 H NMR and 13 C NMR) were recorded on a Varian Mercury 300 spectrometer and referenced with respect to residual solvent. Infrared spectra were obtained using a Bomen B100 Series FT-IR spectrometer. Samples were prepared as films on a NaCl plate by evaporating THF solutions. UV-Vis spectra were obtained using a Hewlett-Packard 8452A diode array spectrophotometer. High-resolution mass spectroscopy was performed by the Mass Spectrometry Center located in the Chemistry Department of the University of Tennessee on a VG Analytical hybrid high performance ZAB-EQ (B-E-Q geometry) instrument using electron impact (EI) ionization technique with a 70 eV electron beam. Thin layer chromatography was carried out on E. Merck Silica Gel 60 F-254 TLC plates.
Example 2
General Procedures for Amination of Bromoporphyrin
The bromoporphyrin, palladium precursor, phosphine ligand and base were placed in an oven-dried, resealable Schlenk tube. The tube was capped with a Teflon screwcap, evacuated, and backfilled with nitrogen. The screwcap was replaced with a rubber septum, and amine was added via syringe, followed by solvent. The tube was purged with nitrogen for 2 min, and then the septum was replaced with the Teflon screwcap. The tube was sealed, and its contents were heated with stirring until the starting bromoporphyrin had been completely consumed as indicated by TLC analysis. The resulting mixture was cooled to room temperature, taken up in ethyl acetate (60 mL) and transferred to a separatory funnel. The mixture was washed with water (×2), dried over anhydrous sodium sulfate, filtered and concentrated in vacuo. The crude product was then purified.
Example 3
Synthesis of [5-(N-Phenylamino)-10,20-diphenylporphvrino]zinc(II) (Table 1, Product 3a)
The general procedure was used to couple [5-bromo-10,20-diphenylporphyrino]zinc(II) (30 mg, 0.050 mmol) with aniline (17 μL, 0.18 mmol), using palladium acetate (0.55 mg, 0.0025 mmol) as the palladium precursor, DPEphos (2.0 mg, 0.0038 mmol) as the phosphine ligand and cesium carbonate (22.8 mg, 0.070 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 13 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate:hexanes (v)=1:4) as purple solids (29 mg, 95%). 1 H NMR (300 MHz, THF-d 8 ): δ 10.08 (s, 1H), 9.48 (d, J=4.8 Hz, 2H), 9.31 (s, 1H), 9.29 (d, J=4.8 Hz, 2H), 8.92 (d, J=4.8 Hz, 2H), 8.81 (d, J=4.8 Hz, 2H), 8.22 (m, 4H), 7.75 (m, 6H), 7.04 (t, J=7.2 Hz, 2H), 6.87 (d, J=7.5 Hz, 2H), 6.65 (t, J=7.2 Hz, 1H). 13 C NMR (75 MHz, THF-d 8 ): δ 164.8, 161.0, 160.8, 160.4, 160.2, 154.0, 145.1, 142.4, 141.7, 139.4, 139.2, 137.6, 136.8, 130.3, 130.2, 127.9, 124.6, 115.4. IR (film, cm −1 ): 3383, 3050, 2953, 1599, 1493, 1307, 1061, 996, 793, 748. UV-vis (THF, λ max , nm): 422, 554, 602. HRMS-EI ([M] + ): calcd for C 38 H 25 N 5 Zn, 615.1401; found: 615.1382 with an isotope distribution pattern that is same as the calculated one.
Example 4
Synthesis of 5-(N-Phenylamino)-10,20-diphenylporphyrin (Table 1, Product 3b)
The general procedure was used to couple 5-bromo-10,20-diphenylporphyrin (27 mg, 0.05 mmol) with aniline (17 μL, 0,18 mmol), using palladium acetate (0.55 mg, 0.0025 mmol) as the palledium precursor, DPEphos (2.0 mg, 0.0038 mmol) as the phosphine ligand and cesium carbonate (22.8 mg, 0.070 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 19 h. The title compound was isolated by flash chromatography (silica gel, ethyl acetate:hexanes (v)=1:4) as red solids (27 mg, 98%). 1 H NMR (300 MHz, THF-d 8 ): δ 10.14 (s, 1H), 9.44 (d, J=4.8 Hz, 2H), 9.42 (s, 1H), 9.30 (d, J=4.8 Hz, 2H), 8.90 (d, J=4.8 Hz, 2H), 8.77 (d, J=4.8 Hz, 2H), 8.21 (m, 4H), 7.78 (m, 6H), 7.06 (t, J=7.4, 2H), 6.86 (d, J=7.4 Hz, 2H), 6.69 (J=7.4 Hz, 1H), −2.54 (s, 2H). 13 C NMR (75 MHz, THF-d 8 ): δ 154.8, 147.7, 142.7, 135.5, 132.1, 131.9, 131.1, 129.7, 128.5, 127.7, 120.6, 120.1, 119.0, 115.5, 105.1. IR (film, cm −1 ): 3302, 3043, 1599, 1495, 1476, 1338, 1309, 1255, 1064, 973, 958, 797, 748. UV-vis(THF, λ max , nm): 412, 512, 582, 660. HRMS-EI ([M] + ): calcd for C 38 H 27 N 5 , 553.2266; found: 553.2274 with an isotope distribution pattern that is same as the calculated one.
Example 5
Synthesis of [5-(N-Methyl-N-phenylamino)-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 4a)
The general procedure was used to couple [5-bromo-10,20-diphenylporphyrino]zinc(II) (30 mg, 0.050 mmol) with N-methylaniline (20 μL, 0.18 mmol), using palladium acetate (0.55 mg, 0.0025 mmol) as the palladium precursor, DPEphos (2.0 mg, 0.0038 mmol) as the phosphine ligand and cesium carbonate (22.8 mg, 0.070 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 13 h. The title compound was isolated by flash column chromatography (silica gel, THF:hexanes (v)=1:8) as purple solids (31 mg, 99%). 1 H NMR (300 MHz, THF-d 8 ): δ 10.20 (s, 1H), 9.36 (d, J=4.8 Hz, 2H), 9.19 (d, J=4.8 Hz, 2H), 8.97 (d, J=4.8 Hz, 2H), 8.87 (d, J=4.8 Hz, 2H), 8.23 (m, 4H), 7.77 (m, 6H), 7.05 (broad, 2H), 6.69 (broad, 2H), 6.61 (t, J=7.2 Hz, 1H), 4.28 (s, 3H). 13 C NMR (75 MHz, THF-d 8 ): δ 156.0, 152.0, 151.2, 150.9, 150.7, 144.2, 135.5, 133.0, 132.8, 132.4, 130.0, 129.3, 128.1, 127.2, 125.3, 120.8, 116.7, 114.1, 106.9, 45.7. IR (film, cm −1 ): 3054, 3023, 2978, 2876, 2807, 1596, 1498, 1341, 1120, 994, 793, 747. UV-vis (THF, λ max , nm): 416, 552, 598. HRMS-EI ([M] + ): calcd for C 39 H 27 N 5 Zn, 629.1558; found: 629.1549 with an isotope distribution pattern that is same as the calculated one.
Example 6
Synthesis of 5-(N-Methyl-N-phenylamino)-10,20-diphenylporphyrin (Table 1, Product 4b)
The general procedure was used to couple 5-bromo-10,20-diphenylporphyrin (54 mg, 0.10 mmol) with N-methylaniline (40 μL, 0.36 mmol), using palladium acetate (1.1 mg, 0.005 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and cesium carbonate (45.6 mg, 0.014 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 16 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate:hexanes (v)=1:4) as purple solids (53 mg, 94%). 1 H NMR (300 MHz, CDCl 3 ): δ 10.18 (s, 1H), 9.30 (d, J=4.8 Hz, 2H), 9.19 (d, J=4.8 Hz, 2H), 9.00 (d, J=4.8 Hz, 2H), 8.90 (d, J=4.8 Hz, 2H), 8.23 (m, 4H), 7.78 (m, 6H), 7.19 (broad, 2H), 6.73 (broad, 3H), 4.26 (s, 3H), −2.82 (s, 2H). 13 C NMR (75 MHz, CDCl 3 ): δ 154.9, 141.6, 134.9, 131.9, 131.7, 131.6, 129.6, 129.1, 128.0, 127.2, 124.2, 119.8, 116.9, 113.9, 105.8, 45.5. IR (film, cm −1 ): 3303, 3055, 3026, 2875, 2810, 1596, 1498, 1351, 1113, 971, 796, 731. UV-vis (CHCl 3 , λ max , m): 410, 512, 548, 592. HRMS-EI ([M] + ): C 39 H 29 N 5 , 567.2423; found: 567.2419 with an isotope distribution pattern that is same as the calculated one.
Example 7
Synthesis of [5-Benzophenoeimino-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 5a)
The general procedure was used to couple [5-bromo-10,20-diphenylporphyrino]zinc(II) (30 mg, 0.050 mmol) with benzophenone imine (31 μL, 0.18 mmol), using palladium acetate (0.55 mg, 0.0025 mmol) as the palladium precursor, DPEphos (2.0 mg, 0.0038 mmol) as the phosphine ligand and cesium carbonate (22.8 mg, 0.070 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 22 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate:hexanes (v)=1:4) as purple solids (33 mg, 94%). 1 H NMR (300 MHz, THF-d 8 ): δ 9.80 (s, 1H), 9.23 (d, J=4.8 Hz, 2H), 9.13 (d, J=4.8 Hz, 2H), 8.79 (d, J=4.8 Hz, 2H), 8.71 (d, J=4.8 Hz, 2H), 8.19 (broad, 6H), 7.73 (m, 6H), 7.66 (broad, 3H), 7.36 (broad, 2H), 6.65 (broad, 3H). 13 C NMR (75 MHz, THF-d 8 ): δ 170.8, 152.0, 150.3, 149.9, 144.5, 142.5, 135, 4, 133.0, 131.6, 131.1, 130.9, 130.0, 129.4, 128.8, 127.9, 127.2, 120.6, 103.7. IR (film, cm −1 ): 3056, 3023, 2962, 1618, 1596, 1578, 1490, 1439, 1124, 1061, 994, 794. UV-vis (THF, λ max , nm): 428, 562, 610. HRMS-EI ([M] + ): calcd for C 45 H 29 N 5 Zn, 703.1714; found: 703.1699 with an isotope distribution pattern that is same as the calculated one.
Example 8
Synthesis of 5-Benzophenoeimino-10,20-diphenylporphyrin (Table 1, Product 5b)
The general procedure was used to couple 5-bromo-10,20-diphenylporphyrin (27 mg, 0.05 mmol) with benzophenone imine (31 μL, 0.18 mmol), using palladium acetace (0.55 mg, 0.0025 mmol) as the palladium precursor, DPEphos (2.0 mg, 0.0038 mmol) as the phosphine ligand and cesium carbonate (22.8 mg, 0.070 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 24 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate: hexanes (v)=1:8) as purple solids (27 mg, 84%). 1 H NMR (300 MHz, CDCl 3 ): δ 9.78 (s, 1H), 9.23 (d, J=4.8 Hz, 2H), 9.08 (d, J=4.8 Hz, 2H), 8.85 (d, J=4.8 Hz, 2H), 8.75 (d, J=4.8 Hz, 2H), 8.26 (broad, 6H), 7.76 (broad, 9H), 7.18 (broad, 2H), 6.61 (broad, 3H), −2.34 (s, 2H). 13 C NMR (75 MHz, CDCl 3 ): δ 171.6, 146.0, 141.7, 134.6, 133.6, 131.6, 130.7, 129.8, 127.9, 127.5, 126.8, 119.4, 102.4. IR (film, cm −1 ): 3306, 3057, 3026, 1808, 1616, 1595, 1576, 1476, 1442, 1405, 1316, 1241, 1097, 976, 954, 845, 797, 745. UV-vis (CHCl 3 , λ max , nm): 424, 526, 564, 604, 658. HRMS-EI ([M] + ): calcd for C 45 H 31 N 5 , 641.2579; found: 641.2591 with an isotope distribution pattern that is same as the calculated one.
Example 9
Synthesis of [5-(N-Diphenylamino)-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 6a)
The general procedure was used to couple [5-bromo-10,20-diphenylporphyrino]zinc(II) (30 mg, 0.05 mmol) with diphenylamine (0.031 g, 0.18 mmol), using palladium acetate (1.1 mg, 0.005 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and sodium tert-butoxide (13.5 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 25 h. The title compound was isolated by flash column chromatography (silica gel, THF: hexanes (v)=1:6) as purple solids (21 mg, 61%). 1 H NMR (300 MHz, THF-d 8 ): δ 10.17 (s, 1H), 9.33 (m, 4H), 8.93 (d, J=4.8 Hz, 2H), 8.80 (d, J=4.8 Hz, 2H), 8.20 (m, 4H), 7.75 (m, 6H), 7.33 (m, 8H), 7.12 (t, J=7.8 Hz, 8H), 6.80 (t, J=7.2 Hz, 4H). 13 C NMR (75 MHz, CDCl 3 ): δ 153.7, 153.0, 151.3, 151.0, 150.1, 144.1, 135.4, 133.3, 132.8, 132.4, 130.9, 129.8, 129.6, 128.1, 127.2, 122.9, 121.1, 120.9, 107.0. IR (film, cm −1 ): 3055, 2961, 2361, 1598, 1587, 1490, 1293, 1273, 1062, 1003, 994, 794, 752. UV-vis (THF, λ max , nm): 412, 558, 604. HRMS-EI ([M] + ): calcd for C 44 H 29 N 5 Zn, 691.1714; found: 691.1712 with an isotope distribution pattern that is same as the calculated one.
Example 10
Synthesis of 5-(N-Diphenylamino)-10,20-diphenylporphyrin (Table 1, Product 6b)
The general procedure was used to couple 5-bromo-10,20-diphenylporphyrin (54 mg, 0.1 mmol) with diphenylamine (0.061 g, 0.36 mmol), using palladium acetate (1.1 mg, 0.005 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and cesium carbonate (45.6 mg, 0.014 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 40 h. The title compound was isolated by flash column chromatography (silica gel, THF: hexanes (v)=1:8) as purple solids (41 mg, 66%). 1 H NMR (300 MHz, CDCl 3 ): δ 10.13 (s, 1H), 9.33 (d, J=4.8 Hz, 2H), 9.26 (d, J=4.8 Hz, 2H), 8.96 (d, J=4.8 Hz, 2H), 8.83 (d, J=4.8 Hz, 2H), 8.20 (m, 4H), 7.76 (m, 6H), 7.35 (m, 4H), 7.20 (t, J=7.2 Hz, 4H), 6.89 (t, J=7.2 Hz, 2H), −2.69 (s, 2H). 13 C NMR (75 MHz, CDCl 3 ): δ 152.5, 141.3, 134.8, 134.6, 132.0, 131.4, 130.1, 129.1, 127.8, 126.8, 122.3, 120.8, 119.6, 105.6. IR (film, cm −1 ): 3307, 3055, 3029, 1591, 1491, 1342, 1184, 973, 796, 750, 731, 695. UV-vis (CHCl 3 , λ max , nm): 407, 523, 577, 656. HRMS-EI ([M] + ): calcd for C 44 H 31 N 5 , 629.2579; found: 629.2576 with an isotope distribution pattern that is same as the calculated one.
Example 11
Synthesis of [5-(N-Hexylamino)-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 7a)
The general procedure was used to couple [5-bromo-10,20-diphenylporphyrino]zinc(II) (30 mg, 0.05 mmol) with hexylamine (0.024 ml, 0.18 mmol), using palladium acetate (0.55 mg, 0.0025 mmol) as the palladium precursor, DPEphos (2.0 mg, 0.0038 mmol) as the phosphine ligand and cesium carbonate (22.8 mg, 0.070 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 50 h. The title compound was isolated by flash column chromatography (silica gel, THF: hexanes (v)=1:8) as purple solids (25 mg, 80%). 1 H NMR (300 MHz, THF-d 8 ): δ 9.63 (s, 1H), 9.43 (d, J=4.8 Hz, 2H), 9.05 (d, J=4.8 Hz, 2H), 8.76 (d, J=4.8 Hz, 2H), 8,65 (d, J=4.8 Hz, 2H), 8.18 (m, 4H), 7.75 (m, 6H), 7.33 (m, 8H), 6.78 (s, 1H), 4.38 (m, 2H), 2.04 (m, 2H), 1.58 (m, 2H), 1.37 (m, 4H), 0.87 (t, J=7.2 Hz, 3H). 13 C NMR (75 MHz, THF-d 8 ): δ 152.7, 149.9, 149.5, 147.0, 144.7, 135.3, 133.0, 131.4, 130.2, 127.8, 127.2, 126.9, 120.5, 102.4, 60.2, 32.8, 32.5, 28.0, 23.5, 14.4. IR (film, cm −1 ): 3330, 3053, 2954, 2925, 2854, 1584, 1542, 1489, 1440, 1213, 1062, 1010, 1002, 992, 836, 789, 780, 750. UV-vis (THF, λ max , nm): 428, 606. HRMS-EI ([M] + ): calcd for C 38 H 33 N 5 Zn, 623.2027; found: 623.2009 with an isotope distribution pattern that is same as the calculated one.
Example 12
Synthesis of [5,15-Bis(N-phenylamino)-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 8a)
The general procedure was used to couple [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) (34 mg, 0.050 mmol) with aniline (22 μL, 0.24 mmol), using palladium acetate (1.1 mg, 0.0050 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and cesium carbonate (45.6 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 13 h. The title compound was isolated by flash column chromatography (silica gel, THF:hexanes (v)=1:4) as purple solids (29 mg, 82%). 1 H NMR (300 MHz, THF-d 8 ): δ 9.36 (d, J=4.8 Hz, 4H), 9.17 (s, 2H), 8.69 (d, J=4.8 Hz, 4H), 8.16 (m, 4H), 7.72 (m, 6H), 7.03 (t, J=6.9, 7.2 Hz, 4H), 6.84 (d, J=8.4 Hz, 4H), 6.64 (t, J=7.2 Hz, 2H). 13 C NMR (75 MHz, THF-d 8 ): δ 155.1, 152.0, 150.5, 144.4, 135.3, 132.2, 129.7, 129.6, 128.0, 127.2, 121.0, 119.9, 118.2, 115.0. IR (film, cm −1 ): 3380, 3047, 3020, 2953, 1599, 1492, 1339, 1308, 1063, 1003, 795, 747. UV-vis (THF, λ max , nm): 440, 564, 620. HRMS-EI ([M] + ): calcd for C 44 H 30 N 6 Zn, 706.1823; found: 706.1840 with an isotope distribution pattern that is same as the calculated one.
Example 13
Synthesis of 5,15-Bis(N-phenylamino)-10,20-diphenylporphrin (Table 1, Product 8b)
The general procedure was used to couple 5,15-dibromo-10,20-diphenylporphyrin (31 mg, 0.05 mmol) with aniline (22 μL, 0.24 mmol), using palladium acetate (1.1 mg, 0.0050 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and cesium carbonate (45.6 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 20 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate:hexanes (v)=1:4) as purple solids (21 mg, 65%). 1 H NMR (300 MHz, THF-d 8 ): δ 9.32 (d, J=4.8 Hz, 4H), 9.29 (s, 2H), 8.65 (d, J=4.8 Hz, 4H), 8.17 (m, 4H), 7.75 (m, 6H), 7.07 (t, J=8.1 Hz, 4H), 6.86 (d, J=8.1 Hz, 4H), 6.69 (t, J=7.4 Hz, 2H), −2.03 (s, 2H). 13 C NMR (75 MHz, THF-d 8 ): δ 154.5, 142.9, 137.1, 135.3, 129.7, 128.5, 127.6, 120.5, 119.7, 118.9, 115.4. IR (film, cm −1 ): 3307, 1599, 1496, 1474, 1340, 1306, 1258, 1071, 974, 797, 732. UV-vis (THF, λ max , nm): 438, 526, 592, 680. HRMS-EI ([M] + ): calcd for C 44 H 32 N 6 , 644.2688; found: 644.2704 with an isotope distribution pattern that is same as the calculated one.
Example 14
Synthesis of [5,15-Bis(N-methyl-N-phenylamino)-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 9a
The general procedure was used to couple [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) (34 mg, 0.050 mmol) with N-methylaniline (26 μL, 0.24 mmol), using palladium acetate (1.1 mg, 0.0050 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and cesium carbonate (45.6 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 17 h. The title compound was isolated by flash column chromatography (silica gel, THF:hexanes (v)=1:8) as purple solids (30 mg, 82%). 1 H NMR (300 MHz, THF-d 8 ): δ 9.10 (d, J=4.8 Hz, 4H), 8.75 (d, J=4.8 Hz, 4H), 8.15 (m, 4H), 7.73 (m, 6H), 7.04 (broad, 4H), 6.69 (broad, 4H), 6.59 (t, J=7.2 Hz, 2H), 4.25 (s, 6H). 13 C NMR (75 MHz, THF-d 8 ): δ 155.8, 152.4, 150.9, 144.0, 135.2, 133.1, 130.1, 129.3, 128.2, 127.2, 125.7, 121.2, 116.8, 114.2, 45.6. IR (film, cm −1 ): 3054, 2985, 2883, 2807, 1597, 1496, 1346, 1118, 1000, 796, 747. UV-vis (THF, λ max , nm): 422, 562, 608. HRMS-EI ([M] + ): calcd for C 46 H 34 N 6 Zn, 734.2136; found: 734.2128 with an isotope distribution pattern that is same as the calculated one.
Example 15
Synthesis of 5,15-Bis(N-methyl-N-phenylamino)-10,20-diphenylporphyrin (Table 1, Product 9b)
The general procedure was used to couple 5,15-dibromo-10,20-diphenylporphyrin (31 mg, 0.05 mmol) with N-methylaniline (26 μL, 0.24 mmol), using palladium acetate (1.1 mg, 0.0050 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and the cesium carbonate (45.6 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 15 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate: hexanes (v)=1:4) as red solids (24 mg, 71%). 1 H NMR (300 MHz, CDCl 3 ): δ 9.08 (d, J=4.8 Hz, 4H), 8.77 (d, J=4.8 Hz, 4H), 8.16 (m, 4H), 7.72 (m, 6H), 7.14 (m, 4H), 6.72 (m, 6H), 4.23 (s, 6H), −2.54 (s, 2H). 13 C NMR (75 MHz, CDCl 3 ): δ 154.4, 141.3, 134.5, 131.9, 128.9, 128, 127.8, 126.8, 124.3, 119.9, 116.7, 113.8, 45.1. IR (film, cm −1 ): 3315, 3026, 2359, 1596, 1498, 1475, 1354, 1114, 972, 798. UV-vis (CHCl 3 , λ max , nm): 412, 522, 562, 596, 608. HRMS-EI ([M] + ): calcd for C 46 H 36 N 6 , 672.3001; found: 672.3003 with an isotope distribution pattern that is same as the calculated one.
Example 16
Synthesis of [5,15-Bis(benzophenoeimino)-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 10a)
The general procedure was used to couple [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) (34 mg, 0.050 mmol) with benzophenoe imine (41 μL, 0.24 mmol), using palladium acetate (1.1 mg, 0.0050 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and cesium carbonate (45.6 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 16 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate:hexanes (v)=1:4) as purple solids (37 mg, 84%). 1 H NMR (300 MHz, CDCl 3 ): δ 9.06 (d, J=4.8 Hz, 4H), 8.57 (d, J=4.8 Hz, 4H), 8.19 (m, 4H), 8.07 (m, 4H), 7.68 (m, 6H), 7.61 (m, 6H), 7.33 (m, 4H), 6.62 (m, 6H). 13 C NMR (75 MHz, CDCl 3 ): δ 170.8, 149.4, 144.7, 143.8, 135.4, 135.2, 132.7, 131.9, 131.5, 130.8, 129.9, 129.3, 128.4, 128.0, 127.7, 127.2, 127.1, 126.9, 120.9. IR (film, cm −1 ): 3054, 3027, 2976, 1618, 1597, 1485, 1442, 1338, 1212, 1118, 1004, 793, 753. UV-vis (THF, λ max , nm): 438, 652. HRMS-EI ([M] + ): calcd for C 58 H 38 N 6 Zn, 882.2449, found: 882.2464 with an isotope distribution pattern that is same as the calculated one.
Example 17
Synthesis of 5,15-Bis(benzophenoeimino-10,20-diphenylporphyrin (Table 1, Product 10b)
The general procedure was used to couple 5,15-dibromo-10,20-diphenylporphyrin (31 mg, 0.05 mmol) with benzophenoe imine (41 μL, 0.24 mmol), using palladium acetate (1.1 mg, 0.0050 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and cesium carbonate (45.6 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 15 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate: hexanes (v)=1:4) as purple solids (39 mg, 95%). 1 H NMR (300 MHz, THF-d 8 ): δ 9.09 (d, J=4.8 Hz, 4H), 8.57 (d, J=4.8 Hz, 4H), 8.10 (m, 8H), 7.64 (m, 12H), 7.23 (broad, 4H), 6.62 (broad, 6H), −1.87 (s, 2H). 13 C NMR (75 MHz, THF-d 8 ): δ 172.3, 143.2, 140.8, 137.9, 135.4, 135.1, 132.1, 131.0, 129.3, 128.9, 128.3, 128.2, 127.5, 120.3, 108.4. IR (film, cm −1 ) 3316, 3056, 3022, 1614, 1596, 1575, 1465, 1443, 1351, 1316, 1278, 1244, 1105, 1066, 976, 950, 798, 725. UV-vis (THF, λ max , nm): 434, 592, 700. HRMS-EI ([M] + ): calcd for C 58 H 40 N 6 , 820.3314; found: 820.3308 with an isotope distribution pattern that is same as the calculated one.
Example 18
Synthesis of [5,15-Bis(N-diphenylamino)-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 11a)
The general procedure was used to couple [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) (34 mg, 0.05 mmol) with diphenylamine (0.041 g, 0.24 mmol), using palladium acetate (1.1 mg, 0.0050 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and sodium tert-butoxide (13.5 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 50 h. The title compound was isolated by flash column chromatography (silica gel, THF: hexanes (v)=1:6) as purple solids (13 mg, 30%). 1 H NMR (300 MHz, CDCl 3 ): δ 9.25 (d, J=4.8 Hz, 4H), 8.75 (d, J=4.8 Hz, 4H), 8.09 (m, 4H), 7.66 (m, 6H), 7.29 (m, 8H), 7.15 (t, J=7.8 Hz, 8H), 6.85 (t, J=7.4 Hz, 4H). 13 C NMR (75 MHz, CDCl 3 ): δ 152.6, 152.3, 149.7, 142.1, 134.3, 133.3, 130.5, 129.1, 127.6, 126.5, 122.8, 122.1, 121.0, 120.7. IR (film, cm −1 ): 3056, 2360, 1595, 1590, 1490, 1341, 1294, 1249, 1002, 794, 750. UV-vis (CHCl 3 , λ max , nm): 406, 460, 572, 628. HRMS-EI ([M] + ): calcd for C 56 H 38 N 6 Zn, 858.2449; found: 858.2436 with an isotope distribution pattern that is same as the calculated one.
Example 19
Synthesis of [5,15-Bis(N-4-trifluoromethylphenylamino)-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 12a)
The general procedure was used to couple [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) (34 mg, 0.05 mmol) with 4-trifluoromethyllaniline (0.030 ml, 0.24 mmol), using palladium acetate (1.1 mg, 0.0050 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and cesium carbonate (45.6 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 17 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate: hexanes (v)=1:2) as purple solids (38 mg, 90%). 1 H NMR (300 MHz, THF-d 8 ): δ 9.84 (s, 2H), 9.43 (d, J=4.8 Hz, 4H), 8.84 (d, J=4.8 Hz, 4H), 8.22 (m, 4H), 7.78 (m, 6H), 7.41 (d, J=8.2 Hz, 4H), 6.93 (d, J=8.2 Hz, 4H). 13 C NMR (75 MHz, THF-d 8 ): δ 157.5, 151.7, 151.0, 144.1, 135.4, 132.9, 129.7, 128.2, 127.3, 127.2, 127.1, 121.6, 119.3, 118.1, 114.1. IR (film, cm −1 ): 3376, 1614, 1522, 1322, 1110, 1065, 1003, 828, 797. UV-vis (THF, λ max , nm): 435, 562, 612. HRMS-EI ([M] + ): calcd for C 46 H 28 N 6 F 6 Zn, 842.1571; found: 842.1590 with an isotope distribution pattern that is same as the calculated one.
Example 20
[5,15-Bis(N-4-methoxyphenylamino)-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 13a)
The general procedure was used to couple [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) (34 mg, 0.05 mmol) with p-anisidine (30 mg, 0.24 mmol), using palladium acetate (1.1 mg, 0.0050 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and cesium carbonate (45.6 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 16 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate: hexanes (v)=1:3 as purple solids (36 g, 94%). 1 H NMR (300 MHz, THF-d 8 ): δ 9.34 (d, J=4.8 Hz, 4H), 8.88 (s, 2H), 8.66 (d, J=4.8 Hz, 4H), 8.17 (m, 4H), 7.73 (m, 6H), 6.87 (d, J=9.0 Hz, 4H), 6.69 (d, J=9.0 Hz, 4H), 3.65 (s, 6H). 13 C NMR (75 MHz, THF-d 8 ): δ 153.5, 151.9, 150.2, 149.6, 144.6, 135.3, 131.9, 129.3, 127.8, 127.1, 121.2, 120.7, 116.6, 115.0, 55.6. IR (film, cm −1 ): 3372, 1597, 1507, 1489, 1339, 1234, 1036, 1002, 797. UV-vis (THF, λ max , nm): 447, 571, 629.
Example 21
Synthesis of [5,15-Bis(N-3,5-di-tert-butylphenylamino)-10,20-diphenylporphyrino]zinc(II) (Table 1, Product 14a)
The general procedure was used to couple [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) (34 mg, 0.05 mmol) with 3,5-di-tert-butylaniline (0.050 g, 0.24 mmol), using palladium acetate (1.1 mg, 0.0050 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.0075 mmol) as the phosphine ligand and cesium carbonate (45.6 mg, 0.14 mmol) as the base. The reaction was conducted in THF (5 mL) at 68° C. for 62 h. The title compound was isolated by flash column chromatography (silica gel, ethyl acetate: hexanes (v)=1:4) as purple solids (44 mg, 95%). 1 H NMR (300 MHz, CDCl 3 ): δ 9.28 (d, J=4.8 Hz, 4H), 8.68 (d, J=4.8 Hz, 4H), 8.14 (m, 4H), 7.71 (m, 8H), 6.87 (m, 6H), 1.21 (s, 36H). 13 C NMR (75 MHz, CDCl 3 ): δ 152.1, 151.5, 150.6, 149.4, 143.0, 134.8, 131.7, 128.5, 127.1, 126.4, 120.4, 118.8, 113.4, 109.6, 34.7, 31.3. IR (film, cm −1 ): 3383, 3055, 2961, 2902, 2867, 1595, 1488, 1436, 1340, 1064, 1004, 796. UV-vis (THF, λ max , nm): 448, 576, 634. HRMS-EI ([M] + ): calcd for C 60 H 62 N 6 Zn, 930.4327; found: 930.4354 with an isotope distribution pattern that is same as the calculated one.
Examples 22 through 47 relate to methods of synthesizing aminophenylporphyrins, and novel aminophenylporphyrins, according to the present invention. In Example 22-47, ligand referred to by number refer to the numbered ligands shown in FIG. 2 .
Example 22
General Considerations
All reactions were carried out under a nitrogen atmosphere in oven-dried Schlenk tube. All amines were purchased from Acros Organics or Aldrich Chemical Co. and used without further purification. Tetrahydrofuran and toluene were continuously refluxed and freshly distilled from sodium benzophenone ketyl under nitrogen. Sodium tert-butoxide was purchased from Aldrich Chemical Co.; Cesium carbonate was obtained as a gift from Chemetall Chemical Products, Inc.
Potassium phosphate, potassium carbonate, palladium(II) acetate, tris(dibenzylideneacetone)dipalladium(0), 2-(di-t-butylphosphino)biphenyl ( FIG. 2 , Ligand 1), 2-(dicyclohexylphosphino)biphenyl ( FIG. 2 , Ligand 2), 2-dicyclohexylphosphino-2′-(N,N-di-methylamino)biphenyl ( FIG. 2 , Ligand 4), bis(2-diphenylphosphinophenyl)ether (DPEphos, FIG. 2 , Ligand 6), Xantphos ( FIG. 2 , Ligand 7), racemic-2-(di-t-butylphosphino)-1,1′-binaphthyl ( FIG. 2 , Ligand 8), (±)BINAP ( FIG. 2 , Ligand 9), dichloro[1,1′-bis(diphenylphosphino)ferrocene]palladium(II) dichloride ((dppf)PdCl 2 , FIG. 2 , Ligand 10) and 1,3-bis(2,6-di-1-propylphenyl)imidazolium chloride ( FIG. 2 , Ligand 11) were purchased from Strem Chemical Co.; 2-(dicyclohexylphosphino)-2′6′dimethyl-biphenyl ( FIG. 2 , Ligand 3) and the ligand shown in FIG. 2 as ligand 5 were synthesized according to literature methods. All ligands and palladium precursors and bases were stored in desiccators filled with anhydrous calcium sulfate, and weighed in the air. 5,15-di-p-bromophenylporphyrin as well as its zinc complex, and tetrakis-p-bromophenylporphyrin were prepared according to the method described in literatures. 1 H NMR and 13 C NMR were recorded on Varian Mercury 300 spectrometer with TMS as an internal standard. UV-Vis spectra were measured on Hewlett-Packard 8452 diode array spectrometer. High resolution mass spectroscopy was determined on a VG analytical hybrid high performance ZAB-EQ(B-E-Q geometry) instrument by the Mass Spectrometry Center (Department of Chemistry, University of Tennessee). All solvents were supplied by Fisher Scientific, Inc. with HPLC grade and used as received. Thin layer chromatography was performed on Silica Gel 60F-254 precasted aluminum TLC plate.
Example 23
General Procedures for Amination of Bromophenylporphyrin
An oven-dried Schlenk tube equipped with stirring bar was degassed on vacuum line and purged with nitrogen. The tube was charged with Pd(OAc) 2 or Pd 2 (dba) 3 (5 mole %), phosphine ligand (10 mole %), bromophenylporphyrin or zinc complex (0.05 mmole), base (NaOtBu or Cs 2 CO 3 , 4.0 equiv for 1.0 equiv Br) and solid amine, if any. The tube was capped with a Teflon screw cap, evacuated on vacuum line for 40-50 min and backfilled with nitrogen. The Teflon screw cap was then replaced with a rubber septum, 2-3 mL of freshly redistilled and dried solvent, and amine (4.0 equiv for 1.0 equiv Br) was added via syringe successively. Additional 2-3 mL of solvent was added against the wall of the tube to wash down the possible reactants on the wall. The tube was purged with nitrogen for 1-2 min, and the septum was then replaced by Teflon screw cap. The tube was tightly sealed and immersed in a 100° C. oil bath. The reaction was preceded under this condition with stirring for 48 h (72 h for tetra-bromophenylporphyrin), and cooled to room temperature. The aliquot of the solution was detected on TLC (methylene chloride:hexanes=8:2 or ethyl acetate:hexanes=5:5) to monitor the result.
Example 24
General Workup Procedures for Amination of Bromophenylporphyrin
The reaction solution was transferred with a long glass pipet to a small round-bottom flask, the residue was washed with acetone or chloroform and pooled to the flask as well. The solution was concentrated on rotavapor to remove the solvent. The residue was redissolved in ethyl acetate and transferred to a separatory funnel, washed with deioned water three times to remove the base and salts. The organic layer was concentrated on rotavapor to dryness. The residue was dissolved in minimal acetone (or methylene chloride, or THF), and small amount of hexanes was added to recrystallize the product. The product gradually precipitated or crystallized from the solution, filtered on funnel, washed with small amount of hexanes to afford the pure product (purity 98-99%). Extra pure compound can be obtained through flash chromatography on silica gel column. (methylene chloride:hexanes (8:2 to 10:0) as elute).
Example 25
Synthesis of 5,15-di-p-(N-phenylamino)phenylporphyrin (Table 2, entry 1, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), (±) BINAP (6.2 mg, 0.01 mmol, 9), Cs 2 CO 3 (130.33 mg, 0.4 mmol), aniline (36.5 μl, 0.4 mmol) and toluene, the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound was obtained as dark-purple solid (22.6 mg, 70%). 1 H NMR (CDCl 3 , 300 MHz) δ 10.29 (s, meso-2H), 9.39 (d, J=4.5 Hz, β-4H), 9.17 (d, J=4.8 Hz, β-4H), 8.14 (d, J=8.7 Hz, 4H), 7.50 (d, J=8.4 Hz, 4H), 7.38-7.46 (m, 8H), 7.06 (m, 2H), 6.13 (s, 2H), −3.05 (s, 2). 13 C NMR (CDCl 3 , 75 MHz) 6142.9, 142.6, 135.9, 131.5, 131.0, 129.6, 121.6, 118.6, 115.7, 105.1. UV-vis (λ max , nm) 421, 508, 548, 580, 637. HRMS-EI ([M+1] + ): calc'd for C 44 H 33 N 6 , 645.2767; found 645.2734
Example 26
Synthesis of 5,15-di-p-(N-phenylamino)phenylporphyrin (Zn II) (Table 1, entry 1, B)
The reactants were as the same as entry 1 A except 5,15-di-p-bromophenylporphyrin was replaced by its zinc complex (34.5 mg, 0.05 mmol). After workup with general procedure, the title compound was obtained as brown solid (23.5 mg, 66%). 1 H NMR (CDCl 3 , 300 MHz) δ 10.31 (s, meso-2H), 9.45 (d, J=4.2 Hz, β-4H), 9.24 (d, J=4.5 Hz, β-4H), 8.14 (d, J=8.1 Hz, 4H), 7.50 (d, J=8.4 Hz, 4H), 7.40-7.47 (m, 8H), 7.06 (m, 2H), 6.11 (s, 2H). 13 C NMR (CDCl 3 , 75 MHz) δ 150.4, 149.3, 135.7, 132.5, 131.6, 129.5, 121.5, 118.4, 115.5, 106.1. UV-vis (λ max , nm) 419, 542, 583. HRMS-EI ([M] + ): calc'd for C 44 H 30 N 6 Zn, 706.1823; found 706.1845
Example 27
Synthesis of 5,15-di-p-[N-(4-nitrophenyl)amino]phenylporphyrin (Table 2, entry 2, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), (±) BINAP (6.2 mg, 0.01 mmol, 9), Cs 2 CO 3 (130.33 mg, 0.4 mmol), 4-nitroaniline (55.3 mg, 0.4 mmol) and toluene, the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound was obtained as brown solid (28.0 mg, 76%). 1 H NMR (DMSO-d 6 , 300 MHz) δ 10.64 (s, meso-2H), 9.82 (s, 2H), 9.67 (d, J=4.2 Hz, β-4H), 9.15 (d, J=4.2 Hz, β-4H), 8.24-8.29 (m, 8H), 7.75 (d, J=7.5 Hz, 4H), 7.45 (d, J=9.0 Hz, 4H), −3.19 (s, 2H). 13 C NMR (DMSO-d 6 , 75 MHz) δ 150.5, 146.7, 144.7, 140.2, 138.4, 135.9, 134.9, 132.7, 130.9, 126.4, 118.9, 114.3, 105.8. UV-vis (λ max , nm) 413, 506, 542, 579, 635. HRMS-EI ([M+1] + ): calc'd for C 44 H 31 N 8 O 4 , 735.2463; found 725.2436.
Example 28
Synthesis of 5,15-di-p-[N-(4-methoxyphenyl)amino]phenylporphyrin (Table 2, entry 3, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 3 (3.8 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), p-anisidine (49.3 mg, 0.4 mmol) and THF, the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound was obtained (32.6 mg, 93%). 1 H NMR (DMSO-d 6 , 300 MHz) δ 10.56 (s, meso-2H), 9.62 (d, J=4.2 Hz, β-4H), 9.15 (d, J=4.8 Hz, β-4H), 8.44 (s, 2H), 8.07 (d, J=7.8 Hz, 4H), 7.37 (d, J=9.0 Hz, 4H), 7.41 (d, J=8.7 Hz, 4H), 7.02 (d, J=8.4 Hz, 4H), 3.78 (s, 6H), −3.09 (s, 2H). 13 C NMR (DMSO-d 6 , 75 MHz) δ 154.3, 147.0, 145.2, 144.4, 136.1, 135.7, 134.7, 134.6, 132.3, 129.9, 121.4, 119.3, 114.7, 113.3, 55.3. UV-vis (λ max , m) 418, 510, 552, 583, 640. HRMS-EI ([M+1] + ): calc'd for, C 46 H 37 N 6 O 2 , 705.2978; found 705.3018.
Example 29
Synthesis of 5,15-di-p-[N-(4-methoxyphenyl)amino]phenylporphyrin (Zn II) (Table 2, entry 3, B)
The general procedure using 5,15-di-p-bromophenylporphyrin (Zn II)(34.5 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 8 (3.98 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), p-anisidine (49.3 mg, 0.4 mmol) and THF, the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound was obtained (26 mg, 68%). 1 H NMR (DMSO-d 6 , 300 MHz) δ 10.29 (s, meso-2H), 9.47 (d, J=4.5 Hz, β-4H), 9.07 (d, J=4.2 Hz, β-4H), 8.36 (s, 2H), 8.02 (d, J=8.1 Hz, 4H), 7.39 (d, J=8.1 Hz, 4H), 7.37 (d, J=8.1 Hz, 4H), 7.01 (d, J=8.1 Hz, 4H), 3.78 (s, 6H). 13 C NMR (DMSO-d 6 , 75 MHz) δ 154.1, 149.8, 148.7, 144.6, 136.1, 135.7, 134.7, 132.3, 131.9, 131.8, 121.0, 119.5, 114.7, 113.0, 105.8, 55.3. UV-vis (λ max , nm) 419, 545, 585.
Example 30
Synthesis of 5,15-di-p-(N-benzylamino)phenylporphyrin (Zn II) (Table 2, entry 4, B)
The general procedure using 5,15-di-p-bromophenylporphyrin (Zn II)(34.2 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 8 (3.98 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), benzylamine (43.7 μl, 0.4 mmol) and THF, the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound was obtained (30.7 mg, 83%). 1 H NMR (CDCl 3 , 300 MHz) δ 10.17 (s, meso-2H), 9.35 (d, J=4.2 Hz, β-4H), 9.17 (d, J=4.8 Hz, β-4H), 8.04 (d, J=7.2 Hz, 4H), 7.58 (d, J=7.5 Hz, 4H), 7.35-7.49 (m, 6H), 7.02 (d, J=7.5 Hz, 4H), 5.5 (s, 2H). UV-vis (λ max , nm) 419, 543, 584.
Example 31
Synthesis of 5,15-di-p-[N-(4-methylpyridyl)amino]phenylporphyrin (Table 2, entry 5, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), (±) BINAP (6.2 mg, 0.01 mmol, 9), NaOtBu (38.22 mg, 0.4 mmol), 4-aminomethylpyridine (41 μl, 0.4 mmol) and THF, the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound was obtained (29.6 mg, 88%). Different yield was observed by using other conditions (table 1). 1 H NMR (DMSO-d 6 , 300 MHz) δ 10.52 (s, meso-2H), 9.58 (d, J=4.5 Hz, β-4H), 9.07 (d, J=4.2 Hz, β-4H), 8.63 (d, J=5.7 Hz, 4H), 7.98 (d, J=8.4 Hz, 4H), 7.58 (d, J=5.7 Hz, 4H), 7.05 (d, J=8.7 Hz, 4H), 6.97 (t, 2H), 4.61 (d, J=5.7, 4H), −3.10 (s, 2H). 13 C NMR (DMSO-d 6 , 75 MHz) δ 149.8, 148.2, 147.1, 144.6, 136.0, 134.6, 134.4, 134.3, 132.2, 130.8, 128.1, 122.5, 111.4, 105.4, 45.6. UV-vis (λ max , nm) 416, 508, 548, 581, 638.
Example 32
Synthesis of 5,15-di-p-[N-(o-methylphenyl)amino]phenylporphyrin (Table 2, entry 6, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 3 (3.8 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), o-toluidine (43 μl, 0.4 mmol) and THF, the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound was obtained (29.1 mg, 87%). 1 H NMR (DMSO-d 6 , 300 MHz) δ 10.56 (s, meso-2H), 9.62 (d, J=4.8 Hz, β-4H), 9.16 (d, J=4.8 Hz, β-4H), 8.08 (d, J=8.7 Hz, 4H), 7.98 (s, 2H), 7.59 (d, J=7.5 Hz, 2H), 7.38 (d, J=8.7 Hz, 4H), 7.27-7.38 (m, 4H), 7.04 (m, 2H), 2.44 (s, 6H), −3.10 (s, 2H). 13 C NMR (DMSO-d 6 , 75 MHz) δ 147.5, 144.9, 142.6, 140.9, 135.9, 131.4, 131.2, 131.0, 128.9, 126.9, 122.6, 119.6, 115.5, 105.1, 18.0. UV-vis (λ max , nm) 419, 510, 552, 583, 640. HRMS-EI ([M+1] + ): calc'd for, C 46 H 37 N 6 , 673.3080; found 673.3107.
Example 33
Synthesis of 5,15-di-p-[N-(o-methylphenyl)amino]phenylporphyrin(Zn(II)) (Table 2, entry 6, B)
The general procedure using 5,15-di-p-bromophenylporphyrin(Zn(II)) (34.2 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 3 (3.8 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), o-toluidine (43 μl, 0.4 mmol) and THF, the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (29.1 mg, 87%) was obtained. 1 H NMR (DMSO-d 6 , 300 MHz) δ 10.23 (s, meso-2H), 9.39 (d, J=4.8 Hz, β-4H), 9.20 (d, J=4.8 Hz, β-4H), 8.11 (d, J=8.1 Hz, 4H), 7.63 (d, J=7.5 Hz, 2H), 7.36 (d, J=8.4 Hz, 4H), 7.27-7.35 (m, 4H), 7.04 (dd, J=7.8 Hz 2H), 5.76 (s, 2H), 2.48 (s, 6H). 13 C NMR (CDCl 3 , 75 MHz) δ 150.3, 149.3, 139.7, 135.8, 132.3, 131.4, 131.1, 122.2, 115.4, 105.8, 18.2. UV-vis (λ max , nm) 421, 542, 583. HRMS-EI ([M-Zn+1] + ): calc'd for, C 46 H 35 N 6 , 673.3080; found 673.3075.
Example 34
Synthesis of 5,15-di-n-butylaminophenylporphyrin (Table 1, entry 7, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 3 (3.78 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), n-butylamine (40 μl, 0.4 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (27.7 mg, 92%) was obtained. By using other ligand or other condition, the same product with different yield was obtained (table 1, entry 7). 1 H NMR (CDCl 3 , 300 MHz) δ 10.25 (s, meso-2H), 9.35 (d, J=4.6 Hz, β-4H), 9.16 (d, J=4.5 Hz, β-4H), 8.06 (d, J=8.4 Hz, 4H), 7.03 (d, J=8.4 Hz, 4H), 3.40 (t, J=6.6, 7.2 Hz, 4H), 1.83 (m, 4H), 1.59 (m, 4H), 1.08 (m, 6H), −3.00 (s, 2H). 13 C NMR (CDCl 3 , 75 MHz) δ 148.1, 147.8, 144.8, 136.1, 131.2, 131.1, 130.0, 119.7, 111.3, 104.9, 44.9, 31.8, 20.5, 14.1. UV-vis (λ max , nm) 419, 511, 553, 586, 641. HRMS-EI ([M+1] + ): calc'd for, C 40 H 41 N 6 , 605.3393; found 605.3395.
Example 35
Synthesis of 5,15-di-n-butylaminophenylporphyrin (Zn II) (Table 2, entry 7, B)
The general procedure using 5,15-di-p-bromophenylporphyrin (Zn II) (34.2 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 8 (3.98 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), n-butylamine (40 μl, 0.4 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (31.1 mg, 93%) was obtained. 1 H NMR (DMSO-d 6 , 300 MHz) δ 10.26 (s, meso-2H), 9.44 (d, J=4.8 Hz, β-4H), 9.04 (d, J=4.8 Hz, β4H), 7.92 (d, J=8.1 Hz, 4H), 7.01 (d, J=8.1 Hz, 4H), 6.04 (t, 2H), 3.28 (m, 4H), 1.76 (m, 4H), 1.55 (m, 4H), 1.05 (m, 6H). 13 C NMR (DMSO-d 6 , 75 MHz) δ 149.9, 148.5, 135.6, 134.5, 134.3, 131.6, 129.5, 110.4, 42.8, 31.2, 20.1, 14.0. UV-vis (λ max , nm419, 545, 586. HRMS-EI ([(M-Zn)+1] + ): calc'd for, C 40 H 41 N 6 , 605.3393; found 605.3360.
Example 36
Synthesis of 5,15-di-n-hexylaminophenylporphyrin (Table 2, entry 8, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 3 (3.78 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), n-hexylamine (52.8 μl, 0.4 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (29.7 mg, 90%) was obtained. 1 H NMR (CDCl 3 , 300 MHz) δ 10.25 (s, meso-2H), 9.35 (d, J=4.8 Hz, β-4H), 9.16 (d, J=4.2 Hz, β-4H), 8.05 (d, J=8.4 Hz, 4H), 7.03 (d, J=8.4 Hz, 4H), 4.05 (br, s, 2H), 3.40 (t, J=7.2 Hz, 4H), 1.84 (m, 4H), 1.54 (m, 4H), 1.43 (m, 4H), 0.97 (m, 6H), −3.00 (s, 2H). 13 C NMR (CDCl 3 , 75 MHz) δ 148.1, 147.8, 144.8, 136.1, 131.2, 131.1, 130.0, 119.7, 111.4, 104.9, 44.3, 31.8, 29.7, 27.0, 22.7, 14.1. UV-vis (λ max , nm) 421, 509, 549, 583, 638.
Example 37
5,15-di-n-hexylaminophenylporphyrin (Zn II) (Table 2, entry 8, B)
The general procedure using 5,15-di-p-bromophenylporphyrin (Zn II) (34.2 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 7 (5.78 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), n-hexylamine (52.8 μl, 0.4 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (17 mg, 53%) was obtained. 1 H NMR (CDCl 3 , 300 MHz) δ 10.22 (s, meso-2H), 9.38 (d, J=4.8 Hz, β-4H), 9.18 (d, J=4.2 Hz, β-4H), 7.95 (d, J=8.1 Hz, 4H), 6.70 (d, J=8.1 Hz, 4H), 3.44 (m, 4H), 2.95 (m, 4H), 1.76 (m, 4H), 1.61 (m, 4H), 1.36 (m, 8H), 0.94 (m, 6H). 13 C NMR (DMSO-d 6 , 75 MHz) δ 150.5, 149.2, 139.4, 135.4, 132.5, 131.1, 111.4, 104.9, 44.1, 31.5, 28.0, 26.6, 22.7, 14.1. UV-vis (λ max , nm) 419, 543, 584.
Example 38
5,15-di-p-(N-methyl, N-phenylamino)phenylporphyrin (Table 2, entry 9, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 3 (3.78 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), N-methylaniline (43.7 μl, 0.4 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (29.5 mg, 88%) was obtained. 1 H NMR (CDCl 3 , 300 MHz) δ 10.28 (s, meso-2H), 9.39 (d, J=4.8 Hz, β-4H), 9.20 (d, J=4.8 Hz, β-4H), 8.14 (d, J=8.7 Hz, 4H), 7.37-7.50 (m, 12H), 7.13 (dd, J=2.1, 6.6 Hz, 2H), 3.62 (s, 6H), −3.02 (s, 2H). 13 C NMR (CDCl 3 , 75 MHz) δ 148.9, 148.5, 147.6, 144.9, 135.8, 133.0, 131.4, 131.1, 129.6, 122.8, 122.7, 119.2, 116.9, 105.1, 40.6. UV-vis (λ max , nm) 413, 510, 552, 583, 640. HRMS-EI ([M] + ): calc'd for C 46 H 36 N 6 , 672.3001; found 672.3010.
Example 39
Synthesis of 5,15-di-p-(N-methyl, N-phenylamino)phenylporphyrin (Zn II) (Table 2, entry 9, B)
The general procedure using 5,15-di-p-bromophenylporphyrin (Zn II) (34.2 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 3 (3.78 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), N-methylaniline (43.7 μl, 0.4 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (27 mg, 73%) was obtained. 1 H NMR (CDCl 3 , 300 MHz) δ 10.24 (s, meso-2H), 9.39 (d, J=4.2 Hz, β-4H), 9.22 (d, J=4.8 Hz, β-4H), 8.12 (d, J=8.1 Hz, 4H), 7.37-7.49 (m, 12H), 7.13 (m, 2H), 3.63 (s, 6H). 13 C NMR (CDCl 3 , 75 MHz) δ 150.4, 149.2, 148.3, 135.6, 134.5, 132.6, 131.5, 129.5, 122.4, 122.2, 117.0, 106.0, 40.6. UV-vis (λ max , nm) 413, 544, 587. HRMS-EI ([M-Zn+1] + ): calc'd for C 46 H 35 N 6 , 673.3080; found 673.3104.
Example 40
Synthesis of 5,15-di-p-diphenylaminophenylporphyrin (Table 2, entry 10, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 3 (3.78 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), diphenylamine (67.7 mg, 0.4 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (32.4 mg, 81%) was obtained. 1 H NMR (CDCl 3 , 300 MHz) δ 10.28 (s, meso-2H), 9.39 (d, J=4.8 Hz, β-4H), 9.20 (d, J=4.8 Hz, β-4H), 8.14 (d, J=8.7 Hz, 4H), 7.37-7.50 (m, 12H), 7.13 (dd, J=2.1, 6.6 Hz, 2H), 3.62 (s, 6H), −3.04 (s, 2H). 13 C NMR (CDCl 3 , 75 MHz) δ 147.8, 135.8, 131.5, 131.0, 129.5, 124.9, 123.3, 121.6, 105.2. UV-vis (λ max , nm) 410, 510, 552, 583, 640. HRMS-EI ([M+1] + ): calc'd for C 56 H 41 N 6 , 797.3393; found 797.3398.
Example 41
Synthesis of 5,15-di-p-diphenylaminophenylporphyrin (Zn II) (Table 2, entry 10, B)
The general procedure using 5,15-di-p-bromophenylporphyrin (Zn II) (34.2 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 8 (3.98 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), diphenylamine (67.7 mg, 0.4 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (24.5 mg, 57%) was obtained. 1 H NMR (DMSO-d 6 , 300 MHz) δ 10.35 (s, meso-2H), 9.52 (d, J=4.8 Hz, β-4H), 9.08 (d, J=4.5 Hz, β-4H), 8.12 (d, J=8.1 Hz, 4H), 7.37-7.51 (m, 12H), 7.17 (m, 4H). 13 C NMR (DMSO-d 6 , 75 MHz) δ 149.4, 148.9, 147.4, 146.6, 136.6, 135.6, 132.1, 129.9, 124.5, 123.4, 121.1, 118.8, 116.7, 106.1. UV-vis (λ max , nm) 416, 543, 584. HRMS-EI ([M-Zn+1] + ): calc'd for C 56 H 41 N 6 Zn, 797.3393; found 797.3408.
Example 42
Synthesis of 5,15-di-p-benzophenone iminophenylporphyrin (Table 2, entry 11, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd 2 (dba) 3 (4.58 mg, 0.005 mmol), ligand 1 (2.98 mg, 0.01 mmol), NaOtBu (38.22 mg, 0.4 mmol), benzophenone imine (67.1 μl, 0.4 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (21.4 mg, 81%) was obtained. 1 H NMR (CDCl 3 , 300 MHz) δ 10.27 (s, meso-2H), 9.36 (d, J=4.8 Hz, β-4H), 9.95 (d, J=4.8 Hz, β-4H), 8.0 (d, J=7.5 Hz, 4H), 7.95 (d, J=8.7 Hz, 4H), 7.52 (m, 12H), 7.43 (m, 4H), 7.13 (d, J=7.5 Hz, 4H), −3.18 (s, 2H). 13 C NMR (CDCl 3 , 75 MHz) δ 142.9, 142.6, 135.9, 131.5, 131.0, 129.6, 121.6, 118.6, 115.7, 105.1. UV-vis (λ max , nm) 412, 506, 541, 578, 634. HRMS-EI ([M+1] + ): calc'd for C 58 H 41 N 6 , 821.3393; found 821.3370.
Example 43
Synthesis of 5,15-di-p-morpholinophenylporphyrin (Table 2, entry 11, A)
The general procedure using 5,15-di-p-bromophenylporphyrin (31.0 mg, 0.05 mmol), Pd(OAc) 2 (1.12 mg, 0.005 mmol), ligand 8 (3.98 mg, 0.01 mmol), Cs 2 CO 3 (130.33 mg, 0.4 mmol), morpholine (35 μl, 0.4 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 48 h. After workup with general procedure, the title compound (25 mg, 76%) was obtained.
Example 44
Synthesis of Tetrakis-p-(N-phenylamino)phenylporphyrin (Table 3, entry 1)
The general procedure using tetrakis-p-bromophenylporphyrin (46.5 mg, 0.05 mmol), Pd(OAc) 2 (2.24 mg, 0.01 mmol), (±) BINAP (12.4 mg, 0.02 mmol, 9), NaOtBu (76.44 mg, 0.8 mmol), aniline (73 μl, 0.8 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 72 h. After workup with general procedure, the title compound (44.6 mg, 91%) was obtained. 1 H NMR (CDCl 3 , 300 MHz) 1 H NMR (CDCl 3 , 300 MHz) δ 8.95 (s, β-8H), 8.08 (d, J=8.1 Hz, 8H), 7.34-7.42 (m, 24H), 7.04 (t, J=6.6, 7.2 Hz, 4H), 6.05 (s, 4H), −2.66 (s, 2H). 13 C NMR (CDCl 3 , 75 MHz) δ 142.9, 142.7, 135.7, 134.6, 129.5, 121.5, 119.9, 118.5, 115.3. UV-vis (λ max , nm) 433, 524, 566, 657. HRMS-EI ([M+1] + ): calc'd for C 68 H 51 N 8 , 979.4237; found 979.4218.
Example 45
Synthesis of Tetrakis-p-(n-butylamino)phenylporphyrin (Table 3, entry 2)
The general procedure using tetrakis-p-bromophenylporphyrin (46.5 mg, 0.05 mmol), Pd(OAc) 2 (2.24 mg, 0.01 mmol), ligand 8 (7.96 mg, 0.02 mmol), NaOtBu (76.44 mg, 0.8 mmol), n-butylamine (80 μl, 0.8 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 72 h. After workup with general procedure, the title compound (38.5 mg, 86%) was obtained. 1 H NMR (CDCl 3 , 300 MHz) δ 8.91 (s, β-8H), 8.01 (d, J=8.1 Hz, 8H), 6.95 (d, J=8.1 Hz, 8H), 3.95 (s, 4H), 3.60 (t, J=7.2, 8.4 Hz, 8H), 1.79 (m, 8H), 1.59 (m, 8H), 1.06 (t, J=6.9, 7.2 Hz, 12H), −2.64 (s, 2H). 13 C NMR (CDCl 3 , 75 MHz) δ 147.9, 135.8, 131.3, 120.3, 110.9, 43.9, 31.9, 20.5, 14.0. UV-vis (λ max , nm) 434, 527, 571, 661. HRMS-EI ([M+1] + ): calc'd for C 60 H 67 N 8 , 899.5489; found 899.5507.
Example 46
Synthesis of Tetrakis-β-(N-methyl, N-phenylamino)phenylporphyrin (Table 3, entry 3)
The general procedure using tetrakis-p-bromophenylporphyrin (46.5 mg, 0.05 mmol), Pd(OAc) 2 (2.24 mg, 0.01 mmol), (±) BINAP (12.4 mg, 0.02 mmol, 9), NaOtBu (76.44 mg, 0.8 mmol), N-methylaniline (87.4 μl, 0.8 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 72 h. After workup with general procedure, the title compound (42.4 mg, 82%) was obtained. 1 H NMR (CDCl 3 , 300 MHz) δ 8.78 (s, β-8H), 7.92 (d, J=7.8 Hz, 8H), 7.21-7.30 (m, 16H), 7.16 (d, J=8.1 Hz, 8H), 7.05 (s, 2H), 6.95 (t, 4H), 3.42 (s, 12H), −2.81 (s, 2H). 13 C NMR (CDCl 3 , 75 MHz) 6148.9, 148.4, 135.6, 134.1, 129.5, 122.7, 122.6, 122.5, 120.1, 116.6, 116.5, 40.5. UV-vis (λ max , nm) 435, 525, 567, 657. HRMS-EI ([M+1] + ): Calc'd for C 72 H 59 N 8 , 1035.4863; found 1035.4836.
Example 47
Synthesis of Tetrakis-p-(diphenylamino)phenylporphyrin (Table 3, entry 4)
The general procedure using tetrakis-p-bromophenylporphyrin (46.5 mg, 0.05 mmol), Pd(OAc) 2 (2.24 mg, 0.01 mmol), ligand 3 (7.56 mg, 0.02 mmol), NaOtBu (76.44 mg, 0.8 mmol), diphenylamine (135.4 mg, 0.8 mmol) and THF (4-6 mL), the reaction proceeded at 100° C. for 72 h. After workup with general procedure, the title compound (52.2 mg, 81%) was obtained. 1 H NMR (CDCl 3 , 300 MHz) δ 9.02 (s, β-8H), 8.12 (d, J=8.7 Hz, 8H), 7.47 (d, J=8.4 Hz, 8H), 7.43 (s, 16H), 7.41 (m, 4H), 7.15 (s, 8H), −2.66 (s, 2H). 13 C NMR (CDCl 3 , 75 MHz) δ 147.8, 147.4, 135.9, 135.7, 129.5, 124.8, 123.3, 121.3, 119.9, 117.7. UV-vis (λ max , nm) 439, 526, 570, 659. HRMS-EI ([M+1] + ): calc'd for C 92 H 67 N 8 , 1283.5489; found 1283.5478.
Example 48 through 58 relate to methods for synthesizing meso-substituted phenoxyporphyrins, and the phenoxyporphyrin compounds so made, according to the present invention.
Example 48
General Procedure
All reactions were carried out under a nitrogen atmosphere in oven-dried glassware using standard Schlenk techniques. Toluene was distilled under nitrogen from sodium benzophenone ketyl. Deuterated solvents were purchased from Cambridge Isotope Laboratories and were used as supplied. All other solvents were of liquid chromatography grade, which were purchased from Fisher Scientific and used as supplied. Phenols were purchased from Acros Organics or Aldrich Chemical Co. and used without further purification. [5-bromo-10,20-diphenylporphyrino]zinc(II) and [5,15-dibromo-10,20-diphenylporphyrino]zinc(II) were synthesized according to the literature. Phosphine ligands notably, bis(2-diphenylphosphinophenyl)ether (DPEphos), were purchased from Strem along with the metal precursors; palladium(II) acetate and tris(dibenzylideneacetone)dipalladium(0). Cesium carbonate was obtained as a gift from Chemetall Chemical Products, Inc. Proton and carbon nuclear magnetic resonance spectra ( 1 H NMR and 13 C NMR) were recorded on a Varian Mercury 300 spectrometer and referenced with respect to residual solvent. Infrared spectra were obtained using a Bomen B100 Series FT-IR spectrometer. Samples were prepared as films on a NaCl plate by evaporating THF solutions. UV-Vis spectra were obtained using a Hewlett-Packard 8452A diode array spectrophotometer. High-resolution mass spectroscopy was performed by the Mass Spectrometry Center located in the Chemistry Department of the University of Tennessee on a VG Analytical hybrid high performance ZAB-EQ (B-E-Q geometry) instrument using electron impact (EI) ionization technique with a 70 eV electron beam. Thin layer chromatography was carried out on E. Merck Silica Gel 60 F-254 TLC plates.
Example 49
General Procedures for Catalytic C—O Coupling of Bromoporphyrin
The bromoporphyrin, palladium precursor, phosphine ligand and base were placed in an oven-dried, resealable Schlenk tube. The tube was sealed with a Teflon screw cap, evacuated, and backfilled with nitrogen. The screw cap was replaced with a rubber septum; the phenol was then added via syringe, followed by solvent. The tube was purged with nitrogen for 2 min, and then the septum was replaced with the Teflon screw cap. The tube was sealed, and its contents were placed in a heated oil-bath with constant stirring until the starting bromoporphyrin had been completely consumed as indicated by TLC analysis. The resulting mixture was cooled to room temperature, taken up in ethyl acetate (60 mL) and transferred to a separatory funnel. The mixture was then washed with water (×2), dried over anhydrous sodium sulfate, filtered and dried in vacuo. The crude product was then purified.
Example 50
Synthesis of 5-phenoxy-10,20-diphenylporphinato zinc(II)
The general procedure was used to couple 5-bromo-10,20-diphenylporphinato zinc(II) (30 mg, 0.05 mmol) with phenol (17 mg, 0.018 mmol), using palladium acetate (1 mg, 0.005 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.015 mmol) as the phosphine ligand and cesium carbonate (24 mg, 0.07 mmol) as the base. The reaction was conducted in toluene (5 mL) at 100° C. for 23 hours. Isolated via flash chromatography (silica gel, THF:hexanes (v)=1:8 as a red solid (24 mg, 80%). 1 H NMR (300 MHz, CDCl 3 ): δ 10.13 (s, 1H), 9.39 (d, J=4.5 Hz, 2H), 9.31 (d, J=4.8 Hz, 2H), 9.09 (d, J=4.5 Hz, 2H), 8.92 (d, J=4.8 Hz, 2H), 8.19 (m, 4H), 7.74 (m, 6H), 7.23 (m, 2H), 7.02 (m, 3H). 13 C NMR (75 MHz, CDCl 3 ): δ 165.9, 150.3, 150.1, 149.7, 145.8, 142.3, 134.5, 132.9, 132.2, 131.8, 129.6, 128.0, 127.5, 126.6, 121.5, 120.7, 116.6, 107.7, 105.6. UV-vis (CHCl 3 , λ max , nm): 218, 418. IR (film, cm −1 ): 3609, 3583, 3047, 2362, 1591, 1544, 1486, 1440, 1384, 1361, 1319, 1295, 1214, 1163, 1147, 1062, 996, 851, 790, 750, 721, 701. HRMS-EI ([M] + ): C 38 H 24 N 4 OZn, 616.124; found: 616.125.
Example 51
Synthesis of 5-(4-methoxyphenoxy)-10,20-diphenylporphinato zinc(II)
The general procedure was used to couple 5-bromo-10,20-diphenylporphinato zinc(II) (30 mg, 0.05 mmol) with 4-methoxyphenol (22 mg, 0.18 mmol), using palladium acetate (1 mg, 0.005 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.015 mmol) as the phosphine ligand and cesium carbonate (24 mg, 0.07 mmol) as the base. The reaction was conducted in toluene (5 mL) at 100° C. for 17 hours. Isolated via flash chromatography (silica gel, THF:hexanes (v)=1:8 as a red solid (29.9 mg, 93%). 1 H NMR (300 MHz, CDCl 3 ): δ 10.02 (s, 1H), 9.35 (d, J=4.2 Hz, 2H), 9.24 (d, J=3.9 Hz, 2H), 8.98 (d, J=4.2 Hz, 2H), 8.8 (d, J=3.9 Hz, 2H), 8.18 (m, 4H), 7.75 (m, 6H), 6.92 (d, J=8.4 Hz, 2H), 6.67 (d, J=8.4 Hz, 2H), 3.60 (S, 3H). 13 C NMR (75 MHz, CDCl 3 ): δ 160.8, 153.9, 150.2, 150.0, 149.5, 145.9, 142.6, 134.6, 132.7, 132.1, 132.0, 131.6, 127.9, 127.4, 126.5, 120.4, 117.1, 114.6, 105.2, 55.6. UV-vis (CHCl 3 , λ max , nm): 418, 548. IR (film, cm −1 ): 3291, 3054, 2973, 2954, 2877, 2833, 2738, 1808, 1721, 1595, 1538, 1502, 1459, 1440, 1385, 1360, 1322, 1294, 1243, 1147, 1103, 1061, 1037, 994, 881, 846, 827, 793, 751, 724, 701. HRMS-EI ([M] + ): C 39 H 26 N 4 O 2 Zn, 646.135; found: 646.137.
Example 52
Synthesis of 5-(4-t-butylphenoxy)-10,20-diphenylporphinato zinc(II)
The general procedure was used to couple 5-bromo-10,20-diphenylporphinato zinc(II) (30 mg, 0.05 mmol) with 4-t-butylphenol (27 mg, 0.18 mmol), using palladium acetate (1 mg, 0.005 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.015 mmol) as the phosphine ligand and cesium carbonate (24 mg, 0.07 mmol) as the base. The reaction was conducted in toluene (5 mL) at 100° C. for 18 hours. Isolated via flash chromatography (silica gel, THF:hexanes (v)=1:8 as a red solid (23.8 mg, 73%). 1 H NMR (300 MHz, CDCl 3 ): δ 10.16 (s, 1H), 9.45 (d, J=4.8 Hz, 2H), 9.34 (d, J=4.2 Hz, 2H), 9.06 (d, J=4.5 Hz, 2H), 8.93 (d, J=4.8 Hz, 2H), 8.22 (m, 4H), 7.77 (m, 6H), 7.24 (d, J=9.9 Hz, 2H), 6.96 (d, J=8.7 Hz, 2H), 1.26 (S, 9H). 13 C NMR (75 MHz, CDCl 3 ): δ 164.0, 159.9, 150.4, 150.1, 149.7, 146.0, 144.1, 142.4, 134.5, 132.9, 132.1, 131.7, 128.1, 127.5, 126.7, 126.3, 120.66, 115.9, 105.5, 31.5, 29.7. UV-vis (CHCl 3 , λ max , nm): 418, 548. IR (film, cm −1 ): 3297, 3054, 3027, 2961, 2872, 1806, 1599, 1542, 1505, 1488, 1460, 1386, 1362, 1322, 1295, 1266, 1220, 1173, 1150, 1110, 1062, 1041, 995, 883, 846, 832, 792, 750, 723, 701. HRMS-EI ([M] + ): C 42 H 32 N 4 OZn, 672.187; found: 672.186.
Example 53
Synthesis of 5-(4-fluorophenoxy)-10,20-diphenylporphinato zinc(II)
The general procedure was used to couple 5-bromo-10,20-diphenylporphinato zinc(II) (30 mg, 0.05 mmol) with 4-fluorophenol (20 mg, 0.18 mmol), using palladium acetate (1 mg, 0.005 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.015 mmol) as the phosphine ligand and cesium carbonate (24 mg, 0.07 mmol) as the base. The reaction was conducted in toluene (5 mL) at 100° C. for 17 hours. Isolated via flash chromatography (silica gel, THF:hexanes (v)=1:8 as a red solid (25.4 mg, 78%). 1 H NMR (300 MHz, CDCl 3 ): δ 10.10 (s, 1H), 9.35 (d, J=4.5 Hz, 2H), 9.29 (d, J=4.2 Hz, 2H), 9.02 (d, J=4.8 Hz, 2H), 8.91 (d, J=4.8 Hz, 2H), 8.19 (m, 4H), 7.76 (m, 6H), 6.93 (m, 4H). 13 C NMR (75 MHz, CDCl 3 ): δ 150.4, 150.2, 149.70, 145.4, 134.5, 132.9, 132.2, 131.8, 127.7, 127.5, 126.6, 120.6, 117.4, 117.2, 116.1, 115.8, 105.6. UV-vis (CHCl 3 , λ max , nm): 418, 546. IR (film, cm −1 ): 3273, 3101, 3073, 3054, 3023, 2974, 2933, 2875, 2740, 2951, 2582, 2552, 1807, 1719, 1597, 1541, 1520, 1498, 1459, 1440, 1386, 1360, 1322, 1295, 1260, 1195, 1145, 1091, 1062, 1041, 995, 885, 847, 832, 793, 751, 724, 701. HRMS-EI ([M] + ): C 38 H 23 N 4 OFZn, 634.115; found: 634.113.
Example 54
Synthesis of 5-(2-isopropylphenoxy)-10,20-diphenylporphinato zinc(II)
The general procedure was used to couple 5-bromo-10,20-diphenylporphinato zinc(II) (30 mg, 0.05 mmol) with 2-isopropylphenol (25 μL, 0.018 mmol), using palladium acetate (1 mg, 0.005 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.015 mmol) as the phosphine ligand and cesium carbonate (24 mg, 0.07 mmol) as the base. The reaction was conducted in toluene (5 mL) at 100° C. for 17 hours. Isolated via flash chromatography (silica gel, THF:hexanes (v)=1:8 as a red solid (23 mg, 72%). 1 H NMR (300 MHz, CDCl 3 ): δ 10.05 (s, 1H), 9.33 (d, J=4.8 Hz, 2H), 9.26 (d, J=4.5 Hz, 2H), 9.01 (d, J=4.8 Hz, 2H), 8.90 (d, J=4.5 Hz, 2H), 8.19 (m, 4H), 7.75 (m, 6H), 7.60 (d, J=7.8 Hz, 1H), 6.96 (t, J=7.5 Hz, 1H), 6.67 (t, J=7.2 Hz, 1H), 6.02 (d, J=8.1 Hz, 1H), 4.40 (m, 1H), 1.82 (d, J=6.9 Hz, 6H). 13 C NMR (75 MHz, CDCl 3 ): δ 163.86, 150.3, 150.0, 149.6, 145.8, 142.5, 135.8, 134.5, 132.8, 132.1, 131.6, 127.9, 127.4, 126.6, 126.5, 121.3, 120.4, 116.4, 105.2, 28.0, 23.3. UV-vis (CHCl 3 , λ max , nm): 418, 546. IR (film, cm −1 ): 3293, 3055, 3026, 2961, 2873, 1805, 1596, 1542, 1483, 1441, 1385, 1360, 1322, 1294, 1261, 1218, 1191, 1154, 1061, 1039, 994, 885, 847, 824, 793, 750, 723, 701. HRMS-EI ([M] + ): C 41 H 30 N 4 OZn, 658.171; found: 658.168.
Example 55
Synthesis of 5-(3-methylphenoxy)-10,20-diphenylporphinato zinc(II)
The general procedure was used to couple 5-bromo-10,20-diphenylporphinato zinc(II) (30 mg, 0.05 mmol) with 3-cresol (20 PL, 0.018 mmol), using palladium DBA (1.5 mg, 0.0075 mmol) as the palladium precursor, DPEphos (9.6 mg, 0.036 mmol) as the phosphine ligand and cesium carbonate (34 mg, 0.1 mmol) as the base. The reaction was conducted in toluene (5 mL) at 100° C. for 16 hours. Isolated via flash chromatography (silica gel, THF:hexanes (v)=1:8 as a red solid (25 mg, 78%). 1 H NMR (300 MHz, CDCl 3 ): δ 10.03 (s, 1H), 9.36 (d, J=4.5 Hz, 2H), 9.25 (d, J=4.5 Hz, 2H), 9.00 (d, J=4.2 Hz, 2H), 8.89 (d, J=4.5 Hz, 2H), 8.2 (m, 4H), 7.76 (m, 6H), 7.10 (t, J=7.5 Hz, 1H), 6.80 (m, 3H), 2.15 (S, 3H). 13 C NMR (75 MHz, CDCl 3 ): δ 166.1, 150.0, 150.2, 149.6, 145.8, 142.7, 139.7, 134.6, 132.7, 132.0, 131.6, 129.3, 127.9, 127.4, 126.5, 122.2, 120.3, 117.3, 113.7, 105.2, 21.4. UV-vis (CHCl 3 , λ max , nm): 418, 546. IR (film, cm −1 ): 3053, 3024, 2922, 2877, 1587, 1542, 1484, 1458, 1440, 1384, 1360, 1321, 1294, 1248, 1217, 1188, 1158, 1061, 1039, 995, 911, 881, 848, 793, 781, 752, 723, 700. HRMS-EI ([M] + ): C 39 H 26 N 4 OZn, 630.140; found: 630.139.
Example 56
Synthesis of 5-(4-methylphenoxy)-10,20-diphenylporphinato zinc(II)
The general procedure was used to couple 5-bromo-10,20-diphenylporphinato zinc(II) (30 mg, 0.05 mmol) with 4-cresol (20 mg, 0.018 mmol), using palladium acetate (1 mg, 0.005 mmol) as the palladium precursor, DPEphos (4.0 mg, 0.015 mmol) as the phosphine ligand and cesium carbonate (24 mg, 0.07 mmol) as the base. The reaction was conducted in toluene (5 mL) at 100° C. for 16 hours. Isolated via flash chromatography (silica gel, toluene:hexanes (v)=3:1 as a red solid (21 mg, 65%). 1 H NMR (300 MHz, CDCl 3 ): δ 9.97 (s, 1H), 9.30 (d, J=4.5 Hz, 2H), 9.21 (d, J=4.5 Hz, 2H), 8.92 (d, J=4.5 Hz, 2H), 8.8 (d, J=4.5 Hz, 2H), 8.13 (m, 4H), 8.13 (m, 6H), 6.97 (d, J=9.0 Hz, 2H), 6.86 (d, J=8.7 Hz, 2H), 2.2 (S, 3H). 13 C NMR (75 MHz, CDCl 3 ): δ 150.3, 145.8, 143.4, 142.7, 134.6, 132.7, 132.0, 131.6, 130.4, 130.0, 128.9, 128.4, 127.9, 127.4, 126.5, 125.2, 120.3, 116.3, 105.2, 24.9. UV-vis (CHCl 3 , λ max , nm): 416, 546. IR (film, cm −1 ): 3324, 2988, 1557, 1505, 1453, 1440, 1384, 1358, 1321, 1294, 1215, 1167, 1145, 1060, 993, 846, 820, 793, 753, 723. HRMS-EI ([M] + ): C 39 H 26 N 4 OZn, 630.140; found: 630.141.
Example 57
Synthesis of 5-(2-methylphenoxy)-10,20-diphenylporphinato zinc(II)
The general procedure was used to couple 5-bromo-10,20-diphenylporphinato zinc(II) (30 mg, 0.05 mmol) with 2-cresol (20 mg, 0.018 mmol), using palladium DBA (1.5 mg, 0.0075 mmol) as the palladium precursor, DPEphos (9.6 mg, 0.036 mmol) as the phosphine ligand and cesium carbonate (24 mg, 0.07 mmol) as the base. The reaction was conducted in toluene (5 mL) at 100° C. for 17 hours. Isolated via flash chromatography (silica gel, toluene:hexanes (v)=3:1 as a red solid (27.8 mg, 89%). 1 H NMR (300 MHz, CDCl 3 ): δ 9.94 (s, 1H), 9.33 (d, J=4.8 Hz, 2H), 9.19 (d, J=4.5 Hz, 2H), 8.97 (d, J=4.2 Hz, 2H), 8.90 (d, J=4.8 Hz, 2H), 8.18 (m, 4H), 7.74 (m, 6H), 7.47 (d, J=6.9 Hz, 1H), 6.90 (t, J=7.2 Hz, 7.5 Hz 1H), 6.68 (t, J=7.5 Hz, 7.2 Hz 1H), 6.02 (d, J=8.4 Hz, 1H), 3.10 (S, 3H). 13 C NMR (75 MHz, CDCl 3 ): δ 150.1, 149.9, 149.6, 145.7, 142.3, 140.7, 140.6, 140.6, 140.5, 134.5, 132.8, 132.1, 131.6, 131.0, 127.8, 127.5, 126.8, 126.6, 121.1, 116.2, 105.3, 17.0. UV-vis (CHCl 3 , λ max , nm): 415, 546. IR (film, cm −1 ): 3047, 3024, 2922, 2877, 1587, 1542, 1484, 1458, 1440, 1384, 1359, 1321, 1294, 1217, 1188, 1158, 1061, 991, 908, 877, 851, 793, 779, 751, 723. HRMS-EI ([M] + ): C 39 H 26 N 4 OZn, 630.140; found: 630.139.
Example 58
Synthesis of bis-5,15-(4-methoxyphenoxy)-10,20-diphenylporphinato zinc(II)
The general procedure was used to couple 5,15-dibromo-10,20-diphenylporphinato zinc(II) (34 mg, 0.05 mmol) with 4-methoxyphenol (22 mg, 0.018 mmol), using palladium DBA (1.5 mg, 0.0075 mmol) as the palladium precursor, DPEphos (9.6 mg, 0.036 mmol) as the phosphine ligand and cesium carbonate (47 mg, 0.14 mmol) as the base. The reaction was conducted in toluene (5 mL) at 100° C. for 18 hours. Isolated via flash chromatography (silica gel, THF:hexanes (v)=1:8 as a purple solid (26 mg, 68%). 1 H NMR (300 MHz, THF-d 8 ): δ 9.28 (m, 4H), 8.77 (m, 4H), 8.17 (m, 4H), 7.73 (m, 6H), 8.8 (d, J=4.5 Hz, 2H), 8.13 (m, 4H), 7.73 (m, 6H), 6.95 (d, J=9.3 Hz, 4H), 6.77 (d, J=9.6 Hz, 4H), 3.67 (s, 6H). 13 C NMR (75 MHz, CDCl 3 ): δ 155.4, 150.4, 147.8, 144.0, 135.3, 132.7, 128.4, 128.2, 127.2, 117.8, 115.3, 55.7. UV-vis (CHCl 3 , λ max , nm): 426, 554. IR (film, cm −1 ): 3056, 2950, 2903, 2833, 2353, 1812, 1722, 1596, 1502, 1490, 1461, 1439, 1332, 1302, 1243, 1198, 1166, 1144, 1103, 1063, 1035, 1003, 920, 884, 827, 796, 751, 735, 722, 702. HRMS-EI ([M] + ): C 46 H 32 N 4 O 4 Zn, 768.162; found: 768.164.
It will be understood that various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation. | Novel methods of synthesizing heteroatom-containing porphyrins and metalloporphyrins are disclosed. Novel heteroatom-containing porphyrin and metalloporphyrin compounds are also disclosed. The new methods advantageously utilize metal-catalyzed cross-coupling and amination reactions to produce porphyrin compounds useful in a variety of practical applications. | 2 |
This is a continuation-in-part application of my Application Ser. No. 910,215 filed May 30, 1978 for ORGANIC ACIDS AND PROCESS FOR PREPARING SAME now U.S. Pat. No. 4,334,084, which issued on June 8, 1982.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a mixture of polycyclic, aromatic polycarboxylic acids carrying nuclear nitro groups that is substantially soluble in an azeotropic mixture of methyl ethyl ketone and ethanol but substantially insoluble in water, and a process for preparing the mixture of polycyclic, aromatic polycarboxylic acids.
2. Description of Prior Art
In U.S. Pat. No. 4,052,448 to J. G. Schulz and E. T. Sabourin, there is disclosed a mixture of polycyclic, aromatic polycarboxylic acids carrying nuclear nitro groups that is substantially soluble in a polar solvent but substantially insoluble in water, and a process for preparing the mixture.
SUMMARY OF THE INVENTION
The process defined and claimed herein is directed to an improvement in the process claimed in U.S. Pat. No. 4,052,448. I have found that if in the process of the patent a mixture of two polar solvents, one being methyl ethyl ketone and the other being ethanol, is used in place of methyl ethyl ketone alone or said ethanol alone in recovering the desired mixture of polycyclic, aromatic polycarboxylic acids, an unexpectedly larger amount of polycyclic, aromatic polycarboxylic acids is obtained than when only methyl ethyl ketone or only ethanol is used.
The individual components of the novel mixtures of polycyclic, aromatic polycarboxylic acids obtained herein are believed to be composed of condensed and/or non-condensed benzene rings, with an average number of rings in the individual molecules ranging from 2 to about 10, but generally from 3 to about 8. On the average, the number of carboxyl groups carried by the individual molecules will range from about 4 to about 10, generally from about 6 to about 8, and the average number of nitro groups from about 1 to about 4, generally from about 2 to about 3. The average molecular weight of the mixture will range from about 600 to about 1500, generally from about 700 to about 1000, and the average neutral equivalent will range from about 80 to about 200, generally from about 100 to about 150. A typical analysis of the novel mixture is defined below in Table I in approximate amounts.
TABLE I______________________________________ Weight Percent Broad Range Preferred Range______________________________________Carbon 50 to 60 52 to 56Hydrogen 3 to 5 3.7 to 4.4Nitrogen 3 to 6 4 to 5Oxygen 25 to 45 30 to 40Sulfur 0.2 to 0.5 0.3 to 0.5Ash 0.1 to 5.0 0.3 to 3.0______________________________________
The amount of each polar solvent present in the solvent mixture defined above will be that amount just sufficient to form an azeotropic mixture when the solvent mixture is subjected to distillation at ambient pressure. Thus, according to "Azeotropic Data", Advances in Chemistry Series, No. 6, published by the American Chemical Society, Washington, D.C., 1951, an azeotropic mixture of methyl ethyl ketone and ethanol will have a weight ratio of 54:46.
The procedure employed herein preferably follows the procedure defined in U.S. Pat. No. 4,052,448. Thus there is introduced into a reactor an aqueous solution of nitric acid and a carbonaceous material. The nitric acid can have a concentration of about 5 to about 90 percent, but preferably will be in the range of about 10 to about 70 percent. The carbonaceous material is preferably a solid in the form of a slurry, for example, an aqueous slurry containing the carbonaceous material in particulate form and from about 50 to about 90 weight percent of water.
The solid carbonaceous material that can be used herein can have the following composition on a moisture-free basis:
TABLE II______________________________________ Weight Percent Broad Range Preferred Range______________________________________Carbon 45 to 95 60 to 92Hydrogen 2.5 to 7 4 to 6Oxygen 2.0 to 45 3 to 25Nitrogen 0.75 to 2.5 0.75 to 2.5Sulfur 0.3 to 10 0.5 to 6______________________________________
The carbon and hydrogen content of the carbonaceous material will reside primarily in multi-ring aromatic compounds (condensed and/or uncondensed), heterocyclic compounds, etc. Oxygen and nitrogen are believed to be present primarily in chemical combination. Some of the sulfur is believed to be present in chemical combination with the aromatic compounds and some in chemical combination with inorganic elements associated therewith, for example, iron and calcium.
In addition to the above, the solid carbonaceous material being treated herein will also contain solid, primarily inorganic, compounds which will not be converted to the desired organic mixture claimed herein, which are termed "ash", and are composed chiefly of compounds of silicon, aluminum, iron and calcium, with smaller amounts of compounds of magnesium, titanium, sodium and potassium. The ash content of the carbonaceous material treated herein will amount to less than about 50 weight percent, based on the moisture-free carbonaceous material, but, in general, will amount to about 0.1 to about 30 weight percent, usually about 0.5 to about 20 weight percent.
Anthracitic, bituminous and subbituminous coal, lignitic materials, and other types of coal products referred to in ASTM D-388 are exemplary of the solid carbonaceous materials which can be treated in accordance with the process defined herein to produce the claimed organic mixture. Some of these carbonaceous materials in their raw state will contain relatively large amounts of water. These can be dried prior to use herein. The carbonaceous material, prior to use, is preferably ground in a suitable attrition machine, such as a hammermill, to a size such that at least about 50 percent of the carbonaceous material will pass through a 40-mesh (U.S. Series) sieve. As noted, the carbonaceous material is slurried in a suitable carrier, preferably water, prior to reaction with nitric acid. If desired, the carbonaceous material can be treated, prior to reaction herein, using any conventional means, to remove therefrom any materials forming a part thereof that will not be converted in reaction with nitric acid herein.
The reactant mixture in the reactor is stirred while being maintained at a temperature of about 15° to about 200° C., preferably about 50° to about 100° C., and a pressure of about atmospheric to about 1000 psig (about atmospheric to about 70 kg/cm 2 ), preferably about atmospheric to about 500 psig (about atmospheric to about 35 kg/cm 2 ) for about 0.5 to about 15 hours, preferably about two to about six hours. In order to obtain the desired mixture herein without losing appreciable amounts of carboxyl and/or nitro groups on the acids that are formed during the oxidation and to obtain the desired acids in high yields in the reactor, it is absolutely critical that the reaction conditions therein, namely nitric acid concentration, temperature, pressure and reaction time, be so correlated to minimize and, preferably, to avoid decarboxylation and denitrofication. Gaseous products, such as nitrogen oxides, can be removed from the reactor as they are formed.
The reaction product is removed from the reactor upon completion of the reaction. The reaction product is soluble in, or reactable with, sodium hydroxide. At this point it is necessary to separate the oxidized product from the water and nitric acid associated therewith. This separation must be accomplished in a manner so that the carboxyl and nitro groups are not removed from the acid product. Distillation for the removal of water will not suffice, because under the conditions required for such separation, a significant loss of carboxyl groups and nitro groups would occur. Accordingly, it has been found that a mechanical separation will suffice. The reaction product is therefore led to a first separator which can be, for example, a filter or a centrifuge.
The solids that are recovered in the first separator, also soluble in sodium hydroxide, are led to a second separator wherein they are subjected to extraction with an azeotropic mixture of polar solvents defined above, that is, methyl ethyl ketone and ethanol, introduced therein by any convenient entry line. Such separation can be carried out at a temperature of about 20° to about 100° C., preferably about 25° to about 50° C., and a pressure of about atmospheric to about 500 psig (about atmospheric to about 35 kg/cm 2 ), preferably about atmospheric to about 100 psig (about atomospheric to about 7 kg/cm 2 ). The amount of the mixture of polar solvents used herein to recover the desired acid mixture can be varied over a wide range in any amount sufficient to extract the desired acid mixture from the solid mixture in the first extractor. Thus, the weight ratio of total polar solvents to solid acid mixture can be in the range of about 1:1 to about 10:1, preferably about 2:1 to about 5:1.
The solid material, insoluble in the mixture of solvents, is removed from the second separator by one line, and the polar solution of the novel acid mixture by another line. The polar solution is then led to a drier wherein the mixture of polar solvents is separated therefrom by one line and the desired novel polar-soluble, water-insoluble polyaromatic, polycarboxylic acid mixture claimed herein is recovered by another line. As before, the acid mixture in the drier must be treated by so correlating the conditions to remove the mixture of polar solvents therefrom in such manner so as to minimize and, preferably, avoid, decarboxylation and denitrofication. The temperature can be in the range of about 10° to about 100° C., preferably about 20° to about 50° C., the pressure about 10 millimeters of mercury to about atmospheric, preferably about 30 millimeters of mercury to about atmospheric, for about 0.5 to about 24 hours, preferably about one to about five hours.
The filtrate obtained in the first separator is removed therefrom and will contain water, nitric acid and most of the inorganic material (ash) that was present in all the carbonaceous charge. In addition there can also be present other oxidized material, which are primarily organic acids soluble in polar solvents and in water.
DESCRIPTION OF PREFERRED EMBODIMENTS
A North Dakota Lignite, analyzing as follows on a substantially moisture-free basis, was subjected to oxidation using: 70 weight percent aqueous nitric acid as the oxidant; 65.03 weight percent carbon; 4.0 weight percent hydrogen; 27.0 weight percent oxygen; 0.92 weight percent sulfur; 0.42 weight percent nitrogen; and 0.04 weight percent moisture. The ash was further analyzed and found to contain 43 weight percent oxygen; 7.8 weight percent sulfur; and the remainder, metals. The weight ratio of lignite to nitric acid (as 100 percent nitric acid) and water in the reactor was 1:1:1. The reaction mixture was stirred and maintained at a temperature of 80° C. and a pressure of 800 psig (55 kg/cm 2 ) for five hours. Nitrogen oxides were permitted to escape from the reaction zone as they evolved.
At the end of the reaction period the product slurry was withdrawn from the reaction zone and filtered to obtain a solids fraction and a filtrate. Portions (100 grams) of the solids fraction were each dissolved in a number of polar solvents with the following results:
TABLE III______________________________________ Solubility Data Wt % Wt %Solvent Grams Soluble Insoluble______________________________________Ethanol 100 70.0 30.0Methyl Ethyl Ketone 100 39.2 60.8______________________________________
Another portion (100 grams) of the solids was dissolved in a mixture of methyl ethyl ketone and ethanol, wherein the components thereof were present in an amount sufficient to form an azeotropic mixture, with the following results:
TABLE IV__________________________________________________________________________Solvent Solution Solubility Data Weight Ratio:Total Ketone/ Wt % Soluble Wt % InsolubleGrams Ketone Alcohol Alcohol* Found Expected** Found Expected**__________________________________________________________________________100 Methyl Ethyl Ketone Ethanol 54.46 89.3 51.5 10.7 48.5__________________________________________________________________________ *Values taken from "Azeotropic Data", Advances in Chemistry Series, No. 6 published by the American Chemical Society, Washington, D.C., 1951. **Expected values based on the solubilities obtained from individual pola solvents in Table III.
Comparison of the data obtained in Table IV with that of Table III clearly illustrates the uniqueness of the invention claimed herein. When the solvent solution contained both methyl ethyl ketone and ethanol, unexpectedly larger amounts of polycyclic aromatic polycarboxylic acids were obtained than would have been predicted on the basis of the results obtained with either of the polar solvents alone. An additional advantage is obtained herein because the mixture of polar solvents form an azeotropic mixture. Thus, when the polar solvent solution containing the desired acid mixture dissolved therein is subjected to drying conditions, as set forth hereinabove, to separate the polar solvents from the desired acid mixture, the solvent mixture will come off cleanly as a single solution which can then be recycled to the second separator defined above for recovery of additional acid mixture. Not only is the separation of solvent solution from the acid mixture thereby facilitated, but since the ratios of components present in the solvent solution will remain constant, the amount of acid mixture recovered will also remain constant.
Since the novel mixtures herein have abundant functionality in both carboxyl and nitro groups, it is apparent that the mixtures lend themselves to many known chemical reactions, for example: esterification of the carboxyl groups; hydrogenation of the nitro groups to amines; etc. Thus, the novel mixtures defined herin are effective blowing agents for the purpose of incorporating the same in well-known resins, such as polyethylene, to permanently increase the volume of the resin as shown in U.S. Pat. No. 4,101,469 of Schulz et al., dated July 18, 1978.
Obviously many modifications and variations of the invention, as herein above set forth, can be made without departing from the spirit and scope thereof and, therefore, only such limitations should be imposed as are indicated in the appended claims. | A mixture of polycyclic, aromatic polycarboxylic acids carrying nuclear nitro groups that is substantially soluble in an azeotropic mixture of methyl ethyl ketone and ethanol but substantially insoluble in water, and a process for preparing the mixture of polycyclic, aromatic polycarboxylic acids. | 2 |
FIELD OF THE INVENTION
This invention relates to a liquid pump assembly of the double-acting type. More particularly, this invention is directed to a reciprocating piston/cylinder liquid pumping assembly for maintaining continuous operation of a pressurized liquid pumping system.
BACKGROUND OF THE INVENTION
The use of double-acting force pumps for providing a continuous flow of liquid is generally well known as disclosed by U.S. Pat. Nos. 662,437; 684,740; 710,856; 2,685,257; and 4,253,804.
U.S. Pat. No. 710,856 discloses a double-acting piston pump that must be connected directly over a well and can only be operated in a straight, upright position. This known liquid pumping assembly cannot be used in a pressurized system but pumps water from a well into an open container.
The liquid pumping assembly of U.S. Pat. No. 684,740 is designed only to be placed inside a well and is gravity-operated in only a vertical position.
U.S. Pat. No. 662,437 discloses a gravity-operated pump that must be disposed in a vertical position to properly operate. Such a prior art liquid pumping assembly cannot operate in a pressurized liquid transmission system.
The double-action liquid pump assembly of U.S. Pat. No. 2,685,257 is designed as a primary internal well pump and particularly for use in a deep well rather than a shallow well.
U.S. Pat. No. 4,253,804 discloses a double-action hand pump structure which is not designed to pump into a pressurized system. It is a hand-operated liquid pump assembly useful for fluid transfer and designed to eliminate the use of friction bearing assemblies in its construction.
U.S. Pat. No. 4,736,675 discloses a primary pump designed to be power-driven with a crank shaft having a double-action drive. The guide rod simply prevents the piston rod from turning about its own axis but does not insure the longitudinal alignment of the piston rod.
The liquid pump assembly of U.S. Pat. No. 4,762,051 is a single-acting pump having a double-acting drive. This known pumping assembly has no rod alignment mechanism and its valve assembly produces a result unlike that of the present invention.
The primary purpose of this invention is to produce a liquid pumping assembly which may be used in a pressurized system.
Another object of the invention is to provide a liquid pumping assembly which may be used as a hand-operated standby pump if for any reason a primary pumping assembly loses power.
A further object of the invention is to provide a liquid pumping assembly which is useful in an environment where no electrical power source may be available and can provide a continuous flow of liquid from an outside source into a pressurized system.
Another object of the invention is to provide a pumping assembly having an alignment mechanism for maintaining the axial longitudinal movement of a piston rod that drives a piston member in a reciprocating movement within a cylinder.
A still further object of this invention is to provide a liquid pumping assembly having no seals or packing that will dry out or set up with all the moving parts and surfaces having bearing material effective to maintain alignment of the various moving parts.
Still another object of this invention is to provide a liquid pumping assembly useful for a shallow well and may be installed with bypass valves between the well and a reservoir for regular use or as standby use when a power source is cut off from a primary pumping system.
A further object of this invention is to provide a liquid pumping assembly which may be used for indoor toilets and faucets of a pressurized system where electricity is generally not available such as in hunting cabins, cottages and the like.
Another object of the invention is to provide a liquid pumping assembly that may be fixedly attached to a floor or wall in any position with respect to the horizontal thereby making it adaptable to virtually any environmental situation.
SUMMARY OF THE INVENTION
The liquid pumping assembly of the invention comprises piston means mounted for reciprocating movement within a liquid pumping cylinder. The cylinder is in liquid flow communication at each end thereof with a respective first and second end cap section. Each end cap section includes liquid inlet means, inner chamber means and liquid discharge means. Biasing means maintains the inlet and outlet valve means in a normally closed condition. The inlet valve means is disposed between the liquid inlet means and the inner chamber means of each end cap section. The outlet valve means is disposed between the inner chamber means and the liquid discharge means of each cap section.
Each inlet valve means is effective to allow inlet liquid flow into the pumping cylinder because a suction condition forms in the cylinder behind the piston means as it moves in a pumping direction away from the respective end cap section causing the inlet valve means to open. Each outlet valve means is effective to allow outlet liquid flow from the pumping cylinder because a pressurized condition forms in the cylinder ahead of the piston means as it moves in a direction toward the respective end cap section causing the outlet valve means to open.
The pumping apparatus of the invention is for use with a pressurized system and comprises a piston/cylinder assembly mounted between two laterally spaced end cap sections attached to base means. The piston/cylinder assembly includes piston rod means for moving a piston member in a cylinder that is connected at each end thereof to a first and second end cap section. The piston rod means is movably supported in and extends outwardly from one of the end cap sections.
Linkage means is connected to the piston rod means for effecting axial longitudinal movement of the piston rod means in first and second pumping directions with respect to the end cap sections. Manually operable handle means is connected to the linkage means for movement inwardly toward and outwardly away from the piston/cylinder assembly to thereby displace the piston rod means in the first and second pumping directions. Support means maintains the axial longitudinal alignment of the piston rod means during its movement within the cylinder.
The first and second end cap sections of the liquid pumping assembly are fixedly mounted at a spaced distance with respect to each other with the liquid pumping cylinder extending therebetween. Each end cap section includes liquid inlet means and liquid discharge means. The liquid inlet means includes first tubing means in liquid flow communication between liquid inlet chamber means located in each of the end cap sections. The liquid discharge means includes second tubing means in liquid flow communication between the liquid discharge chamber means located in each of the end cap sections.
A particular feature of the liquid pumping assembly is directed to the use of liquid inlet means for directing liquid from outside the assembly into the liquid inlet chamber means of one of the end cap sections. The other of the end cap sections includes liquid discharge means for directing liquid out of the assembly from the liquid discharge chamber means of the other of the end cap sections. The first tubing means includes a first elongate rigid tube member which connects the liquid inlet chamber means for liquid flow between the end cap sections. The second tubing means includes a second elongate rigid tube member which connects the liquid discharge chamber means for liquid flow between the end cap sections.
The support means includes bearing means for prohibiting transverse movement of the piston rod means as it axially moves through one of the end cap sections. The bearing means includes a bearing member having an outer surface, an inner surface and sealing means to preclude liquid leaking from the end cap section along the bearing member surfaces. The bearing inner surface includes a piston rod engaging portion and the sealing means includes first sealing members disposed at opposed ends of the piston rod engaging portion to preclude liquid leaking along the bearing inner surface. The sealing means includes a second sealing member disposed around the outside surface to preclude liquid leaking therealong.
Externally, the support means includes at least one elongated guide rod member fixedly connected for longitudinal movement with the piston rod means. At least one elongated guide rod member slidably extends through the two end cap sections. A connecting member has respective portions fixedly secured to the elongated guide rod member and the piston rod means extending outwardly from the end cap section.
In a specific embodiment, the support means includes two elongated guide rod members fixedly connected for longitudinal movement with the rod means and are laterally spaced from the piston rod means and from each other. The guide rod members slidably extend through the end cap sections and a connecting member fixedly secures the guide rod members to the piston rod means extending outwardly from one of the end cap sections.
Another feature of the invention is directed to the support means which include stabilizing means attached to the connecting member and mounted to prohibit lateral movement of the piston rod means when it is in an extended outward position with respect to the end cap section. The stabilizing means includes a stabilizer rod member fixedly secured at one end thereof to the connecting member and slidably supported by stabilizer rod guide means. The stabilizer rod guide means is fixedly mounted to the base means and includes a tubular section through which an outer free end section of the stabilizing rod member extends. The tubular section has sealed bearing members located at opposed ends of the tubular section and are in slidable contact with the stabilizer rod member.
Another feature of the invention is directed to the linkage means which includes coupling link means having one end portion thereof pivotably connected to the outer end of the piston rod means and another end portion pivotably connected to one end of the handle means which pivots about a handle axis of rotation. The linkage means includes tie-rod means having an inner end pivotably connected to rotate about a fixed axis of rotation and having the handle axis of rotation located at an outer end thereof whereby the handle axis of rotation rotationally moves about the fixed axis of rotation of the tie-rod means.
In a specific embodiment, the tie-rod means includes two tie-rod members located on opposing sides of the first end cap section through which the piston rod means extends. The inner ends of the tie-rod members are pivotably secured to the second end cap section and the outer ends of the tie-rod members are pivotably secured to opposing sides of the handle means which rotates about the handle axis of rotation. The handle means includes an elongated handle member secured at a fixed angular position with respect to the handle axis of rotation to cause the longitudinal movement of the piston rod means between first and second pumping positions. The handle axis of rotation constitutes the fulcrum point for the coupling link means and handle member acting in combination as lever means. The handle means includes means to adjust the fixed angular position of the handle member with respect to the handle axis of rotation.
The first end cap section has outer end edge surfaces facing a respective tie-rod member. The support means includes a bearing plate member mounted to each of the outer edge surfaces to slidably engage each tie-rod member which moves along a respective outer edge surface as the handle means effects longitudinal movement of the piston rod means.
Water tube means is operatively connected at each end thereof to the respective first and second end cap sections for causing liquid to move continuously from liquid inlet means to a liquid discharge means as the piston means moves in either the first or second pumping directions toward either the first or second end cap section, respectively. The water tube means includes a water-in tube member and a water-out tube member, each in liquid flow communication with the first and second end cap sections. Each of the end cap sections include inlet valve means and outlet valve means as described above.
The valve assembly of the invention comprises a valve member mounted for movement in a valve seat section between a closed condition and an open condition. The valve member includes a valve seat engaging surface for abutting the valve seat portion. Biasing means is effective to urge the valve seat engaging surface in a normally closed condition against the valve seat portion preventing liquid flow through the valve assembly. The valve seat portion includes a Y-shaped vertical cross-section having a recessed portion with a valve head engaging surface and a hub section with an end surface projecting outwardly away from the recessed portion. The valve seat portion has a peripheral collar portion located around the recessed portion.
In a specific embodiment of the valve assembly, the valve member includes a valve head having a valve seat engaging surface for abutting the valve head engaging surface of the recessed portion. A valve stem extends through the hub section and has an outer end which carries retainer means at a spaced distance from the hub end surface when the valve means is in a closed condition. The biasing means includes a spring member disposed between the retainer means and the valve seat portion urging the valve head against the recessed portion. The liquid flow-through section is located between the peripheral collar portion and the hub section. The valve seat portion is composed of a resilient material that does not absorb the liquid flowing through the valve assembly.
A feature of the pumping assembly is that the piston means is effective to cause the inlet valve means to open to liquid flow while the outlet valve means remains closed to liquid flow when the piston means moves within the cylinder away from each end cap section. The piston means is further effective to cause the outlet means to open to liquid flow while the inlet valve means remains closed to liquid flow when the piston means moves within the cylinder toward each end cap section. The biasing means acts on the valve stem to urge the valve seat engaging surface against the valve seat portion preventing liquid flow through the valve means until an applied force is sufficient to overcome the operation of the biasing means causing liquid to flow through the valve means.
BRIEF DESCRIPTION OF DRAWINGS
Other objects of this invention will appear in the following description and appended claims, reference being made to the accompanying drawings forming a part of the specification wherein like reference characters designate corresponding parts in the several views.
FIG. 1 is a perspective view of a pumping apparatus made in accordance with this invention;
FIG. 2 is a flow diagram showing a valve system for attaching the pumping apparatus of the invention into a pressurized system;
FIG. 3 is a longitudinal sectional view of a pumping assembly made in accordance with this invention;
FIG. 4 is a sectional view showing an end cap section taken along IV--IV of FIG. 3;
FIG. 5 is a sectional view showing the other end cap section taken along line V--V of FIG. 3; and
FIG. 6 is a vertical cross-sectional view of a valve assembly made in accordance with this invention.
DETAILED DESCRIPTION
The pumping apparatus, generally designated 10, comprises piston rod 13 connected to piston member 11 movably disposed in cylinder 12 which is connected at each end thereof to a respective first end cap section 16 and a second end cap section 14. Piston rod 13 is movably supported in a fixedly disposed bearing assembly 34 and extends outwardly from end cap section 16. In this embodiment, piston member 11 has a diameter of about 2.5 to 3.0 inches and has a wear surface 11A between piston seals 11B.
Linkage mechanism, generally designated 26, is connected to piston rod 13 to effect axial longitudinal movement of piston rod 13 in first and second pumping directions with respect to end cap sections 14 and 16. Manually operable handle 25 is connected to linkage mechanism 26 for movement inwardly toward and outwardly away from cylinder 12 to thereby displace piston 11 in the first and second pumping directions. Arrow A indicates inward movement for handle 25. Support guide rods 27, 29 and 36 are slidably mounted in bearing bushings (not shown) to maintain alignment of piston rod 13 during its longitudinal axial movement through cap section 16.
Liquid pumping assembly 40 as shown in FIG. 3 comprises two end cap sections 14 and 16 fixedly mounted to base member 18 at a spaced distance with respect to each other with the liquid pumping cylinder 12 extending therebetween. Cylinder 12 is in liquid flow communication at each end thereof with respective first and second cap sections 14 and 16. Each cap section 14 and 16 includes a liquid inlet chamber 14A and 16A, an inner chamber 14B and 16B and a liquid discharge chamber 14C and 16C.
Inlet valve assemblies 50A and 50B are disposed between respective liquid inlet chambers 14A and 16A and inner chambers 14B and 16B of end cap sections 14 and 16. Outlet valve assemblies 50C and 50D are disposed between respective inner chambers 14B and 16B and the liquid discharge chambers 14C and 16C in end cap sections 14 and 16. As piston member 11 reciprocates back and forth within cylinder 12, diagonally disposed pairs of valve assemblies 50A, 50D and 50B, 50C alternately open and close.
As shown in FIG. 3, as piston member 11 (not shown) moves in the pumping direction of arrow B away from end cap 16 and toward end cap 14, a suction condition forms behind piston member 11 in cylinder 12 thereby causing valve assembly 50B to open thereby allowing liquid to flow into pumping cylinder 12. At the same time, a pressurized condition forms in cylinder 12 ahead of piston member 11 which is moving toward end cap section 14 thereby causing outlet valve assembly 50C to open thereby allowing liquid to flow from inner chamber 14B to discharge chamber 14C.
A first water-in tube 42 is in liquid flow communication between liquid inlet chambers 14A and 16A. Water-out tube 44 is in liquid flow communication between liquid discharge chambers 14C and 16C located in respective cap sections 14 and 16. Inlet pipe 19 (FIG. 1) is inserted into the inlet opening 41 (FIG. 4) of end cap section 16. Outlet pipe 20 (FIG. 1) is inserted in outlet opening 43 (FIG. 5) in end cap section 14. A standard pressure gauge 38 disposed in operating contact with discharge chamber 16C in end cap section 16 monitors the pressure within the system into which liquid is being pumped.
The flow diagram of FIG. 2 shows how pump assembly 10 may be connected into a pressurized system having a normally open primary valve 70 and normally closed by pass valves 71 and 72. Primary pump 73 causes liquid to flow from liquid source 74 through pirmary valve 70 into the pressurized system. In the event that the primary pump shuts down, valve 70 is then closed and by pass valves 71 and 72 are opened thereby connecting pump inlet opening 41 and pump outlet opening 43 via inlet pipe 19 and outlet pipe 20 thereby causing liquid to flow through pump assembly 10 from liquid source 74 into the pressurized system.
Water tubes 42 and 44 are composed of brass and fit into respective annular grooves 42A and 44A (FIG. 3). Neoprene O-rings 42B and 44B disposed in grooves 42A and 44A seal the respective ends of tubes 42 and 44. Each end of brass cylinder 12 fits into an annular groove 12A having an O-ring sealing member 12B to effect a seal when end cap sections 14 and 16 are secured to base member 18. In this embodiment, end cap sections 14 and 16 are fixedly secured to base member 18 at a spaced distance with respect to each other effective to provide a positive seal at the respective ends of the cylinder 12 and water tubes 42 and 44 as shown in FIG. 3.
FIG. 6 shows a valve assembly 50 including valve member 51 mounted for movement in a valve seat portion 61 between a closed condition and an open condition. Valve assembly 50 is shown in the closed condition with valve seat engaging surface 62 abutting valve seat portion 61. Stainless steel spring 58 constitutes biasing means effective to urge valve seat engaging surface 62 against valve seat portion 61 thereby preventing liquid flow through valve assembly 50.
Valve seat portion 61 has a Y-shaped vertical cross-section having a recessed portion with a valve head engaging surface 61A and hub section 53 with an end surface 60 projecting outwardly away from the recessed portion. Valve seat portion 61 includes a peripheral collar portion 55 located around the recessed portion. Apertures 54 comprise a flow-through section located between collar portion 55 and hub section 53.
Valve head 51 abuts the valve head engaging surface 61A of valve seat portion 61 and valve stem 52 projects through hub section 53. Stem 52 carries a brass retainer 56 secured by snap ring 57. Retainer 56 is located at a spaced distance from hub end surface 60 when valve assembly 50 is in a closed condition and is effective to keep spring 58 centered and limits the movement of valve head 51. In this specific embodiment, valve seat portion 61 is composed of a Duron which is a resilient material that does not absorb water flowing through valve assembly 50. Where other liquids are being pumped, different resilient materials may be used. The valve seat material is stiff enough to support the various moving parts but will allow engaging surface 62 to sink slightly into valve head engaging surface 61A of valve seat portion 61 to effect the desired seal.
Spring 58 urges valve seat engaging surface 62 against valve seat portion 61 via retainer member 56 thereby preventing liquid flow through valve assembly 50 until an applied force is sufficient to overcome the operation of spring 58 causing liquid to flow through openings 54. Sleeve members 63 and 64 abut peripheral collar portions 55 of respective valve assemblies 50B and 50D as shown to fix them in place within cap section 16. Similar sleeve members maintain valve assemblies 50A and 50C in end cap section 14 as shown.
In operation, inlet valve assemblies 50A and 50B open to liquid flow when piston member 11 moves away from each respective end cap section 14 and 16. On the other hand, piston member 11 causes outlet valve assemblies 50C and 50D to open to liquid flow when piston member 11 moves toward each respective end cap section 14 and 16.
The support means for maintaining axial alignment of piston rod 13 includes bearing assembly 34 having a bearing member 45 with an outer surface, an inner surface and sealing rings 46A, 46B and 47. Bearing member 45 includes a piston rod engaging portion 45A with sealing members 46A and 46B disposed at opposed ends thereof to preclude liquid leaking along the inner surface. The second sealing member 47 is disposed around the outer surface of bearing member 45 to preclude liquid leaking therealong. Each sealing member 46A, 46B and 47 is a Neoprene O-ring disposed in inner and annular grooves as shown. The inner surface rod engaging portion 45A is in sliding contact with piston rod 13 working to maintain the alignment thereof.
End cap sections 14 and 16 are composed of material that may be drilled to form the openings required to receive the various parts or form the chambers through which the pumped liquid flows. In this embodiment, aluminum is used for the pumping of water. The simplicity of construction minimizes the need for service. Bolts (not shown) threadlingly engage and secure cap sections 14 and 16 to base member 18 in a well known manner. Snap ring 34A and washer 34B hold bearing member 45 in place. Pipe plugs 65 fix sleeve members 63 and 64 in place thereby securing the various valve assemblies 50A, 50B, 50C and 50D as shown.
The support mechanism of pumping apparatus 10 is designed to prohibit transverse movement of piston rod 13 as it moves through end cap section 16. The support means of this embodiment includes two elongated guide rod members 27 and 29 fixedly connected for longitudinal movement with piston rod 13. Guide rod members 27 and 29 are laterally spaced from piston rod 13 and from each other. Guide rods 27 and 29 slidably extend through both end cap sections 14 and 16.
Tubes 31 and 33 (FIG. 1) are disposed around rods 27 and 29, respectively, and are sealed between end caps 14 and 16. A lubricant material may be disposed within tubes 31 and 33. Guide rods 27 and 29 also are in sliding contact with bearing members (not shown) disposed in end cap sections 14 and 16 to maintain alignment of rods 27, 29 and 13. Connecting member 26A fixedly secures guide rods 27 and 29 to piston rod 13.
Stabilizer rod 36 is fixedly secured at one end thereof to connecting member 26A and is slidably supported by stabilizer guide rod tube 35 through which an outer free end section of stabilizer rod member 36 extends. Sealed bearing members (not shown) are located at opposed ends of guide rod tube 35 and are in slidable contact with stabilizer rod 36. Support members 37 fixedly connect stabilizing guide rod tube 35 to base member 18 via bolts (not shown).
Coupling link member 30A has one end portion pivotally connected to the outer end of piston rod 13. A stainless steel spherical bearing is used in this specific embodiment to connect the end of piston rod 13 to coupling link member 30A. Coupling link member 30A is pivotally connected at the other end to rotate about the handle axis of rotation 23 located at the end of two tie-rod members 22 and 24 which are pivoted at the other end thereof adjacent the bottom of end cap section 14.
Tie-rod members 22 and 24 are located on opposing sides of end cap section 16 through which piston rod 13 extends. Elongated handle member 25 is secured at a fixed angular position with respect to handle axis of rotation 23 to cause the longitudinal movement of piston rod 13 between first and second pumping positions. The handle axis of rotation 23 constitutes the fulcrum point for the coupling link member 30A and handle member 25 acting in combination as a lever member. Adjustment mechanism 28 includes a pair of rings 28A having set screws 28B for fixing the angular position of handle member 25 secured to rings 28A which rotate with respect to the handle axis of rotation 23 when set screws 28B are loosened.
Plate 32 composed of a bearing material is mounted to each of the outer edge surfaces of end cap section 26 to slidably engage each tie-rod or pivot bar member 22 and 24 which move along a respective outer edge surface as handle 25 effects longitudinal movement of piston rod 13. Epoxy is used to adher plates 32 to the opposed sides of end cap section 16. Pivot bar members 22 and 24 keep all the pressure points centered on two sets of sealed ball bearings at either end thereof. As pivot bar members 22 and 24 ride up and down on bearing plates 32, the alignment of piston rod 13 is enchanced. Tie-rod members 22 and 24 hinge on hardened shoulder bolt members with bearing inserts and washers (not shown) to minimize wear.
Flexible tubing is used over inlet member 19 and outlet member 20 and is effective to withstand large vacuum and pressure conditions caused by the use of the pumping assembly made in accordance with this invention.
The pumping assembly of this invention is designed to be bolted to the floor or to the wall between studs in any home or building. With the capability of adjusting the angular position of handle member 25, the liquid pump assembly of the present invention may be used under virtually any environmental conditions. The assembly may be used to pump any kind of liquid such as petroleum products, processing and processed products in addition to water.
While the liquid pump assembly has been shown and described in detail, it is obvious that this invention is not to be considered as limited to the exact form disclosed, and that changes in detail and construction may be made therein within the scope of the invention without departing from the spirit thereof. | A pumping apparatus comprises a piston/cylinder assembly mounted between two laterally spaced end cap sections attached to base means and including spring-loaded valve devices. A piston rod is movably supported in and extends outwardly from one of the end cap sections. A manually operated linkage mechanism effects axial longitudinal movement of the piston rod and a support mechanism maintains longitudinal axial alignment of the piston rod during its longitudinal axial movement. The longitudinal movement of the piston rod operates in concert with the spring-loaded valve devices to pump fluid manually when the pumping apparatus is positioned in any angular disposition with respect to the horizontal. | 5 |
SUMMARY OF THE INVENTION
The present invention relates to a knot tying apparatus and to a method of tying a knot in an elongated flexible member such as a string or rope or cord and has particular relation to such a device which reliably and automatically insures that a knot is tied at a predetermined distance from the end of the member.
A primary purpose of the invention is a knot tying method and apparatus which has application to such as window cords, drapery pulls, venetian blind cords, the starter ropes for gasoline engines as used in outboard motors, lawn mowers, snow blowers and the like.
Another purpose is a simply constructed, reliably operable knot tying mechanism which insures accurately positioned knots in an elongated member such as a cord or the like.
Other purposes will appear in the ensuing specification, drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated diagrammatically in the following drawings wherein:
FIG. 1 is a top plan view of the knot tying apparatus of the present invention,
FIG. 2 is a side view of the apparatus shown in FIG. 1,
FIG. 3 is an enlarged partial side view of the apparatus in FIG. 1 in an initial or start position,
FIG. 4 is an end view of the clamp shaft of the apparatus of FIG. 3,
FIG. 5 is a view along plane 5--5 of FIG. 4,
FIG. 6 is a section along plane 6--6 of FIG. 4,
FIG. 7 is an enlarged partial top view showing the knot tying apparatus in the start position of FIG. 3,
FIG. 8 is a top view, similar to FIG. 7, but with the apparatus moved to a position in which the cord has been severed and wound into a loop,
FIG. 9 is a side view, on the same scale as in FIG. 3, but with the cord moved to partially form the knot loop,
FIG. 10 is a top view, on the same scale as FIGS. 7, 8 and 9, but showing the loop fully made and the end clamped, and
FIG. 11 is a top view of a completed knot.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus is indicated generally in the top and side views of FIGS. 1 and 2 wherein a base or platform is indicated at 10. Shuttle gibs 12 and 14 mount a shuttle 16. The shuttle is moved back and forth within the way provided by the gibs by means of an air cylinder 18 which is mounted on a support 20 fastened to the base 10. A rod 22 extends outwardly from the air cylinder and is connected to a support 24 mounted on shuttle 16, which support in turn mounts a second air cylinder 26 having a reciprocal output rod 28. Rod 28 is attached to a rack 30 having a downwardly-facing toothed surface 32 illustrated in more detail in FIG. 3. Rack 32 is in mesh with a gear 34 mounted on one end of a shaft 36 with the other end of the shaft mounting a hook 38 to the end that reciprocal movement of rack 30 will cause rotary movement of hook 38. Shaft 36 is mounted in a support member 39.
Also mounted on shuttle 16 is a cut-off device in the form of a hot wire 40 which is used to sever the cord or string, depending upon the application, into predetermined lengths. Movement of the shuttle 16 is effective to move the hot wire toward and away from the cut-off position.
Base 10 also mounts a pair of support elements 42 and 44 which mount and position a rack 46 reciprocally moved by an air cylinder 48 having an output rod 50. Rack 46 is in mesh with a gear 52 which is fast on a clamp shaft 54. Reciprocal movement of the rack is effective to turn gear 52 and thus rotate shaft 54. Clamp shaft 54 is supported in bearing structures 56 and 58 mounted on base 10.
As illustrated in FIGS. 3-6, clamp shaft 54 has an internal piston 60 movable by an air cylinder 59. Piston 60 has a pair of spaced relieved areas 62 and 64 which together define four cam surfaces indicated at 66, 68, 70 and 72. There are a pair of clamps 74 and 76 mounted on clamp shaft 54 for use in clamping the cord during the time it is formed into a loop and during the time the cord is pulled tight to form the loop into a knot. Clamp 74, which is mounted on the top of shaft 54 in the release position is pivoted, as at 78, within a bracket 80 mounted to the clamp shaft by screws 82. Clamp 74 has a nose 84 with a small slot 86, best shown in FIG. 6. There are a pair of balls 88 and 90 positioned in shaft slots 89 and 91 which cooperate with cam surfaces 66 and 68 on piston 60 to cause the clamp 74 to move from the closed or operated position of FIG. 3 to the open position of FIG. 6. Ball 88 cooperates with a lower flat surface 92 on clamp 74 and ball 90 cooperates with a slanted surface 94 on the bottom of clamp 74, as particularly shown in FIG. 3. Clamp 76 has a hook-shaped nose 96 which fits within a slot 98 in clamp shaft 54, as particularly shown in FIG. 6. Clamp 76 is pivoted to the clamp shaft, as at 100, and has a pair of balls 102 and 104 positioned in shaft slots 103 and 105 which cooperate with cam surfaces 68 and 70 to effect movement of clamp 76 between the closed position of FIG. 6 and the open position of FIG. 5. Ball 102 cooperates with surface 106 of clamp member 76 and ball 104 cooperates with slanted surface 108 of clamp 76.
The invention is designed to tie knots in what has been termed "elongated members" such as cord, string or rope. For purposes of illustration, the invention will be described in connection with cord of the type used on drapery pulls. The cord may be fed from a continuous reel (not shown) and there will be a device which will pull the cord from the reel through the mechanism shown herein. Turning particularly to FIGS. 7-11, cord 110 will be pulled from a suitable source, whether it be a reel or otherwise, in the direction of arrow 112 and the amount of cord that is pulled will be predetermined and when the desired length has been reached, the cord pulling mechanism will stop. Note that the cord is positioned within the small groove 86 in clamp 74. After the predetermined length of cord has been pulled, the first step in the knot tying procedure is the clamp shaft 54 will have clamp 74 closed and clamp 76 open and piston 60 will be in the position illustrated in FIG. 3. Cord 110 will be held by clamp 74 a predetermined distance from its end. The air cylinder 18 will move shuttle 16 to the right so that hot wire 40 carried by and movable with shuttle 16 will sever cord 110.
Air cylinder 48 will now move rack 46, causing gear 52 to turn, resulting in the rotation of clamp shaft 54 in the direction shown by arrow 114. The clamp shaft will turn through approximately 270 degrees until the cord 110 has formed a loop, as illustrated in FIG. 8. When the apparatus is in the position of FIG. 7, the hot wire has not been moved to the cut-off position, but it will be moved toward the cut-off position in the direction of arrow 116. The position of the wire after cut-off, is illustrated in FIG. 8.
As clamp shaft 54 turns in the direction of arrow 114, cord 110 will form a loop, as shown in FIG. 8, and the free end 118 of the loop will be pressed against a deflector surface 120 formed on support 39. The deflector surface will cause the free end 118 to extend upwardly and be positioned adjacent hook 38.
Air cylinder 26 will now cause movement of rack 30 and through gear 34 turn shaft 36. This will result in a rotation of hook 38 and the hook will catch and then rotate the free end 118 of the cord, as illustrated in FIG. 9, and the free end will be rotated in a counterclockwise direction until it extends within upwardly-facing slot 121 in clamp shaft 54. In the position of FIG. 9, the free end of the cord is within slot 121 and has been so positioned by rotation of the hook.
Air cylinder 59, which is attached to and effective to cause movement of piston 60, will now draw the piston toward the right, away from the start position of FIG. 3 toward the fully operated position of FIG. 6. As the piston so moves, the balls 88, 90 and 102,104 will cooperate with the mating surfaces on clamps 74 and 76 to release clamp 74 and operate clamp 76 so that its nose 96 clamps the end 118 of cord 110 within slot 121. As can be seen from FIGS. 3 and 6, as piston 60 moves to the right, there will be a small degree of overlap for the operation of the two clamps. In effect, the operated clamp does not fully release until the release clamp has been at least partially operated. Thus, clamp 76 will have clamped on the end 118 of cord 110 just slightly prior to the full release of clamp 74. Once clamp 76 has fully engaged the end 118 of the cord, pulling pressure will be applied to the end 122 of the cord in the direction of arrow 124, as shown in FIG. 10. This pressure will be sufficient to pull the cord between the adjacent ends of clamp shaft 54 and support 39. The force applied in the direction of arrow 124 will first draw the cord between these elements as described and then complete the knot. Air cylinder 59 will then move piston 60 back toward the left so as to release clamp 76 and operate clamp 74. The release of clamp 76 allows the completed knot to be pulled out of the apparatus and the operation of clamp 74 is necessary for the next knot tying operation. As this happens, air cylinder 18 will move the shuttle 16 toward the left, returning the shuttle to the full release position and in a position to be ready for the next knot tying operation.
Whereas the preferred form of the invention has been shown and described herein, it should be realized that there may be many modifications, substitutions and alterations thereto. | A method and apparatus is disclosed for the tying of knots in elongated flexible members such as string or rope. The method includes the steps of first providing an elongated member of a desired length and then clamping the elongated member at a location spaced a predetermined distance from the free end thereof while rotating the clamped location to form a loop, with the free end crossing over the loop. The free end of the elongated member is then removed through the loop and the end is then clamped. The initial clamping pressure is released and the elongated member is then pulled to complete the tying of a knot. | 1 |
GOVERNMENT INTEREST
[0001] The invention described herein may be manufactured, used and licensed by or for the U.S. Government.
FIELD OF INVENTION
[0002] Embodiments of the present invention generally relate to magnetic imaging and, more particularly, to an apparatus for mechanically robust thermal isolation of components in an imaging device.
BACKGROUND OF THE INVENTION
[0003] Magnetic resonance force microscopy (MRFM) is an imaging technique that acquires magnetic resonance images (MRI) at nanometer scales, and possibly at atomic scales in the future. An MRFM system comprises a probe, method of applying a background magnetic field, electronics, and optics. The system measures variations in a resonant frequency of a cantilever or variations in the amplitude of an oscillating cantilever. The changes in the characteristic of the cantilever being monitored are indicative of the tomography of the sample. More specifically, as depicted in FIG. 1 , an MRFM probe 100 comprises a base 102 with a cantilever 104 tipped with a magnetic (for example, Samarium Cobalt) particle 106 to resonate as the spin of the electrons or nuclei in the sample 101 are reversed. There is a background magnetic field 108 generated by a background magnetic field generator 110 which creates a uniform background magnetic field in the sample 101 . As the magnetic tip 106 moves close to the sample 101 , the atoms' electrons or nuclear spins become attracted (force detection) to the tip and generate a small force on the cantilever 104 . Using a radio frequency (RF) magnetic field applied by an RF antenna 117 through the RF source 105 , the spins are then repeatedly flipped at the cantilever's resonant frequency, causing the cantilever 104 to oscillate at its resonant frequency. In the geometry shown, when the cantilever 104 oscillates, the magnetic particle's 106 magnetic moment remains parallel to the background magnetic field 108 , and thus it experiences no torque. The displacement of the cantilever is measured with an optical sensor 114 comprised of an interferometer (laser beam) 116 and an optical fiber 118 to create a series of 2-D images of the sample 101 held by sample stage 120 , which are combined to generate a 3-D image. The interferometer measures the timer dependent displacement of the cantilever 104 . Smaller magnetic particles and softer cantilevers increase the signal to noise ratio of the sensor.
[0004] Nano-MRI and nano NMR spectroscopy are both performed at a temperature of 4 Kelvin, or colder, to improve signal-to-noise ratio (SNR) over room temperature. The large RF magnetic fields required frequently come with large amounts of heat (1 Watt) that must be conducted out of the base 102 without heating the rest of the apparatus 100 . At 4 K, 1 Watt is a large amount of heat for these small probes, typically only 5 to 10 cm in diameter, that often heat the rest of the probe 100 reducing the signal to noise ratio.
[0005] Therefore, there is a need in the art for an apparatus mechanically robust thermal isolation of components in an imaging device preventing other probe components from overheating and reducing the signal to noise ratio.
BRIEF SUMMARY OF THE INVENTION
[0006] Embodiments of the present invention relate to an apparatus for thermally isolating components in an imaging device comprising a mount for mounting the components; a clamp for holding the mount, and an accompanying first plate on the opposite side of the mount, for preventing rotation of the mount; particulate matter, positioned between the clamp and the mount, and the first plate and the mount, for absorbing heat generated by the components and isolating the mount thermally from the rest of the apparatus; and a second plate coupled to the first plate and a third plate coupled to the clamp, both coupled to a securing mechanism for compressing the apparatus and preventing breakage of the first plate and the clamp.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0008] FIG. 1 depicts a conventional MRFM system known to those of ordinary skill in the art;
[0009] FIG. 2 depicts a block diagram of an MRFM system in accordance with an exemplary embodiment of the present invention;
[0010] FIG. 3 is an illustration of a thermal isolation apparatus in accordance with exemplary embodiments of the present invention;
[0011] FIG. 4 is an illustration of another configuration of a thermal isolation apparatus in accordance with exemplary embodiments of the present invention;
[0012] FIG. 5 is an end-view of the thermal isolating apparatus in accordance with exemplary embodiments of the present invention;
DETAILED DESCRIPTION OF THE INVENTION
[0013] Embodiments of the present invention comprise a mechanically robust thermal isolation mechanism for components to absorb heat and avoid heat transfer to thermally-sensitive components in a probe head. Often the RF antenna of a probe head, as described in related U.S. Patent Application Attorney Docket Number ARL08-09, hereby incorporated by reference in its entirety, generates heat and transfers this heat undesirably to electrical components or sensitive components such as an optical fiber or cantilever, skewing accuracy of measurements or causing dysfunction. As such, the RF antenna component must be kept thermally isolated from other parts of a probe head. Therefore, the thermal isolation apparatus discussed herein is a sub-component of the apparatus disclosed in U.S. Patent Application Attorney Docket Number ARL08-11, hereby incorporated by reference in its entirety, to prevent heat thorn the RF component mounting.
[0014] FIG. 2 depicts a block diagram of an MRFM system 200 in accordance with an exemplary embodiment of the present invention. The system 200 generally has an RF source 202 coupled to a probe 204 . The probe 204 is coupled to an interferometer 206 for performing optical measurements using the optical sensor 216 in the probe 204 of sample 201 . The interferometer 206 transmits the measurements to a processor 208 . The processor 208 generates an output image 210 based on the measurements or oscillations of portions of the probe 204 . The probe 204 comprise's a magnetic sensor 212 , an RF antenna 214 and an optical sensor 216 . The apparatus 200 is kept in a spatially homogeneous background magnetic field 217 (approximately 9 T) generated by a background magnetic field generator 218 . In an exemplary embodiment, the background magnetic field generator 218 comprises two one inch diameter Samarium Cobalt (SmCo) magnets. In an exemplary embodiment, the magnetic sensor 212 is comprised of a bridge coupled with a smaller SmCo particle (for example, 10 μm in diameter) which generates a spatially inhomogeneous field. The magnetic field experienced at a particular point in the sample 201 is the sum of the background magnetic field and the magnetic field generated by the magnetic sensor 212 . The RF antenna 214 at least partially circumscribes the magnetic sensor 212 . The RF antenna 214 generates an RF magnetic field which causes the spin in the particles of the sample 201 to reverse and oppose the SmCo particle on the bridge of the magnetic sensor 212 . This repeated reversal of the spin of the particles in sample 201 causes the magnetic sensor 212 to oscillate at a particular frequency. The interferometer 206 senses oscillation of the magnetic sensor 212 using optical sensor 216 by using optical fiber 217 to reflect a laser off of the magnetic sensor 212 . In another exemplary embodiment, the sample 201 is directly coupled to the bridge comprising the magnetic sensor 212 and a magnetic particle array of SmCo particles is proximate the magnetic sensor 212 . According to an exemplary embodiment, the optical fiber is 125 microns in diameter and is within approximately 1/10 of a millimeter of the magnetic sensor 212 . In an exemplary embodiment, the optical sensor 216 is an optical fiber approximately twenty five times greater in diameter than the width of the bridge of the magnetic sensor 212 . The gap between the optical fiber and the magnetic sensor 212 is fixed at a particular distance in this embodiment. Thermal isolation apparatus 215 isolates the heat generated by the RF antenna 214 from other probe components so accuracy of measurements is not skewed, or the signal to noise ratio is not significantly reduced due to Brownian motion in the magnetic sensor 212 .
[0015] FIG. 3 is an illustration of a thermal isolation apparatus 300 in accordance with exemplary embodiments of the present invention. The apparatus 300 is one embodiment of isolation apparatus 215 of FIG. 2 . The isolation apparatus 300 thermally isolates a component mount 302 , using plates 304 , 306 , clamp 308 and plate 310 , from mechanical mount 312 . The isolated component mount 302 is made of a very hard surface material that small objects are not able to penetrate. In an exemplary embodiment, the component mount 302 is made of sapphire and RF antenna components 214 which generate heat are mounted on component mount 302 . Plates 304 and 308 also have a hard surface material and are located on either side of isolated component mount 302 . In an exemplary embodiment, plates 304 and 308 are made of Macor®, a machineable glass-ceramic with excellent thermal characteristics, acting as efficient insulation, and stable up to temperatures of 1000° C., with very little thermal expansion or out-gassing.
[0016] Plates 306 and 310 are located adjacent to plates 304 and 306 , coupled to their out-facing surfaces. In exemplary embodiments, plates 306 and 310 are made of more malleable material than plates 304 and 308 , particularly metals such as capper and the like, that can better withstand mechanical compression caused by screw 314 . The screw 314 passes through component mount 302 through a hole (not shown) that is larger than the diameter of screw 314 , therefore the component mount 302 is thermally isolated from the screw 314 . In another embodiment, the screw 314 is not a screw but another securing mechanism under tension to compress all the components together such as a wire pulled tight and attached to 306 and 312 under tension, a rod under tension attached to 306 and 312 via glue, welding, epoxy, swaging, soldering and other methods know to experts in the art. In an exemplary embodiment, mechanical mount 312 is made of titanium or any non-magnetic material and is responsible for positioning the RF antenna components mounted on component mount 302 . In other embodiments, plates 306 and 310 are washers instead of plates. Though not shown in the figure, component mount 302 , plate 304 , clamp 308 and plate 310 have a large hole bored into them allowing the screw 314 to pass through these components without any contact with 302 , 304 , 308 , and 310 .
[0017] Particulate matter, or, dust, 316 is held by a securing substance 318 , which in an exemplary embodiment, is comprised of wax. In exemplary embodiments, the dust 316 is composed of hard material such as sapphire pieces, ceramics, glass, semiconductors or other hard and poor thermal conductivity material. In this exemplary embodiment, the dust 316 is 75 μm diameter glass spheres. The dust 316 covers the surface of plate 304 , clamp 308 and component mount 302 well enough so even when the components are Compressed together, the surfaces of component 304 and 302 , and 308 and 302 do not come into direct contact with each other. The dust 316 enclosed in a securing material 118 is sandwiched between the two elements 308 and 302 , therefore there is no surface contact between element 308 and 302 . This is also true for the upper portion of the clamp 308 , where the top lip of clam 308 touches the component mount 302 . A layer of dust 316 is suspended by securing substance 318 for eliminating the surface area contact between the lip of clamp 308 and component mount 302 at the top and bottom of clamp 308 , though not shown in the Figure.
[0018] By prohibiting the large flat surfaces of plates 304 , 302 and 308 from coming into direct contact with each other, heat generated by component mount 302 can only be conducted to plates 304 and 308 through the dust 316 , as disclosed in a paper entitled “Thermal Impedance of pressed contacts at temperatures below 4° K” by Yoo and Andersen, hereby incorporated by reference. Since the dust 316 and its mating surfaces are all hard materials, under compression, deformation of the plates and components is minimized and the contact area between the two remains miniscule. Reduction of the contact area between two objects directly results in lesser thermal conductivity between the two. It is necessary to provide a mechanism to remove the heat generated in the components mounted on the component mount 302 or the component mount 302 will rapidly overheat. Heat generated in the components mounted on the component mount 302 is removed from 302 by conduction through a thermal link with one end attached to 302 and the other end attached to a heat sink in the system. To help mechanically stabilize the apparatus 300 from rotation with respect to mechanical mount 312 , plate 310 is attached to clamp 308 using a securing material such as glue or epoxy. Similarly, plates 304 , 306 and 314 are optionally attached to each other with glue, epoxy or other securing material.
[0019] In this exemplary embodiment clamp 308 is in a C shape for holding component mount 302 from rotating around the axis created by the screw 314 , along with plate 304 . In other embodiments, other shapes for the clamp 308 are possible as long as component mount 302 is not allowed to rotate around the axis defined by 314 or translate in the plane defined by the dust 316 . According to another exemplary embodiment, the clamp 308 has a pronged portion at the top and the bottom so that the securing material only need be placed at the contact points between clamp 308 and component mount 302 . As disclosed in related U.S. Patent Application Attorney Docket Number ARL08-11, hereby incorporated by reference in its entirety, a cantilever is also an important part of an MRFM imaging apparatus probe head along with the RF antenna. The component mount 302 upon which the RF antenna 214 is mounted must not rotate relative to the cantilever of the probe head 204 , otherwise the RF magnetic field from the RF antenna 214 will be distorted and measurements of structure of the sample 201 will be inaccurate. In this exemplary embodiment, one translational and two rotational degrees of freedom for component mount 302 are very well constrained by the compression of materials by screw 314 , while one translational degree of freedom is constrained by the friction between the components of the apparatus 300 . In this exemplary embodiment, one rotational and one translational degree of freedom for component mount 302 are very well constrained by the top and bottom of the clamp 308 . In other exemplary embodiments, the number of translational and rotational degrees of freedom that component mount 302 possesses must be constrained depending on the application and the direction of the applied torque and forces on the apparatus 300 .
[0020] FIG. 4 is an illustration of another configuration of a thermal isolation apparatus 200 in accordance with exemplary embodiments of the present invention. FIG. 4 is largely similar to FIG. 1 , with the exception that in this embodiment, plate 310 is formed into a C clamp as opposed to clamp 308 in FIG. 1 . In this embodiment, clamp 308 is separated into bars 308 a, 308 b and plate 308 c. The machining of plates 308 a, 308 b, and 308 c is easy and the design is more robust as clamp 310 is made of metal instead of a brittle material. Therefore, clamp 310 is physically stronger and able to withstand more stress and compression caused by screw 314 and the component mount 302 . In this embodiment, 308 a, 308 b and 308 c are under compressive forces and not sheer forces as in FIG. 1 . Plates 308 a, 308 b and 308 c are coated with securing material 318 within which dust 316 is suspended, to minimize contact between the plates and the component mount 302 . If the component mount 302 is not a hard surfaced material, a securing material such as glue or epoxy is used to attach a hard material to the component mount 302 to stabilize it for better grip and to prevent the dust 316 from penetrating the surface of component mount 302 . This apparatus 400 , as compared to previous embodiments, is heavier but more robust.
[0021] In other exemplary embodiments, apparatus 300 and 400 both contain thermal guard rings to capture any residual heat that does leak out of the compressed component plates. In an exemplary embodiment, plates 306 and mechanical mount 312 are made of a good thermal conductor such as copper and via the same or separate connections, are thermally grounded to an appropriate cold point (heatsink) in the system. In this configuration, any heat absorbed into the screw 314 and through screw 314 into mechanical mount 312 is dissipated into the thermal ground before being absorbed by the other components of the apparatuses 300 or 400 . Thermally grounding plate 306 causes the heat from the compressed plates to be removed before the heat might be transferred to screw 314 , reducing the overall temperature for some components in apparatuses 300 and 400 .
[0022] FIG. 5 is an end-view of thermal isolating apparatus 300 in accordance with exemplary embodiments of the present invention. Dust 316 is shown secured by a securing material 318 such as wax between components 302 and plates 304 and 308 . As discussed above, the dust 316 reduces the contact surface area between the component mount 302 and the plates 304 and 308 and therefore reducing the heat transferred from components 302 to plates 308 and 304 .
[0023] The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the present disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as may be suited to the particular use contemplated.
[0024] Various elements, devices, modules and circuits are described above in associated with their respective functions. These elements, devices, modules and circuits are considered means for performing their respective functions as described herein. While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | An apparatus for scanning over a surface of an arbitrarily sized sample in magnetic resonance force microscopy comprising a cantilever for holding a magnetic particle at the cantilever tip, an RF antenna, positioned around the cantilever, for emitting an RF magnetic field across a portion of the sample causing spin of particles in the sample to reverse attracting and opposing the magnetic particle at the cantilever tip, an optical fiber, positioned close to the cantilever tip, for measuring displacements of the cantilever tip where the RF antenna, cantilever, magnetic particle and optical fiber are in fixed positions relative to each other and the sample is positionable according to a sample stage. | 6 |
FIELD OF THE INVENTION
This invention relates to oven or stove shields. In particular, it relates to oven shields that prevent spills, that occur on the stove top, from reaching the oven control knobs, handle and the surrounding surfaces.
BACKGROUND OF THE INVENTION
Several types of oven shields are currently available. The problems facing these shields with regards to protecting the oven knobs from spills and debris are: the ability to easily remove the device from the stove or oven for cleaning, the intended location of the shield on the stove or oven, and the materials from which the previous shields are made.
The French patent 2626-064-A to Panieri discloses the use of a safety panel for a different application, namely to prevent small children from touching the stove burners or cooking utensils, which are disposed on the top, horizontal surface of an oven. The shield is affixed with a complex mounting assembly comprised of threaded hooks or catches. The intended use of the panel is to protect small children from touching the cooking surface or the control knobs; thus, the panel is preferably affixed below the oven knobs. The use of Panieri's safety panel would not prevent debris coming from the stove top from reaching the control knobs and handle of his oven.
U.S. Pat. No. 4,964,393 to Knudsen discloses the use of a protective shield for an oven that is also designed to prevent small children from burning themselves. Knudsen discloses that his shield is attached on the top of the oven door by an "L" shaped bracket that is fastened to the oven by screws, thus making the shield difficult to remove for cleaning. When mounted to an oven, Knudsen's shield is perpendicular to the surface of the stove top.
It is, by contrast to these patents, proposed by this invention to protect the oven control knobs and handles from spills that occur on the stove top. Knobs and handles have hard to reach surfaces and are difficult to clean. A shield needs to prevent debris and food substances from reaching such surfaces. Indicia (letters and numbering) are disposed on the oven knobs and are often removed by repeated washings. A shield also needs to be easily and quickly removed and re-installed on the oven. Further, the shield should permit a cook to readily view the control knobs when the shield is installed.
The following patents are characteristic of the present state of this field. U.S. Pat. No. 4,517,955 to Ehrlich discloses the use of barrier system that attaches to the oven by detachable hinges. U.S. Pat. No. 4,157,705 to Caan is a "U"-shaped guard attached to the top of the stove by brackets.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a new and improved shield for use with a stove to prevent food from spilling over from the stove top onto the control knobs and other surfaces on the stove front.
It is a further object of this invention to provide a new and improved shield which is easily mounted and removed from a stove.
It is a still further object of this invention to provide a new and improved shield which may be easily washed.
In accordance with these and other objects of this invention, a shield assembly is disclosed for use with a stove, which comprises a work surface, a heating mechanism disposed on the work surface, and at least one control knob affixed to the work surface. The shield assembly comprises a shield made of a material transparent to visible radiation, and a mechanism affixed to the shield assembly for releasably securing the shield assembly to the work surface at a point intermediate the control knob and the heating mechanism to overlie and shield the control knob from the spatter of food being cooked on the heating mechanism.
In one aspect of this invention, the shield assembly is adapted for a stove, which includes a slot disposed through the work surface. The shield assembly further includes a substantially flat mounting member of a configuration conforming substantially to that of the slot and of dimensions such that the mounting member may be readily inserted into the slot and retained therein.
In a further aspect of this invention, the shield assembly comprises a mounting member affixed to the shield and at least one magnet affixed to the mounting member for releasably securing the shield assembly to the work surface.
BRIEF DESCRIPTION OF THE DRAWINGS
A written description setting forth the best mode presently contemplated for carrying out the present invention, and of the manner for implementing and using it, is provided below with respect to the following drawings:
FIG. 1 is a top, plan view of a shield assembly in accordance with the teachings of this invention;
FIG. 2A is a side, cross-sectioned view of the shield assembly with a mounting member, as taken along line 2--2 of FIG. 1;
FIG. 2B is an enlarged side, cross-sectioned view of the rivet and surrounding portion of the shield assembly as seen in FIG. 2A;
FIG. 2C is a side, cross-sectioned view of an alternative embodiment of this invention;
FIG. 3 is a side, elevational view of the shield assembly illustrating how it is used with a gas stove having a recessed grove therein;
FIG. 4 is a perspective view of a further embodiment of this invention in the form of a shield with a magnetic mounting assembly;
FIG. 5 is a bottom view of the shield and its magnetic mounting assembly, as shown in FIG. 4;
FIG. 6 is a side, elevational view of the shield of FIG. 4 with a magnetic mounting assembly as it is used with a conventional electrical stove having an essentially flat front surface; and
FIG. 7 is a side, cross-sectioned view of an alternative embodiment of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and in particular to FIG. 1, the preferred form of a shield assembly 10 is shown as comprising a transparent shield 14, a mounting member 16, and a connecting mechanism 12, which connects the transparent shield 14 and the mounting member 16 together. The shield assembly 10 has rounded edges 20 a, b, c and d. The transparent shield 14 is a flat member made of a heat resistent, polycarbonate plastic such as "Tuffak-A" or glass such as "Pyrex". A shield 14 of "Tuffak-A Polycarbonate Sheet" may be used at temperatures as high as 270° F. The transparent shield 14 has a plurality of large rivet openings 28 a, b, c and d, which are disposed in a line adjacent to and parallel with its bottom most edge of the transparent shield 14, as shown in FIG. 1. The mounting member 16 is made of a durable, lightweight metal such as aluminum or stainless steal. The mounting member 16 includes a mounting tongue 23, which is substantially flat, a support portion 25, and a connecting portion 22, which is disposed between and interconnects the tongue 23 and the support portion 25. The connecting mechanism 12 comprises a plurality of rivets 18 that are disposed in a line adjacent to and parallel with the top most edge of the mounting member 16, as seen in FIG. 1. Each of the rivets 18 comprises, as shown in FIG. 2B, a head 19 and a shank 21. The rivets 18 are made of a durable metal, illustratively brass.
As seen in FIG. 2A, the connecting mechanism 12 joins the transparent shield 14 and the mounting member 16. Now referring to FIG. 2B, the support area 25 includes a support surface 24. The connecting portion of the shield 22 presents a shield butt surface 26. The support surface 24 and the shield butt surface 26 form a pocket for receiving and supporting an edge portion of the transparent shield 14. In particular, the bottom surface of the transparent shield 14 is held horizontally by the support area 25 of the mounting member 16.
As best shown in FIG. 2B, a first set of rivet openings 30 is formed in the mounting member 16, and a second set of large rivet openings 28 is formed in the transparent shield 14. The rivet openings 30 are spaced from each other and oriented to be aligned with the large rivet openings 28 of the transparent shield 14, when the transparent shield 14 is disposed over the mounting member 16, as best shown in FIG. 2B.
The transparent shield 14 and the mounting member 16 are fastened together by the plurality of rivets 18. The opening 28 through the transparent shield 14 has a diameter identified by the letter C, and the opening 30 through the mounting member 16 has a diameter A. As best seen in FIG. 2B, it is apparent that each of the aligned pairs of rivet openings 28 and 30 receives a rivet 18. The dimensions of the rivet 18 and the openings of 28 and 30 are carefully selected. The rivet head 19 has a diameter D and the rivet shank 21 has a diameter B. To secure the transparent shield 14 to the support surface 24, the diameter D of the rivet head 19 is made larger than the diameter of the rivet opening 28. The diameter A of the rivet shank 21 is set slightly less than the diameter B of the opening 30, whereby the shank 21 fits tightly within the opening 30.
The metal of which the rivets are made, e.g., brass or steel, has a coefficient of thermal expansion, which is greater than that of the plastic material of which the shield 16 is made, e.g., "Tuffak-A Polycarbonate Sheet". In particular, steel has a coefficient of 0.63, whereas "Tuffax-A Polycarbonate Sheet" has a coefficient of 3.80 In/In ° F. 10 -5 . Thus when heated, the metal used in the rivets 18 expands at a greater rate than the plastic or glass used in the transparent shield 14. To prevent the rivet shank 21 from breaking the transparent shield 14 when heated, the diameter C of the rivet opening 28 in the transparent shield 14 is made larger than the diameter B. In an illustrative embodiment of this invention, the diameter C is set equal to 2B, i.e., twice the shank diameter.
As seen in FIG. 3, gas stoves typically have a slot 54 disposed between a horizontal stove top 32 and a vertical stove front 34. The mounting member 16 slides horizontally into the slot 54 of the stove 52 and thus the transparent shield 14 lies perpendicular to the stove front 34. The shield 14 is disposed between a burner 40 on the stove top 32 and all of the control knobs 36 and handles 38 affixed to the stove front 34. Thus, the assembly 10 prevents spills that occur on the stove top 32 from reaching the stove front 34, control knobs 36 and oven handle 38. Further the shield 14 is made of a transparent material, whereby a cook standing over the stove 52 may look downward as shown in FIG. 3 to readily observe the controls 36 and the handles 38.
To mount the shield assembly 10, one need only to insert the mounting member 16 horizontally into the slot 54 of a stove 52 as seen in FIG. 3. To remove the shield assembly 10 from the stove 52 for cleaning, the mounting member 16 is pulled horizontally out of the slot 54. Thus, the shield assembly 10 may be quickly removed, cleaned and re-installed.
Referring now to FIG. 2C, there is shown a further embodiment of the shield assembly, where similar elements are identified by like numbers, but distinguished by a'. The shield assembly 10' has a mounting member 16' including a mounting tongue 23' divided into a first portion 23'a and 23'b. The portions 23'a and 23'a are essentially flat plate like elements, which are connected at an angle with respect to each other of θ 1 . It is contemplated that the tongue portion 23'a could be inserted into the slot 54 as illustrated in FIG. 3. In such an embodiment, the angle θ 1 would be set at a value of 30° to 45°, whereby the transparent shield 14' would be disposed at a similar angle with respect to ground and between the control knobs 36 and the food being cooked on the burners 40. In a further embodiment as shown in FIG. 3, a slot 54' could be disposed within the stove top 32 and the angle 81 be set at 90°, whereby the tongue portion 23'b and the transparent shield 14' would extend parallel to the stove top 32 and to the ground below.
A further embodiment of this invention is illustrated in FIGS. 4, 5 and 6. A magnetic shield assembly 44 takes the shape of an L-shaped member as shown in FIG. 4, and comprises a transparent shield portion 46, a bend 45 and a magnetic mounting portion 48, which comprises a mounting surface 47. A plurality of magnets 43 are secured to the mounting surface 47. As seen in FIGS. 4 and 5, the magnetic shield assembly 42 has rounded edges 50 A, B, C and D. The transparent shield portion 46 is mounted perpendicularly to the mounting surface 47 by the bend 45 to form an L-shape. The mounting surface 47 is attached to the magnets 43 by an adhesive 48 such as contact cement, lamination, or other heat resistent adhesives, e.g., "Super Glue" or "Weldwood" contact cement.
The magnetic shield assembly 42 addresses the problems of protecting the control knobs 36 and oven handle 38 from spills. Electric stoves 52' often do not have a slot 54, as shown in FIG. 3. The magnetic shield assembly 42 is attached by a magnetic mounting assembly 44 as seen in FIG. 4 to the stove 52' with or with out a slot. The magnetic mounting assembly 44 is mountable on the stove front 34' and, in particular, to a substantially flat surface 35' presented thereby so that the transparent shield 46 is oriented in a horizontal relation to the floor and perpendicular to the stove front surface 35'.
To use the magnetic shield assembly 42, one places the magnetic mounting assembly 44 against the surface of the stove front 34' as seen in FIG. 6. To remove magnetic shield assembly 42 from the stove 52' for cleaning, the shield 44 is simply pulled off of the stove front surface 35' and washed with a suitable detergent before being remounted.
Referring now to FIG. 7, there is shown a further embodiment of a magnetic shield assembly, where similar elements are identified with like numbers but distinguished by a ' e g., the assembly of FIG. 7 is identified by the numeral 42'. The magnetic assembly has the mounting surface 47' for receiving a plurality of the magnets 43' and a transparent shield 46'. As shown in FIG. 7, the transparent shield 46' is oriented at an angle θ 2 with respect to the plane of the mounting surface 47'. In contrast to the mounting of the L-shaped magnetic shield assembly 42 on the front surface 35' of the stove front 34' the magnetic shield assembly 42' is adapted as shown by the dotted line in FIG. 6 to be used with a set of control knobs 36" which are mounted on the front edge of the stove top 32'. In particular, the magnets 43' would serve to releasably attach the magnetic shield assembly 42' to the stove top 32' so that its transparent shield 46' overlies and protects the control knobs 36". The transparent shield 46' is set at an angle θ 2 with respect to the mounting surface 47' in the range of 15°-45°, whereby the transparent shield 46' further shields the control knobs 36" and permits access by the user from the front of the stove 52'.
In considering this invention, it should be remembered that the present disclosure is illustrative and the scope of the invention should be determined by the appended claims. | A shield assembly is disclosed for use with a stove, which comprises a stove top with a work surface, a heating mechanism disposed on the horizontal top surface and at least one control knob affixed to the work front surface. The shield assembly comprises a shield made of a material transparent to visible radiation, and a mechanism affixed to the shield assembly for releasably securing the shield assembly to the vertical front surface at a point intermediate the control knob and the heating mechanism. | 5 |
This invention relates to improvements in constructional supports of the type capable of supporting building structures.
BACKGROUND OF THE INVENTION
Concrete and wooden stumps and piers are commonly used to support building structures constructed from timber beams, fabricated steel beams, aluminium beams and other structural materials. The concrete and wooden stumps and piers support a frame structure adapted to support flooring materials of various types to which internal frames constructed of various materials are in turn attached to form the complete building structure. The installation of concrete or wooden stumps or piers is labour intensive, requiring numerous holes and/or footings to be formed in the ground followed by the installation of the stumps or piers set at the required levels. Where a building is to be constructed on unstable soils, the stumps must be buried to a level where stable soil is present to provide the necessary support for the stump.
As a result of extensive testing and investigation, an alternative constructional support which performs satisfactorily in most soil types, including unstable soils or reactive clays, has been developed. The support can be installed by relatively unskilled operators, and does not require excavation or the formation of concrete footings.
The patent literature discloses several pile arrangements with angular anchor legs, such as SU949066 and SU947284, but these arrangements are not suitable for use in most domestic constructions. Similarly, New Zealand Patent 272260 discloses a driven foundation post arrangement with angled diagonally placed anchor posts. This arrangement does not lend itself to adaption from a driven foundation post arrangement to a relatively simple building stump replacement.
SUMMARY OF INVENTION AND OBJECT
It is the object of the present invention to provide a constructional support adapted to replace concrete or wooden stumps or piers in building constructions which provides at least equivalent support for a building structure and is installed with less difficulty than the known methods of installing concrete and wooden stumps or piers.
The invention provides a constructional support including a central support means for a load bearing member having a central longitudinal axis, three guide means secured to said support means and arranged in an equilateral triangular configuration, said guide means having passages with longitudinal axes extending angularly with respect to said central axis at an acute angle less than about 30°, said guide means being constructed to receive, as a snug fit, elongate substantially tubular anchor means for engaging the ground, and means for securing said anchor means in said guide means after said anchor means have been driven into the ground.
In the present specification, the term “tubular” is not restricted to circular configurations but includes oval, square, hexagonal, octagonal and other generally symmetrical configurations.
The invention also provides a method of installing a constructional support as defined above, including the steps of locating the constructional support in the required position on the ground, partially engaging the constructional support with the ground, inserting an elongate drilling means in each guide means in turn and drilling the ground along the axis of each guide means to a predetermined depth, inserting a tubular anchor means into each guide means, and securing each anchor means to each guide means or to the support.
Following the insertion of the anchor means, they are filled with a suitable grouting means. Alternatively or additionally, a further tubular means may be inserted into each anchor means to provide additional rigidity.
In one form of the invention, the central support means is adapted for engagement by said load bearing member adapted to support part of a building structure, such as a bearer support. If the bearer support is threaded, the central means may be threaded, or adjustment nuts may be fitted to the bearer support at positions above and below the central support means, to enable the bearer support to be rigidly secured with respect to the central support means. Alternatively, the bearer support may have a substantially tubular portion, in which case the central support member is configured to receive said substantially tubular portion.
The three guide means are preferably substantially tubular members and are secured together by means of an apertured plate or a threaded nut or the like defining said central support means, said tubular members being connected in the required angular orientation by bracing means, such as struts, which interconnect adjacent tubular members.
The guide means may comprise three lengths of plastics pipe held in an equilateral triangular pattern by means of a molded plastics collar or plate defining said central support means and engaging said pipes adjacent one end and holding them in an equilateral triangular pattern, said pipes also being engaged by a further molded plastic collar or plate, defining said bracing means closer to the other end of said pipes and which maintains said pipes in the required angular orientation while bracing them with respect to each other.
In a still further form of the invention, three metal tubular members defining the guide means are secured by welding to a central tubular riser defining the central support, the tubular members being skewed in a plane parallel to the central longitudinal axis of the riser so that the ends of the tubular members are accessible for drilling and for receiving the anchor means without being fouled by the central riser. Since the guide means are securely welded to the central riser, the bracing struts or bracing collar of the previous embodiments are not required.
The central riser is adapted to receive a bearer support, which is adjustable in height by telescoping the bearer support to the required level and bolting the support to the riser as required.
In the above embodiments, each of the guide means is preferably arranged at an acute angle to the central perpendicular axis or plane of the load support at an angle of about 5 to 20° to the central axis, and preferably at about 10° to 15° to the central axis.
The guide means are adapted to receive the anchor means as a snug fit within the passage. Where the pipes are plastic, they are fixed in position by a suitable plastics glue or by self-tapping screw means engaging the guide means and the anchor pipe engaged therein. If the guide pipes are metal and/or the anchor pipes are metal, screws are used to secure the anchor pipes in the guide pipes, or a blocking collar is secured in the open end of each guide means.
In use, the support is placed on the ground in the required position and at about the required level and the guide means are used to guide a drill for drilling holes adapted to receive the tubular anchor means to the required depth.
In order that the invention may be more readily understood, two presently preferred embodiments of the invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a first constructional support member showing an attached threaded bearer support;
FIG. 2 is a top plan view of a second constructional support embodying the invention;
FIG. 3 is a side elevation of the constructional support of FIG. 2;
FIG. 4 is an elevation of the third embodiment of the constructional support;
FIG. 4A is a schematic elevation showing a bearer support attached to the constructional support of FIG. 4;
FIG. 5 is a schematic illustration showing the support being installed by means of a hand post driver;
FIG. 5A is a plan view of the support of FIG. 4, and
FIG. 6 is a perspective view from the lower one end of the support of FIG. 4 . Dimensions illustrated in these drawings are typical rather than restrictive.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the constructional support comprises three lengths of steel tubing 1 , 2 and 3 arranged in a equilateral triangular pattern, similar to that illustrated in FIG. 2, with each tube 1 , 2 and 3 extending outwardly from a central perpendicular axis at an acute angle of about 10°. The tubes 1 , 2 and 3 are held together at the top by a central threaded nut 4 , to which each of the tubes 1 , 2 and 3 are welded. The tubes 1 , 2 and 3 are braced at a lower position by three straps 5 , 6 and 7 , each of which is welded to an adjacent tube 1 , 2 and 3 to brace the tubes 1 , 2 and 3 in the above defined angular orientation.
The central nut 4 is adapted to receive a threaded bearer support 8 of known configuration, as shown. Alternatively, the central nut 4 may be unthreaded or may comprise an apertured plate and the threaded support 8 is fixed adjustably by locking nuts above and below the central member.
In use the support is driven partly into the ground until the straps 5 , 6 and 7 are about level with the ground. The tubes 1 , 2 and 3 are then used to guide a drill which drills three holes to the required depth in the ground. Following drilling, three plastic or metal anchor pipes (not shown) are inserted as a snug fit into the tubes 1 , 2 and 3 and are driven into the drilled holes in the ground to the required depth. The anchor pipes are secured to the tubes by self-tapping screws, or secured against escape from the guide tubes 1 , 2 and 3 by collars of the type shown in broken outline in FIG. 4, and are then filled with a cement slurry or some other reinforcing material, if desired. The length of each anchor pipe is selected according to the soil type, but is typically about 300 to 450 mm for stable soils and about 450 to 550 mm for unstable soils. For particularly unstable soils, such as reactive clays, it may be necessary for the anchor tubes to be of a length sufficient to engage stable soil.
Referring now to FIGS. 2 and 3, in this embodiment, three plastic pipes 10 , 11 and 12 which may be made from recycled plastics such as recycled PET, are held in an equilateral triangular configuration, illustrated in FIG. 2, by a molded plastic plate 13 having accurately formed openings receiving the pipes 10 , 11 and 12 as a friction fit. The plate 13 comprises a flat plate of molded plastics having a central hole 14 drilled and tapped with a suitable thread capable of receiving a threaded bearer support of the type shown in FIG. 1 . Alternatively, as described above, the hole 14 is untapped and locking nuts are positioned above and below the plate 13 .
The pipes 10 , 11 and 12 are held in an angular orientation of about 10° to a central perpendicular axis by a second molded collar or plate 15 , illustrated in FIG. 3, having accurately positioned openings which receive the pipes 10 , 11 and 12 in the configuration shown and maintain them in this position under the loadings expected to be experienced in use.
This embodiment of the invention is used in a manner equivalent to that described above, and in each case, the plastic anchor pipes (not shown), which are received in the guide pipes 10 to 12 as a snug fit, are held in their final driven positions by plastics cement or by screws engaging the guide pipes and the anchor pipes or by collars similar to those described below.
Referring now to FIGS. 4 to 6 , the constructional support embodying the invention comprises three lengths of steel tubing 20 , 21 and 22 , welded in an equilateral triangular configuration to a central riser in the form of a further length of steel tubing 23 . Each of the guide tubes 20 , 21 and 22 extends angularly to the central riser tube 23 in a plane parallel to the central vertical axis of the riser 23 . In this way, the guide tubes 20 , 21 and 22 are skewed with respect to the central riser so that their upper ends are free to receive a drill followed by metal or plastic anchor pipes as in the previous embodiments.
By providing a rigid central riser to which the guide tubes 20 , 21 and 22 are securely welded, the bracing plates of the embodiment of FIG. 1 are not required and the relatively expensive central nut 4 is replaced by a less expensive tubular riser by means of which the constructional support can be driven into the ground for installation by means of a hand held post driver, as illustrated schematically in FIG. 5 of the drawings.
The central riser 23 is adapted to receive a bearer support which can be drilled and bolted at any desired adjusted height, as shown in FIG. 4 A.
In the embodiment of FIGS. 4 to 6 , it has been found that the guide tubes 20 , 21 and 22 are most conveniently arranged at an angle of about 15° to the central vertical axis of the riser 23 . This angle may be changed without reducing the effectiveness of the support, the only requirement being that the ends of the guide tubes 20 , 21 and 22 are free to receive a drill and anchor tube without being fouled by the central riser tube 23 .
The support of FIGS. 4 to 6 can be inexpensively fabricated using a jig and a welding machine. The fabrication process lends itself to automation whereby production costs can be further reduced.
It will be appreciated that the above embodiments of the invention stress the importance of arranging the guide pipes in an equilateral triangular pattern since this pattern provides equal support in every direction of the supporting device while minimising fabrication costs. The embodiments also stress the need for the anchor means to be tubular and to be a snug fit within the guide pipes. This does not require both the guide pipes and the anchor pipes to be of the same configuration, although this is probably most convenient, but rather that the anchor pipes should engage the guide pipes sufficiently to prevent the anchor pipes moving externally to any material extent within the guide pipes.
The support of the present invention provides a viable, relatively low cost, alternative to wooden or concrete stumps and is in effect a three legged stump or a three legged mini-piling system in which the anchor pipes which engage the holes drilled in the ground constitute small piles which provide the necessary constructional support for bearers engaging the bearer support engaged with the central nut or opening in the top collar of the support, or the central riser. It will be appreciated that the collar described above may have any desired shape, including a rectangular shape which is adapted to engage a bearer channel. Similarly, in the embodiment of FIG. 1, the central nut 4 can be replaced by a metal support plate, similar to collar 13 to which the guide pipes are secured such as by welding.
The embodiment of FIG. 4 provides a relatively inexpensive alternative to the embodiment of FIG. 1 which lends itself to efficient fabrication techniques. In each of the above embodiments the anchor pipes can be held in the guide tubes by means of self tapping threaded screws or by means of narrow collars, such as 24 illustrated in FIG. 4, engaging the upper ends of the pipes 20 to 22 and held in place by anchor screws 25 . Where plastic anchor pipes are used, the anchoring performance can be improved by the insertion of a galvanized metal pipe within the anchor pipe and extending for at least part of the length of the plastic pipe, the galvanized metal pipe being filled with suitable grouting material to seal the pipe, the outer plastic pipe acting to protect the galvanized pipe against corrosion from the surrounding soil. | A constructional support including three tubes secured to a central support member with the tubes defining guides for drilling holes into the ground and for guiding anchor members as they are being driven into the holes to secure the support with respect to the ground. In one embodiment, the longitudinal axes of the tubes intersect at a point along the longitudinal axis of the central support member. In another embodiment, the longitudinal axes of the tubes each lie in a respective plane which is parallel to the longitudinal axis of the central support member. | 4 |
FIELD OF THE INVENTION
The present invention relates generally to a fracture reduction clamp for the temporary reduction or fixation of a fractured bone during a surgical procedure and more specifically, to an improved fracture reduction clamp which provides substantially complete circumferential compression of a fractured bone.
BACKGROUND OF THE INVENTION
Fracture reduction clamps known in the art are used to adjust the tension of a strap or wire surrounding a fractured bone. Known fracture reduction clamps are generally clamp or plier shaped and generally provide only temporary and partial compression of a fractured bone. In use, known fracture reduction clamps generally only provide a two-point compression of a fractured bone and placement of a permanent fixation device onto a fractured bone being reduced generally requires release of the fractured bone by the reduction clamp.
While not clinically used as a fracture reduction clamp, a wire tensioner sold by Howmedica is used to implant a permanent fixation wire about a fractured bone. The bone tensioner of Howmedica comprises a tube-shaped body, a strap guiding head, an adjustable strap retainer and a tension adjustment handle attached to the body and threadably engaged with the strap retainer for adjusting the tension of a strap engaged with the strap retainer and strap guiding head.
The wire tensioner sold by Howmedica generally operates as follows. A strap is passed between a bone having a fracture and the muscle surrounding the bone. The strap is then looped completely around the fractured bone and each end is optionally laced through a crimping sleeve. Each end is then laced through a wheeled end of a strap guiding head and through an adjustable strap retainer. The looping of the wire about the bone provides permanent circumferential compression of the fractured bone when the crimping sleeve is crimped onto the wire. The struts comprising the strap guiding head generally do not grip or resiliently contact the fractured bone. In order to tighten the wire about the bone, a handle on the clamp is rotated thereby displacing the strap retainer further from the fractured bone and tightening the strap surrounding the fractured bone. As the strap tightens about the fractured bone, the bone fragments align and the fracture is reduced. The crimping sleeve is then crimped onto the strap thereby permanently fixating the fractured bone. While the wire tensioner of Howmedica is not used as a fracture reduction clamp, it does share some structural similarity with the presently claimed fracture reduction clamp. However, were the Howmedica wire tensioner to be used in a fashion similar to the present fracture reduction clamp, it could not provide the substantially complete circumferential compression of the fractured bone both before and during placement of a permanent fixation device such as a plate or screw onto or into the fractured bone.
Known fracture reduction clamps generally reduce fractured bones by grasping the bone in a manner resembling pliers. None of the known fracture reduction clamps permit the placement of a bone fixation plate along side a fracture while a strap is tightly surrounding a major portion of the fractured bone, i.e., while maintaining substantially complete circumferential compression of the bone, and none of the known devices comprise a retractable spike in a strap guiding head of the fracture reduction clamp.
SUMMARY OF THE INVENTION
The present invention seeks to address the disadvantages present in fracture reduction clamps known in the art. The fracture reduction clamp can provide substantially complete circumferential compression of a fractured bone while a permanent fixation device is being implanted between the bone and a strap guiding head of the device. The present fracture reduction clamp can provide an orthopedic surgeon the advantages of: reduced overall surgery time; reduced time in which the patient is under anesthesia; reduced blood loss by the patient; reduced stress on the fractured bone and surrounding tissue; and rapid alignment of the fractured bone.
In one aspect, the present invention provides a fracture reduction clamp for tightening a strap about a fractured bone, said clamp comprising:
a substantially hollow tubular body having opposing first and second ends, a coextensive bore therethrough and two slots interposed said first and second ends and intersecting with said bore;
a handle rotatably engaged with said first end of said tubular body;
an externally threaded drive shaft which is fixedly engaged with said handle, disposed within said bore of said tubular body, substantially coaxial with said tubular body, and accessible through said two slots of said body;
a strap retainer which is threadably engaged with said drive shaft, is slidable with respect to said tubular body and extends through said two slots of said tubular body; and
a strap guiding head engaged with said second end of said body and comprising opposing, spaced apart, first and second strap guiding struts, each strut having a bore to permit passage of a strap therethrough;
wherein rotation of said handle causes displacement of said strap retainer with respect to said head.
In one embodiment, the fracture reduction clamp can be dismantled by hand into separate components. In another embodiment, the fracture reduction clamp comprises a retractable spike in the head and a thumbwheel to retract and extend the spike. The retractable spike can include a flattened shaft portion which engages a flattened bore portion in the head thereby prohibiting rotation of the spike when the thumbwheel is rotated to displace the spike with respect to the head.
The head of the fracture reduction clamp can include two or more struts having stepped ends for contacting a bone being reduced by the device.
The strap retainer will be adapted to receive and retain a strap that is being used to reduce a bone having a fracture.
The fracture reduction clamp will be adapted to provide substantially complete circumferential compression of a fractured bone, preferably both before and during implantation of a permanent bone fixation device, such as a plate or pin, into or onto the fractured bone, wherein the strap itself is not the permanent fixation device.
The spacing between the first and second strap guiding struts can be made adjustable. In addition, the first and second strap guiding struts can be hingedly mounted onto the strap guiding head.
Another aspect of the invention provides a fracture reduction clamp for tightening a strap about a bone having a fracture, said clamp comprising:
a strap guiding head comprising a spike and at least one strap guide;
a body having a first end engaged with said strap guiding head and a second end;
a rotatable drive engaged with said second end of said body;
and
a strap retainer adapted to receive and retain a strap passed through said strap guide, said retainer being threadably engaged with said rotatable drive and slidable with respect to said body;
wherein:
said strap retainer is displaced with respect to said strap guiding head when said rotatable driver is rotated.
The strap guiding head can have a bifurcation point at which first and second struts join. The first and second struts can each be comprise a strap guide adapted to permit passage of a strap therethrough. The strap guiding head can also comprise a retractable spike which is slidable with respect to said first and second struts. The spike can be made retractable by way of threads on the spike and a thumbwheel threadably engaged with said spike for retracting and extending said spike. The strap guiding head, retractable spike, thumbwheel, tubular body, rotatable drive and strap retainer can each be shaped as desired to optimize performance for a particular use.
Yet another aspect of the invention provides a method of reducing a fractured bone, said method comprising the steps of:
passing a strap around a fractured bone such that said strap surrounds at least a portion of said bone;
passing each of first and second ends of said strap through at least one strap guide in a strap guiding head of a fracture reduction clamp;
engaging each of said first and second ends of said strap with a strap retainer that is slidable with respect to said strap guiding head and is threadably engaged with a rotatable strap tensioner of said fracture reduction clamp; and
rotating said strap tensioner such that said strap retainer is displaced away from said strap guiding head thereby tightening said strap about said bone.
The method of the present invention can further comprise the steps of extending or retracting a retractable spike comprised within a strap guiding head used in the method of the invention. Since temporary bone reduction is used in preparation of semi-permanent or permanent bone fixation, the present method of the invention can include steps directed toward fixation of the reduced bone. The bone fixation can be effected with any of a number of available bone fixation apparatuses.
In another embodiment, the invention provides a kit for a fracture reduction clamp, said kit comprising:
at least one tubular body having first and second ends;
at least one strap retainer;
at least two different, removable and interchangeable strap guiding heads which are engageable with said first end of said body; and
at least one strap tensioner engageable with said second end of said body and operably engaged with said at least one strap retainer.
The kit of the present invention can independently comprise one or more of each of the individual components of a fracture reduction clamp as described herein. Strap guiding heads of the kit can independently include retractable spikes. The strap guiding heads can differ in dimensions, shape, use, presence or absence of spikes, and in other manners. The strap guiding heads can also include first and second struts having passages for passing a strap therethrough and/or having stepped ends for contacting the surface of a fractured bone being reduced. The individual components of a kit according to the invention can be assembled by hand to form at least one fracture reduction clamp.
Still another embodiment of the invention provides a fracture reduction clamp which together with a strap retained by said clamp is capable of providing substantially complete circumferential compression of a fractured bone before and during implantation of a permanent fixation device into or onto the fractured bone, wherein the strap need not completely encircle the fractured bone.
In this embodiment, the permanent fixation device can be implanted without significantly loosening the strap about the bone. This clamp can also comprise one or more of a spike and a pair of strap guiding struts for contacting the fractured bone during reduction of the fracture. The spike can be fixed or retractable with respect to the clamp. The clamp can also comprise a strap retainer and strap tensioner, and rotation of the strap tensioner can be made to result in tightening of the strap about the fractured bone when the strap is retained by the strap retainer.
Each aspect and embodiment of the invention provides unique and advantageous features which overcome the disadvantages of and which are substantially different than known devices and methods.
Other features, advantages and embodiments of the invention will be apparent to those skilled in the art by the following description, accompanying examples and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings form part of the present specification and are included to further demonstrate certain aspects of the invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of the specific embodiments presented herein.
FIG. 1 is a perspective view of a fracture reduction clamp according to the invention.
FIG. 2 is an exploded view of the fracture reduction clamp of FIG. 1 .
FIG. 3 is a cross-sectional view of the strap guiding head ( 2 ) according to the invention.
FIG. 4 is a cross-sectional view along lines 4 — 4 of the strap guiding means ( 2 ) in FIG. 2 .
FIG. 5 is a front elevation view of a strap retainer according to the invention.
FIG. 6 is a top plan view along lines 6 — 6 of the retainer ( 5 ) of FIG. 5 .
FIG. 7 is a front elevation view of a second embodiment of the strap retainer according to the invention.
FIG. 8 is a partial sectional view of a third embodiment of the passageway of the strap retainer according to the invention.
FIG. 9 is a partial sectional view of a fourth embodiment of the passageway of the strap retainer according to the invention.
FIG. 10 is a top plan view of a fifth embodiment of the strap retainer according to the invention.
FIG. 11 is a front elevation view of the strap retainer of FIG. 10 .
FIGS. 12 a - 12 c are top plan views of various alternate embodiments of the strap used with the fracture reduction clamp according to the invention.
FIG. 13 a is a bottom plan view of the cap of a strap or retainer according to the invention.
FIG. 13 b is a front elevation view of the cap of FIG. 13 a.
FIG. 13 c is a front elevation view of the body of a sixth embodiment of a strap retainer according to the invention. The body of FIG. 13 c is engaged with the caps of FIG. 13 b to form a strap retainer.
FIG. 13 d is a top plan view of the body of the strap retainer of FIG. 13 c.
FIG. 14 is a perspective view of a fracture reduction clamp according to the invention reducing a fractured bone.
FIGS. 15 a - 15 d are side elevation views of the fraction reduction clamp reducing a variety of different types of fractures.
FIG. 16 is a side elevation view of another embodiment of the strap guiding head of the invention having hingedly or pivotally mounted struts.
FIG. 17 is a side elevation view of another embodiment of the strap guiding head of the invention wherein the spacing between the struts is adjustable.
FIG. 18 is a perspective view of another embodiment of the strap guiding head of the invention wherein the head has no struts but includes a spike.
DETAILED DESCRIPTION OF THE INVENTION
The fracture reduction clamp of the present invention permits a user to apply a torque force to a fractured bone and to place a bone fixation plate alongside a fracture in the fractured bone while a strap of the device is still tightly surrounding the fractured bone and provide either partial or substantially total circumferential compression of a fractured bone. The present fracture reduction clamp is easy to manufacture and can be made with interchangeable heads to permit use of the clamp with various size bones.
FIG. 1 depicts a first embodiment of the fracture reduction clamp ( 1 ) according to the invention, wherein the clamp ( 1 ) comprises a strap guiding head ( 2 ), a tubular body ( 3 ), a rotatable handle ( 4 ), and a strap retainer ( 5 ). In the embodiment of FIG. 1, the clamp generally operates as follows. The ends of a strap ( 6 ) are passed through bores ( 11 a and 11 b ) which extend through opposing first and second struts in the strap guiding head ( 2 ) mounted on a first end of the tubular body ( 3 ). The ends of the strap ( 6 ) are then engaged with the strap retainer ( 5 ). The handle ( 4 ) is rotatably engaged with the tubular body ( 3 ) and fixedly engaged with the drive shaft ( 12 ). The strap retainer ( 5 ) is threadably engaged with the drive shaft ( 12 ) and is slidable within the slots ( 9 ) of the tubular body ( 3 ). As the handle ( 4 ) is rotated in the direction of the arrow (R T ), the strap retainer ( 5 ) is displaced longitudinally along the arrow (T) away from the strap guiding head ( 2 ). Since the strap ( 6 ) is fixedly engaged with the strap retainer ( 5 ), displacement of the strap retainer ( 5 ) along the arrow (T) effects a tightening of the strap ( 6 ). In a reverse manner, the strap ( 6 ) can be loosened by rotating the handle ( 4 ) in the direction of the arrow (R L ) which effects a forward displacement of the strap retainer ( 5 ) in the direction of the arrow (L) toward the strap guiding head ( 2 ).
In one embodiment, the fracture reduction clamp ( 1 ) includes a strap guiding head ( 2 ) that comprises among other things a retractable spike ( 7 ) which is operable with a thumbwheel ( 8 ). The retractable spike ( 7 ) can be extended and retracted during use of the clamp ( 1 ). When the spike ( 7 ) is brought into contact with a bone (shown in dashed lines) held by the strap ( 6 ) and the clamp ( 1 ), the spike helps the clamp to grip the bone more firmly.
FIG. 2 depicts an exploded view of the fracture reduction clamp ( 1 ) of FIG. 1 . The tubular body ( 3 ) has a first end ( 3 a ) which is engageable with the strap guiding head ( 2 ) and a second end ( 3 b ) which is engageable with the handle ( 4 ). The handle ( 4 ) comprises a bore ( 14 ) which is adapted to receive the second end ( 3 b ) of the tubular body ( 3 ). In a like fashion, the strap guiding head ( 2 ) has a bore ( 22 ) which is adapted to receive the first end ( 3 a ) of the tubular body ( 3 ). The handle ( 4 ) and the first end ( 3 b ) are held together by a friction joint comprising a retainer ring (not shown), a retainer ring channel ( 15 a ) in the handle ( 4 ) and a retainer ring channel ( 15 b ) in the end ( 3 b ) of the tube ( 3 ). In a similar fashion, the strap guiding head ( 2 ) is engaged with the first end ( 3 ) of the tube by way of a compression joint comprising a retainer ring (not shown), a retainer ring channel ( 16 a ) in the end ( 2 c ) of the head ( 2 ) and a retainer ring channel ( 16 b ) in the end ( 3 a ) of the tube ( 3 ).
The handle ( 4 ) is fixedly engaged with a drive shaft ( 12 ) which comprises a first end ( 12 a ), a middle portion ( 12 b ) and a second end ( 12 c ). The bore ( 14 ) of the handle ( 4 ) is countersunk and has a wide diameter portion ( 14 a ) and a deeper narrow diameter portion ( 14 b ). The portion ( 12 c ) of the drive shaft ( 12 ) is fixedly engaged with the narrow bore ( 14 b ) of the handle. The middle portion ( 12 b ) of the drive shaft and the inner surface of the bore portion ( 14 a ) of the handle define a clearance into which the end ( 3 b ) of the tubular body ( 3 ) can be placed. The end ( 3 b ) has a bore portion ( 21 ) which is adapted to receive the drive shaft portion ( 12 b ). The outer diameter of the end ( 3 b ) is smaller than the inner diameter of the bore ( 14 a ) in the handle ( 4 ). When the handle ( 4 ) is engaged with the end ( 3 b ), the end ( 12 a ) of the drive shaft ( 12 ) will engage a narrow bore ( 20 b ) in the tubular body ( 3 ), and the end ( 3 b ) will occupy the cavity defined by the inner surface of the bore ( 14 a ) and the outer surface of the drive shaft portion ( 12 b ).
The strap retainer ( 5 ) which is slidably engaged with the body ( 3 ) is disposed within a slot ( 9 ) in the body ( 3 ). The slot passes through the body and intersects with a bore which extends throughout the body ( 3 ).
When the handle ( 4 ) is engaged with the end ( 3 b ), the drive shaft passes through the bore ( 21 ) and threadably engages the strap retainer ( 5 ). Ultimately, the end ( 12 a ) of the drive shaft ( 12 ) will engage the narrow bore ( 20 b ) which serves as a guide or bearing for the end ( 12 a ).
The strap guiding head ( 2 ) has a countersunk bore ( 22 ) therethrough from a first end ( 2 c ) to a point of bifurcation ( 2 d ). The countersunk bore has a narrower diameter bore portion ( 13 ) which is adapted to receive the shaft of a retractable spike ( 7 ). The head ( 2 ) has a slot ( 2 e ) therethrough which intersects with the bore portion ( 13 ) and which is adapted to receive a thumbwheel ( 8 ). When the spike ( 7 ) and the end ( 3 a ) are engaged with their respective bore portions ( 13 and 22 ) of the head ( 2 ), the shaft of the spike ( 7 ) will pass through the bore portion ( 13 ) and into the bore ( 20 ) located at the first end ( 3 a ) of the tubular body ( 3 ).
Referring now to FIG. 3, the strap guiding head ( 2 ) comprises a first strut ( 2 a ) and a second strut ( 2 b ), the first strut ( 2 a ) having a bore ( 11 a ) therethrough and the second strut ( 2 b ) having a bore ( 11 b ) therethrough. The bores ( 11 a and 11 b ) are adapted to receive respective portions ( 6 a and 6 b ) of a strap ( 6 ) when the fracture reduction clamp is in use. The spike depicted in FIG. 3 has a head portion ( 7 a ), a shaft portion ( 7 b ) and an opposing end ( 7 d ). The shaft portion ( 7 b ) will have a flattened surface portion which extends substantially coaxially with the linear axis of the spike ( 7 ). The spike ( 7 ) will also have an externally threaded portion ( 7 c ) which also extends substantially coaxially with the linear axis of the spike ( 7 ). The thumbwheel ( 8 ) is shown as being threadably engaged with the threaded portion ( 7 c ) of the spike ( 7 ).
The end ( 3 a ) of the body ( 3 ) has a male coupling comprising a pair of projections ( 19 a and 19 b ) which engage with a female coupling comprising a pair of recesses ( 24 a and 24 b ) disposed within the inner bore ( 22 ) of the head ( 2 ). The male coupling of the end ( 3 a ) and the female coupling of the head ( 2 ) serve to prohibit rotation of the tubular body ( 3 ) within the bore ( 20 ) of the head ( 2 ) so that when the handle ( 4 ) is rotated, the body ( 3 ) will not rotate with respect to the head ( 2 ). When the end ( 3 a ) and the spike ( 7 ) are engaged with the head ( 2 ), the end ( 70 ) of the spike will pass through the bore ( 13 ) and into the bore ( 22 ). The outer surface of the shaft portion of the spike and the inner surface of the bore ( 22 ) of the head will define a clearance within which the end ( 3 a ) of the tubular body ( 3 ) is placed.
By rotation of the thumbwheel in either a counterclockwise or clockwise direction, the spike ( 7 ) can be made to retract and extend longitudinally along the axis of the bore ( 13 ) in the direction of the arrow (X).
FIG. 4 depicts a cross-sectional end view of the head ( 2 ) along lines 4 — 4 of FIG. 2 . The bore ( 13 ) located at the bifurcation point ( 2 d ) of the head ( 2 ) comprises a flattened portion ( 13 a ) which engages the flattened portion ( 7 b ) of the shaft of the spike ( 7 ). The engagement of the flattened portion ( 13 a ) and flattened portion ( 7 b ) assures that the shaft of the spike ( 7 ) will not rotate within the bore ( 13 ) when the thumbwheel ( 8 ) is rotated, thereby making it possible for the thumbwheel ( 8 ) to drive the spike in a reciprocal manner within the bore ( 13 ). The flattened portion ( 13 a ) can be considered exemplary of a stopping means adapted to stop rotation of the spike shaft when it is engaged with a rotatable thumbwheel ( 8 ). Other means for stopping the rotation of a shaft can be used in place of the flattened portion ( 13 a ). Such means can include a slot and pin combination, a channel and pin combinations, a key and notch combination wherein the key is on the shaft and the notch is in the strap guiding head and others known to those of ordinary skill in the art.
Referring again to FIG. 3, the bores ( 11 a and 11 b ) extend substantially the entire length of the struts ( 2 a and 2 b ), respectively. However, it is only necessary that the bores ( 11 a and 11 b ) extend a sufficient length of their respective struts ( 2 a and 2 b ) to permit passage of strap portions ( 6 a and 6 b ) through the bores ( 11 a and 11 b ).
The ends ( 10 a and 10 b ) of the struts ( 2 a and 2 b ), respectively, are depicted as having stepped ends that are declined toward each other and toward the bifurcation point ( 2 d ). However, the ends ( 10 a and 10 b ) can be smooth, stepped, serrated, roughened, knurled, inclined, declined or otherwise formed. In a preferred embodiment, the ends ( 10 a and 10 b ) will enhance the gripping of a fractured bone by the fracture reduction clamp so that the clamp can be used to apply a torque to a bone being reduced by the clamp.
Various alternate embodiments of the strap guiding head according to the invention are shown in FIGS. 16-18. FIG. 16 depicts a first embodiment wherein the strap guiding head ( 100 ) comprises first ( 101 ) and second ( 102 ) struts which are hingedly or pivotally mounted onto the body ( 103 ). In order to provide a firm grasp of a reduced bone, the strap guiding head ( 100 ) can also comprise a locking means (not shown) which is used, when needed, to secure the relative positions of the struts. FIG. 17 depicts a second embodiment wherein the strap guiding head ( 105 ) comprises first ( 106 ) and second ( 107 ) struts adjustably mounted onto the body ( 108 ) by way of adjustment means comprising the slot ( 109 ) and locking screws ( 110 ). The spacing (S) between the struts ( 106 , 107 ) is made adjustable with adjustment means. The strap guiding heads ( 100 , 105 ) can be used to fit a variety of different bone sizes. In other alternate embodiments, a strap guiding head can include hingedly mounted first and second struts which are also adjustable such that a space therebetween can be adjusted.
FIG. 18 depicts a third embodiment of the strap guiding head ( 115 ) wherein the head has no struts but does include a spike ( 117 ) which is fixed or retractable engaged with the body ( 116 ). The strap guiding head ( 116 ) comprises strap guides ( 118 , 119 ) which are adapted to permit passage of a strap therethrough. As used herein, the term “strap guide” can be, for example, a loop, tube, channel, passageway, or hook.
The strap retainer ( 5 ) according to the invention will be threadably engaged to a drive shaft ( 12 ) or other drive means, will be slidable with respect to the tubular body ( 3 ) and will be displaceable away from or toward the strap guiding head ( 2 ) in response to rotation of the drive shaft ( 12 ). The retainer ( 5 ) will not rotate with respect to the tubular body ( 3 ).
The strap retainer according to the invention will retain a strap in either a reversible or irreversible fashion. In the embodiment of FIG. 5, the strap retainer ( 5 ) comprises at least one retaining member ( 17 a ), a passageway ( 5 a ) adapted to receive a strap, a body ( 25 a ) and an internally threaded bore ( 26 ) which is adapted to threadably engage a drive shaft ( 12 ).
In the embodiment of FIG. 5, the strap retainer ( 5 ) comprises a body portion ( 25 a ) and a cover portion ( 25 b ) which are secured to each other by way of attachment means. The attachment means can comprise any known means for securing two solids to each other. By way of example and without limitation, the attachment means in the embodiment of FIG. 5 includes at least one screw ( 29 a ) and at least one threaded bore ( 27 a ) in the body portion ( 25 a ). Attachment means can include clamps, adhesive, welds, screws, rivets, nails, brackets, straps, pins and other such means known to those of skill in the art.
The body portion ( 25 a ) comprises a threaded bore ( 26 ) therethrough which is threadably engageable with a drive shaft ( 12 ). The body portion ( 25 a ) also includes a passageway such as, by way of example and without limitation, an aperture, bore, channel, space, clearance, cavity or crevice which is adapted to receive a strap.
The body portion ( 25 a ) also includes at least one retaining member ( 17 a ) which is disposed either within or adjacent the passageway ( 5 a ) and which is adapted to retain a strap inserted through the bore ( 5 a ) at least momentarily. The retaining member ( 17 a ) will engage a strap either reversibly or irreversibly depending on the particular construction of the retaining member ( 17 a ) and of the strap used. In a preferred embodiment, the strap retainer ( 5 ) will comprise two bores ( 5 a , 5 b ) therethrough which are adapted to receive a strap and two retaining members ( 17 a and 17 b ) disposed in the respective bores ( 5 a and 5 b ) which are adapted to retain respective first and second ends of a strap.
Referring now to FIG. 6, the body portion ( 25 a ) of the strap retainer ( 5 ) of FIG. 1 is depicted as having two passageways ( 5 a and 5 b ) for receiving respective first and second ends of a strap. When the passageways ( 5 a and 5 b ) are covered with the cover portion ( 25 b ), the passageways together with the respective portions of the cover ( 25 b ) form bores through the strap retainer ( 5 ). In order to assist in maintaining a strap ( 6 ) engaged with a respective strap retaining member ( 17 b ), the strap retainer ( 5 ) can further comprise strap biasing means ( 28 a , 28 b ) which bias a strap ( 6 ) disposed within the passageway ( 5 b ) toward the retaining member ( 17 b ).
FIG. 7 depicts another embodiment of the strap retainer ( 30 ) according to the invention comprising a first body portion ( 30 a ) and a second body portion ( 30 b ) wherein the body portions are held together by attachment means. In this embodiment, the body portion ( 30 a ) comprises a strap biasing means (not shown), and the body portion ( 30 b ) comprises a threaded bore ( 31 ) and two retaining members ( 33 a and 33 b ). When assembled to form the strap retainer ( 30 ), the body portions ( 30 a and 30 b ) together define two passageways ( 32 a and 32 b ) which are adapted to receive first and second ends of a strap (not shown). The retaining members ( 33 a and 3 b ) will be disposed within the passageways ( 32 a and 32 b ), respectively.
FIG. 8 depicts a partial cross-sectional view of a strap retainer ( 47 ) which comprises a passageway ( 48 ) which is adapted to receive a strap (not shown) inserted therethrough in the direction of the arrow (I). The strap retainer ( 47 ) will irreversibly retain a strap, i.e., once inserted through the passageway ( 48 ) in the direction of the arrow (I), a strap will not be able to be withdrawn in a direction opposite of the arrow (I). The irreversible retention of the strap is made possible by the use of a strap having slots or apertures which irreversibly engage one or more of the retaining members ( 49 a , 49 b and 49 c ) disposed within the passageway ( 48 ). The strap retainer ( 47 ) need not comprise strap biasing means as placement of the retaining members ( 49 a and 49 c ) in a direction opposite that of the retaining member ( 49 b ) assures a secure engagement of the retaining members with the strap.
FIG. 9 depicts a partial cross-sectional view of yet another embodiment of the strap retainer ( 50 ) according to the invention wherein the strap retainer comprises an arcuate passageway ( 51 ) and a retaining member ( 53 ) disposed therein. In this embodiment, the curved wall ( 52 ) serves as a strap biasing means as described above.
FIGS. 13 a-d depict various elevation and plan views of another embodiment of the strap retainer ( 60 ) according to the invention. The strap retainer comprises a body ( 61 ), two opposing end caps ( 62 a ) and ( 62 b ) mounted on opposing ends ( 61 a ) and ( 61 b ), respectively, of the body ( 61 ), a threaded bore ( 73 ) which can be threadably engaged with a threaded drive shaft ( 12 ), a first retaining member ( 66 a ) and a second retaining member ( 66 b ). The end caps ( 62 a ) and ( 62 b ) depicted in FIG. 13 b comprise cover portions ( 70 a ) and ( 70 b ), respectively, convex arcuate surfaces ( 68 a ) and ( 66 b ), respectively, adjacent the end cap, retaining members ( 66 a ) and ( 66 b ), respectively, adjacent the convex arcuate surfaces ( 68 a ) and ( 68 b ), respectively, and end portions ( 64 a ) and ( 64 b ), respectively. When the end cap ( 70 a ) is engaged with the end portion ( 61 a ) of the body ( 61 ), the end portion ( 64 a ) of the end cap ( 62 a ) abuts the end portion ( 63 a ) of the body ( 61 ). The cover portion ( 70 a ), the channel ( 67 a ) and the body ( 61 ) together define a passageway through which a strap can be passed and retained by the strap retainer ( 61 ). The channel ( 67 a ) is defined by an arcuate convex surface ( 65 a ) and an opposing biasing surface comprising a first ( 69 a ) and a second ( 71 a ) biasing means. The biasing surface biases a strap disposed within the channel ( 67 a ) toward the arcuate surface ( 65 a ), the arcuate surface ( 68 a ) of the end cap ( 62 a ) and the retaining member ( 66 a ) of the end cap ( 62 a ). When the strap is inserted in the channel ( 67 a ), notches or slots within the strap will engage the retaining member ( 66 a ) preferably in an irreversible manner.
The end caps ( 62 a ) and ( 62 b ) are attached to the respective end portions ( 63 a ) and ( 63 b ) of the body ( 61 ) by way of attachment means which can comprise any means used to affix, attach, or engage two solids together. In the embodiment of FIG. 13 b and 13 c , the strap retainer ( 61 ) comprises a countersunk bore ( 63 b ) in the first end ( 61 b ) of the body ( 61 ) and a threaded bore ( 70 b ) in the end cap ( 62 b ). The end cap and the body can be held together by a threaded screw that is engaged with both the end cap and the body.
In the embodiment of FIGS. 13 a-d , the strap retainer ( 61 ) comprises two retaining members ( 66 a , 66 b ), two biasing means, a body portion ( 61 ), two end caps ( 62 a , 62 b ), two channels ( 67 a , 67 b ), and a threaded bore ( 73 ) in the body portion ( 61 ).
It is not necessary that the strap retainer engage a strap irreversibly. The strap retainer ( 35 ) depicted in FIG. 10 permits reversible engagement of a strap (not shown). The strap retainer ( 35 ) comprises a body portion ( 54 ), a threaded passageway ( 34 ) which is threadably engageable with a threaded drive shaft ( 12 ) or rotatable driving means, a first thumbwheel ( 36 a ) and a second thumbwheel ( 36 b ). Each thumbwheel has a respective outer periphery ( 38 a and 38 b ) which, together with adjacent portions of the body ( 54 ), define clearances ( 35 a and 35 b ), respectively, which are adapted to receive first and second ends of a strap. The wheels ( 36 a and 36 b ) are mounted eccentrically onto the body ( 54 ) by way of wheel retainers ( 37 a and 37 b ) about which the respective wheels ( 36 a and 36 b ) pivot. When the handle ( 55 a ), which is attached to the wheel ( 36 a ), is swung in the direction of the arrow (P A ), the outer periphery ( 38 a ) is brought closer to an opposing portion of the body ( 54 ) thereby narrowing the clearance of the passageway ( 35 a ). When a strap is inserted in the passageway ( 35 a ) in the direction of the arrow (I) and the outer periphery ( 38 a ) is in resilient or firm contact with the strap, the strap will temporarily not be able to be retracted from the clearance ( 35 a ) in a direction opposite to that of the arrow (I). A strap being retained by the strap retainer ( 35 ) can be released simply by swinging the handle ( 55 a ) away from the strap in a direction opposite that of the arrow (P A ), thereby making engagement of a strap by the retainer ( 35 ) reversible.
Referring now to FIG. 11, the wheels ( 36 a and 36 b ) of the strap retainer ( 35 ) can have textured ( 39 ) outer peripheries to facilitate gripping of a strap being retained by the strap retainer ( 35 ). The texture ( 39 ) can be hash marks, knurling, surface roughening, and other such textures that increase the frictional resistance between the surface of a strap and the surface on the outer periphery of the respective wheels. It will be understood that the textured surface can occur on the surface of the retainer that defines the passageway rather than on the outer periphery of the wheels.
The strap retainer according to the invention can be adapted to engage and retain a wide variety of straps. FIGS. 12 a , 12 b and 12 c depict three alternate embodiments of straps that can be used. FIG. 12 a depicts a strap ( 40 ) having plural apertures or slots ( 41 ) which apertures engage with at least one retaining member in a strap retainer according to the invention. FIG. 12 b depicts a strap ( 42 ) having plural incisions ( 43 ) which form plural flap portions ( 44 ) in the strap when it is engaged with a retaining member. The flap ( 44 ) will be displaced from its first position to a second position thereby permitting a retaining member to engage with an aperture formed by the incision ( 43 ). FIG. 12 c depicts a strap ( 45 ) having a textured surface ( 46 ) which increases the friction between the strap ( 45 ) and a retaining member. The texture on the surface ( 46 ) can include by way of example and without limitation hash marks, knurlings, irregular surface markings, and other such friction-enhancing means known to those of skill in the art.
As used herein, the term “strap” is taken to mean a strip of material, a cord, a string, a wire, a barlock, a cable, a twine, a fiber, a band, a nylon cord, fishing string, a strand, and other such materials that can be used in the art of bone reduction and fixation. A strap according to the invention will be flexible and dimensioned to permit retention by a strap retainer according to the invention. A strap for use in the present clamp can be obtained from the Tyton Corporation (Milwaukee, Wis.).
The fracture reduction clamp according to the invention need not be, but is preferably, adapted to being dismantled and assembled by hand. A fracture reduction clamp can be provided as a unit having a strap guiding head permanently affixed to an end of a tubular body or removably engaged with an end of a tubular body. The tubular body can be adapted to removably and interchangeably engage with at least two different strap guiding heads.
When the fracture reduction clamp according to the invention is provided as a kit, the kit will comprise at least one tubular body having first and second ends, at least one strap retainer, at least two different removable end interchangeable strap guiding heads which are engageable with the first end of the tubular body, and at least one strap tensioner engageable with the second end of the body and operably engageable with the at least one strap retainer.
It will be preferred that at least one of the strap guiding heads present in the kit will have a retractable spike and even more preferable that the strap guiding head further include a thumbwheel for retracting and extending the retractable spike. Generally, the strap guiding heads will have first and second struts wherein each strut has a bore which is adapted to permit passage of a strap therethrough. The at least two different, removable and interchangeable strap guiding heads can differ in size, dimension, shape, use, materials of construction, purpose of use, and/or design.
The at least one retainer in the kit according to the invention can be adapted to either reversibly or irreversibly retain a strap and can comprise fixed, movable, or rotatable retaining members which engage the strap. When the components of a kit according to the invention are assembled to form a fracture reduction clamp, the strap retainer will preferably be slidable with respect to the body and displaceable from the strap guiding head. Even more preferred, the strap retainer will be threadably engaged with the strap tensioner, and the strap retainer will slide with respect to the tubular body when the strap tensioner is rotated.
Although a wide variety of constructions for the retractable spike can be used in the present invention, a preferred retractable spike will have a first head portion, a shaft portion, a longitudinally extending threaded portion and a longitudinally extending unthreaded and flattened portion. Even more preferably, the retractable spike will retract and extend from a point of bifurcation in the strap guiding head in response to rotation of a thumbwheel in the strap guiding head.
The fracture reduction clamp according to the present invention is useful for a variety of methods of reducing a fractured bone. One such general method comprises the following steps:
passing a strap around a fractured bone such that the strap is disposed between the outer surface of the bone and overlying muscle tissue;
passing first and second ends of the strap through strap guides in a strap guiding head of a fracture reduction clamp;
engaging the first and second ends of the strap with a strap retainer that is displaceable away from and slidable with respect to the strap guiding head and is threadably engaged with a rotatable strap tensioner included in the clamp; and
rotating the strap tensioner such that the strap retainer is displaced away from the strap guiding head thereby tightening the strap about the fractured bone and at least temporarily reducing the fracture.
In one embodiment, the method of the invention can further comprise the step of extending a retractable spike comprised within a strap guiding head, wherein this particular step can be conducted either before or after any one of the other steps in the method of the invention. The method can also comprise the step of retracting the retractable spike after the step of rotating the strap tensioner.
The method according to the invention can further comprise the step of placing a bone fixation apparatus between the strap guiding head and the fractured bone wherein the step can be conducted before or after any one of the other steps of the invention. The bone fixation apparatus can also be placed between the retractable spike and the fractured bone. Either after partial or complete reduction of a fractured bone by the fracture reduction clamp according to the invention, the method of the invention allows for fixation of the fractured bone with a bone fixation apparatus.
One embodiment of the method of the invention is shown in FIG. 14 which depicts a reduction clamp ( 80 ) being used to reduce an obligue fracture in the bone ( 81 ). The clamp ( 80 ) comprises a strap guiding head ( 79 ) which comprises first ( 85 a ) and second ( 85 b ) struts, a retractable spike ( 90 ), a thumbwheel ( 86 ) used to retract the spike ( 90 ), and a bore ( 88 ) through the struts ( 85 a , 85 b ) through which a strap ( 87 ) passes. The fixation plate ( 82 ) is shown affixed to the bone ( 81 ) by way of a fixation screw ( 84 ) which passes through a hole ( 83 ) in the plate.
The method of the invention, as depicted in FIG. 14, was conducted as follows. The strap ( 87 ) was passed around the bone ( 81 ) between the bone and surrounding muscle tissue (not shown). The ends of the strap ( 87 ) were passed through the bore ( 88 ) in each of the first ( 85 a ) and second ( 85 b ) struts and subsequently engaged with a strap retainer (not shown) of the clamp ( 80 ). The strap ( 87 ) was then tightened about the bone until the ends ( 89 a , 89 b ) of the struts ( 85 a , 85 b ) abutted the bone ( 81 ). The spike ( 90 ) was then extended until it contacted the bone ( 81 ). This step can be done before several of the previous and following steps. As the strap ( 87 ) was further tightened, the fracture was reduced by the clamp ( 80 ). The struts ( 85 a , 85 b ) in combination with the strap ( 87 ) and the spike ( 90 ) provided a substantially complete circumferential compression of and a firm grasp of the bone ( 81 ). The spike ( 90 ) was then retracted, by way of the thumbwheel ( 86 ), a sufficient amount to permit insertion of the fixation plate ( 82 ) over the oblique fracture in the bone ( 81 ) without any significant loss in circumferential compression. The head of the spike ( 90 ) was then extended again and engaged with a hole ( 83 ) in the plate ( 82 ). The plate ( 82 ) was then affixed to the bone ( 81 ) with a screw ( 84 ). Following completion of bone fixation with the plate ( 82 ) and other screws ( 84 ), the strap ( 87 ) was loosened and then removed.
It should be noted that the grasp of a bone by the clamp of the invention is sufficiently firm that the expected range of motion of the fractured bone, once it has healed, can be predicted simply by reduction of the fractured bone and articulation of the bone. This method can be practiced without having to permanently fixate the fractured bone with a fixation device. An exemplary embodiment of the method of predicting the range of motion of a fractured bone, once the bone has healed, includes the steps of:
reducing a fractured bone with a fracture reduction clamp according to the invention; and
articulating the fractured bone that has been reduced to determine its range of motion;
wherein the range of motion of the fractured bone that has been reduced approximates the range of motion that can be achieved for the bone once its fracture has healed.
FIGS. 15 a - 15 d depict several different types of fractures that can be reduced with the present fracture reduction clamp. Such fractures include simple, compound and comminuted fractures such as, for example, butterfly fractures (FIG. 15 a ), spiral fractures (FIG. 15 b ), long oblique fractures (FIG. 15 c ) and transverse fractures (FIG. 15 d ). As depicted in these figures, it may necessary to employ more than one fracture reduction clamp (only shown in part) in reducing a fractured bone. Accordingly, the method of the invention can include additional steps directed toward reducing a fractured bone with one or more clamps according to the invention.
As used herein, a bone fixation apparatus can comprise a screw, nail, wire, plate, bracket, rod, pin, adhesives clamp, or other such apparatuses known to those of skill in the art.
It will be understood by those of ordinary skill in the art that the materials of construction for the fracture reduction clamp of the present invention can comprise any known materials typically used for this purpose. For example, various metals, stainless steel, alloys, plastics, and/or polymers.
The fracture reduction clamp depicted in the attached figures can be used by either a right-handed or left-handed person; however, the bone reduction apparatus can be adapted for preferred use by just a right-handed or just a left-handed user.
The above is a detailed description of particular embodiments of the invention. It is recognized that departures from the disclosed embodiments may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. Those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed herein and still obtain a like or similar result without departing from the spirit and scope of the invention. All of the embodiments disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. | A fracture reduction clamp for the reduction of a fractured bone. The fracture reduction clamp is particularly suitable for surgical procedures wherein a bone having a fracture is to be fixated with a fixation apparatus after reduction of the bone with a strap. The fracture reduction clamp includes a bifurcated strap guiding head for contacting and firmly gripping the fractured bone, and a strap retainer disposed between the strap guiding head and a rotatable strap tensioner for retaining the ends of the strap being used to reduce the fractured bone. The strap guiding head can include a retractable spike for enhancing the grip of the fractured bone by the fracture reduction clamp. Rotation of the strap tensioner will tighten or loosen the strap about the fractured bone. | 0 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The claimed invention relates to motion platforms for video simulation equipment; and more particularly, to a mechanical platform and related components being configured to simulate simultaneous yaw and roll motion for use in such video simulation equipment.
[0003] 2. Description of the Related Art
[0004] Video simulation systems are becoming increasingly popular for applications such as video gaming and operator skill and developmental training. Such video simulation systems are generally designed to mimic an object environment for a targeted application. For example, video simulators have been proposed for simulating the dynamics of aircraft, marine vessels, locomotives and automobiles. In each of these examples, the objective of the video simulation system is to mimic visual and motion characteristics of an environment associated with operation of the object under simulated conditions.
[0005] For purposes herein, a particular interest is aimed at yaw motion about a vertical axis and roll motion about a horizontal axis for simulating motion characteristics of aircraft and marine vessels, and more particularly such motion for helicopter simulation.
[0006] It is important to accurately simulate the dynamics of an object environment, especially where the associated application is flight operator training. The idea being that the operator experience within the simulator must closely resemble real-world conditions in order to build adequate experience, skill and to anticipate reactions of the operator in preparation for a real-world event or condition.
[0007] Currently available systems have yet to provide a cost effective and adequate yaw and roll motion simulation platform. To be cost effective, it would be beneficial to provide such a platform with relatively few moving components. Moreover, it is a need in the art to overcome the challenges of providing fewer mechanical parts while maintaining adequate motion simulation. Thus, there is an ongoing need for improved motion platforms for use with video simulation systems, especially such platforms configured for roll-motion and yaw-motion simulation, and further configured for low cost, simple and effective mechanical motion simulation.
SUMMARY
[0008] A motion platform for use with a video simulation system is described. The motion platform is configured to provide simultaneous and constantly varying roll-axis and yaw-axis motion about multiple pivot points for simulating a helicopter aircraft or similar environment. Additionally, the motion platform is configured to achieve roll and yaw-motion using a single linear actuator, and thus is provided at a significantly reduced cost compared to conventional multi-actuator motion platforms. Other benefits of the motion platform include improved power efficiency, reduced weight for increased portability, and reduced maintenance due to only one linear actuator driving the system, among others.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The claimed invention can be further understood upon a thorough review of the following detailed description in conjunction with the appended drawings, wherein:
[0010] FIG. 1 shows a video simulation system in accordance with an illustrated embodiment;
[0011] FIG. 2 shows a motion platform for use with a video simulation system of the illustrated embodiment;
[0012] FIG. 3 shows an exploded view of the key components making up the motion platform of the illustrated embodiment;
[0013] FIG. 4A shows a perspective view of a base from the components of the illustrated embodiment;
[0014] FIG. 4B shows a rear view of the base;
[0015] FIG. 5 shows a pivot from the components of the illustrated embodiment;
[0016] FIG. 6 shows a linkage from the components of the illustrated embodiment;
[0017] FIG. 7 shows a linear actuator from the components of the illustrated embodiment;
[0018] FIG. 8A shows a perspective view of a chassis from the components of the illustrated embodiment;
[0019] FIG. 8B shows a rear view of the chassis;
[0020] FIG. 8C shows a bottom view of the chassis;
[0021] FIG. 9A shows yaw-motion of the motion platform; and
[0022] FIG. 9B shows roll-motion of the motion platform.
DETAILED DESCRIPTION
[0023] In the following description, for purposes of explanation and not limitation, details and descriptions are set forth in order to provide a thorough understanding of the claimed invention. However, it will be apparent to those skilled in the art that the claimed invention may be practiced in other embodiments that depart from these details and descriptions without departing from the spirit and scope of the invention. Certain embodiments will be described below with reference to the drawings wherein illustrative features are denoted by reference numerals.
[0024] A motion platform suited for low-cost production and effective motion simulation within a video simulation system is disclosed. The motion platform comprises a single actuator, resulting in low-cost implementation, reduced power consumption, reduced weight for improved portability, simplified servicing or replacement, and improved longevity with reduced maintenance.
[0025] In one embodiment, referenced herein as a “technology advanced flight motion system”, the motion platform includes: an articulating floor-mounted structure supporting a simulator cockpit through two acentric rotating arms mounted at the rear. A single forward mounting point allows the cockpit to rotate right and left in a horizontal plane and to roll clockwise and counter clockwise.
[0026] The technology advanced flight motion system creates a sensation of being supported on air or other fluid medium such as water. Acentric mounted pivoting arms support the cockpit, rotating right to left about a fixed pivot. This results in a compound simultaneous acentric yaw and roll, being flatter in the center and accelerating as it approaches the ends of the right/left rotation. This results in a constant-varying simultaneous yawing and rolling motion. The unique mechanism allows an accurate motion and feeling of coordinated and uncoordinated turns in a skid or slide. Uncoordinated turns are a major cause/contributor to aviation accidents.
[0027] This compound motion is driven by a single linear actuator that is programmed to simulate turbulence ranging from extremely light to severe. The programming of light turbulence to be always active when the aircraft is in simulated flight, no fixed point or position is ever experienced. This compound motion simulates the feeling of being supported in a fluid medium of constantly moving body of air or water.
[0028] Now turning to the drawings, FIG. 1 illustrates a video simulation system 50 including a motion platform 10 , a cockpit 30 coupled to the motion platform, and a plurality of video display panels 20 . In this embodiment, the video simulation system resembles a helicopter, but it should be noted that the motion platform provides simultaneous roll-axis and yaw-axis motion simulation capable of use with an alternative aircraft or marine vessel object environment.
[0029] FIG. 2 shows the motion platform 10 in accordance with the illustrated embodiment of FIG. 1 . The motion platform is shown with a front-side, rear-side, left-side and right-side as labeled.
[0030] FIG. 3 shows the motion platform 10 in an exploded view illustrating several key components thereof. The motion platform comprises a base 100 , a chassis 200 , a pivot 400 configured to couple with each of the base and the chassis, a linear actuator 500 , and a pair of linkages including a first linkage 300 a and a second linkage 300 b each being configured to couple with the base and the chassis.
[0031] In accordance with one embodiment, FIG. 4A shows a perspective view of the base 100 , while FIG. 4B shows a rear view of the base. As shown in FIGS. 4(A-B) , the base 100 comprises:
[0032] a first lateral support member 101 extending along a width W of the base from a left-side to a right-side;
[0033] a second lateral support member 102 extending along the width of the base, the second lateral support member being parallel with the first lateral support;
[0034] a pair of longitudinal support members 103 a ; 103 b extending along a length L of the base from a front-side to a rear-side, each of the longitudinal support members being coupled with the first lateral support member at the front-side and further coupled with the second lateral support member at the rear-side;
[0035] a first vertical post 104 extending vertically from a center of the base at the front-side thereof, and
[0036] a second vertical post 105 extending vertically from the base at the rear-side.
[0037] In certain embodiments, the base can be reinforced for additional support with a front support plate 106 being attached to the first lateral support member and the first vertical post. Similarly, a rear support plate 107 can be attached to the second lateral support member and the second vertical post. Various sizes and designs of the plate can be implemented to provide additional support for carrying a load above the vertical posts and respective lateral and longitudinal support members of the base.
[0038] In various alternative embodiments envisioned by those with skill in the art (not shown), the base may comprise a v-shaped leg assembly having a center, a first leg extending outwardly from the center, and a second leg extending outwardly from the center, the first and second legs forming an angle therebetween. The v-shaped leg assembly can be substituted for one or both of the lateral support members. Thus, the design of the lateral support members and longitudinal support members can be readily altered in various configurations that may depart from the illustrated preferred embodiment.
[0039] The first vertical post 104 further comprises a means for attaching the chassis and an associated bushing, such as a pivot busing. As shown, the first vertical post comprises a pivot plate 108 disposed at a top end of the first vertical post and configured with a pair of pivot plate apertures 109 for attaching a pivot to the base.
[0040] The second lateral support member 102 further comprises a pair of bottom linkage nodes, including a first bottom linkage node 110 a and a second bottom linkage node 110 b . Each of the first and second bottom linkage nodes may comprise a through-hole for receiving a bolt or other attachment device for attaching a bottom end of a respective linkage, or any other means for attaching a linkage.
[0041] The second vertical post 105 further comprises an actuator node 111 . The actuator node may comprise a through-hole for receiving a bolt or other attachment device for attaching a linear actuator, or any other means for attaching an actuator.
[0042] In the illustrated embodiment, metal tubing such as steel tubing is used to fabricate each of the first and second lateral support members, the longitudinal support members and the vertical posts. The hollow tubing is commercially available and suitable for fabrication of the base. However, any composite material, hollow tubing or otherwise, or an alternative metal, wood, or other material may be used to fabricate the base components.
[0043] Other configurable implementations may include positioning the bottom linkage node 110 a and second bottom linkage node 110 b at a first distance therebetween, and further positioning the first upper linkage node 202 a and second upper linkage node 202 b at a second distance therebetween, such that the linkages being coupled therewith can be angled to simulate a particular roll-axis and yaw-axis motion. Thus, in one embodiment, the second distance is greater than the first distance such that as the motion platform yaws out the corresponding roll motion is downward clockwise to the right and counter clockwise to the left.
[0044] FIG. 5 illustrates a pivot according to an embodiment. The pivot 400 comprises a pivot base 401 , and a pivot bushing 402 attached to the pivot base. The pivot base 401 is shown with pivot base apertures 403 , a bolt or other attachment means (not shown) extends through the pivot base apertures 403 and the pivot plate apertures 109 for attaching the pivot to the base 100 . The pivot base is generally fabricated from a metal plate, whereas the pivot bushing is generally a molded plastic or similar soft volume for facilitating a rotational pivot motion between the chassis 200 and the base.
[0045] A pivot axis P′ extends vertically through the pivot. The motion platform is configured to provide simultaneous roll-axis and yaw-axis motion, the yaw axis motion produced about the pivot axis.
[0046] FIG. 6 shows a linkage in accordance with various embodiments. Each of the first and second linkages 300 a ; 300 b , respectively, are similar in form and function but may individual comprise a distinct length depending on the desired movement. The linkages generally comprise a linkage rod 301 extending from a bottom end to a top end of the linkage, a first eyelet 302 a disposed at the bottom end and a second eyelet 302 b disposed at the top end, a first spherical bearing 303 a housed within the first eyelet 302 a and a second spherical bearing 303 b housed within the second eyelet 303 b . Although spherical bearings and eyelets are shown, a simple rod with apertures disposed at each end of the rod may be used. Several embodiments are possible; however the preferred embodiment is as shows since such linkages are commercial available.
[0047] FIG. 7 shows a linear actuator in accordance with an embodiment. Several linear actuators are commercially available and may be implemented with little design experimentation. However, for purposes of illustration the linear actuator 500 may generally comprise an actuator mechanism 501 (hydraulic, electric or other) an actuator body 502 , an actuator shaft 503 extending from the actuator body and configured to translate therethrough, and an actuator bearing 504 at a distal end of the linear actuator (such as a spherical bearing or other bearing). Note a translational axis T′ shown extending through the actuator shaft, the linear actuator is configured to translate the shaft about the bod along the translational axis T′.
[0048] The linear actuator may further comprise an actuator linkage 505 . The actuator may be coupled to the actuator node 111 of the base at the actuator linkage 505 , and further coupled to the chassis at a side thereof, or more preferably, at a rear corner thereof.
[0049] FIGS. 8(A-C) illustrate the chassis in accordance with an embodiment. FIG. 8A shows a perspective view, FIG. 8B shows a rear view, and FIG. 8C shows a top view of the chassis. The chassis generally includes a rigid frame structure 205 ; here the chassis resembles a skid of a helicopter however another structure can be similarly incorporated. The chassis comprises: the rigid frame structure 205 having a pivot node 201 centered between the left and right sides of the chassis at a front end, a first upper linkage node 202 a and a second upper linkage node 202 b disposed along a rear side of the chassis.
[0050] FIG. 9A shows yaw-motion of the motion platform, with the platform being yawed with respect to the base. The yaw-motion is achieved by a single linear actuator, which is configured to translate along the translational axis. Here, the linear actuator is contracted as indicated by dashed-arrow 550 . Solid arrows indicate direction and magnitude of the yaw movement. FIG. 9B shows roll motion of the platform. The roll-motion is also achieved by the single linear actuator. The linear actuator is contracted as indicated by dashed-arrow 550 . Solid arrows indicate direction and magnitude of the roll movement.
[0051] As the linear actuator expands/contracts, the chassis moves about the pivot and the first and second linkages to produce a combined yaw and roll movement. The yaw motion is derived in a horizontal plane about the pivot, and has yaw motion components associated with each of the linkages. Note that as each linkage approaches a horizontal orientation, the yaw component is minimized and a roll component is maximized. Moreover, as each linkage approaches a vertical orientation, the roll component is minimized and the yaw component is maximized. Thus, as the chassis moves about the base, roll is intensified as a function of the yaw movement. In this regard, the chassis is configured for simultaneous and constantly varying yaw and roll motion about the base.
[0052] It is important to note that the motion platform achieves a combined yaw and roll movement that accurately simulates the movement of helicopters, among other applications, and provides such simulation using a single linear actuator, thereby reducing costs and maintenance associated with the motion platform.
[0053] The relation of yaw and roll in the dynamics of the motion platform are configured by adjusting the fixed position and orientation of the linkages with respect to one another, the size of the linkages, the angles between each linkage and the chassis, the angles between each linkage and the base, the length of the chassis, and the fixed position, size and orientation of the linear actuator with the chassis disposed in a home position (centered and level above the base).
[0054] Now, although particular features and embodiments have been described in an effort to enable those with skill in the art to make and use the claimed invention, it should be understood that several variations, alterations or substitutions can be achieved to integrate the motion platform for use with a variety of motion simulation environments. Nothing in this description shall be construed as limiting the spirit and scope of the invention as set forth in the appended claims, below.
FEATURE LIST
[0000]
( 10 ) motion platform
( 20 ) display panel
( 30 ) cockpit
( 50 ) video simulation system
( 100 ) base
( 101 ) first lateral support member
( 102 ) second lateral support member
( 103 ) longitudinal support members
( 104 ) first vertical post
( 105 ) second vertical post
( 106 ) front support plate
( 107 ) rear support plate
( 108 ) pivot plate
( 109 ) pivot plate apertures
( 110 a ) first bottom linkage node
( 110 b ) second bottom linkage node
( 111 ) actuator node
( 200 ) chassis
( 201 ) pivot node
( 202 a ) first upper linkage node
( 202 b ) second upper linkage node
( 205 ) rigid frame structure
( 300 a ) first linkage
( 300 b ) second linkage
( 301 ) linkage rod
( 302 a ; 302 b ) eyelets
( 303 a ; 303 b ) spherical bearings
( 400 ) pivot
( 401 ) pivot base
( 402 ) pivot bushing
( 403 ) pivot base apertures
( 500 ) linear actuator
( 501 ) actuator mechanism
( 502 ) actuator body
( 503 ) actuator shaft
( 504 ) actuator bearing
( 505 ) actuator linkage
( 550 ) contracted actuator
(L) length
(P′) vertical pivot axis
(T′) translational axis
(W) width | A motion platform for use with a video simulation system is described. The platform is configured to provide simultaneous roll-axis and yaw-axis motion about a pivot point for simulating a aircraft environment. Additionally, the motion platform is configured to achieve motion using a single linear actuator, and thus is provided at a significantly reduced cost compared to conventional motion platforms. Other benefits of the motion platform include improved power efficiency, reduced weight for increased portability, and reduced maintenance due to only one linear actuator driving the system. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to a press, in particular a fine-blanking press for producing fine-blanked parts from a metal strip or preforming by means of a tool which is fastened to a top tool-mounting plate and a bottom tool-mounting plate, a ram being assigned in each case to one of the tool-mounting plates.
Such a press has been disclosed, for example, by DE 196 42 635 A1. There, the ram is connected with little play to the guide pillars and is moved by the latter from an open position into a closed position. In this case, considerable masses are to be moved; furthermore, tilting of the ram may occur, which reduces the service life of the press and tools.
The object of the present invention is to develop a press of the above-mentioned type in which press elements forming the rigidity and the guide of the ram are uncoupled and no transverse forces or moments act on the guide.
SUMMARY OF THE INVENTION
The foregoing object is achieved by a press wherein the ram is supported via at least one ram-drive piston unit against an element which is fixed to the machine and which is firmly connected via at least two guide pillars to an opposite element which is likewise fixed to the machine and on which the other tool-mounting plate is arranged, the ram being displaceable along the guide pillar.
In this press concept, the outer press frame absorbs the static and dynamic forces of the system, but performs no ram guidance task. This results in an extremely rigid system in which, even during extremely concentric and eccentric loading, transverse forces and moments from the press frame have no effect on the ram guidance, a factor which has an extremely positive effect on the ram guidance and the tool life.
Two synchronously working ram-drive piston units are preferably provided, by means of which the four movements “quick closing, feeling, blanking/forming, quick return” are carried out. This involves clamped, double-acting cylinders. Rapid-traverse cylinders as used in known presses are no longer necessary.
The ram guidance is preferably effected with two to four guide pillars in the corner regions of the press. The guide pillars primarily serve to guide the ram and absorb only tilting moments from the stress on the tools. In the limit regions of the press load, the guide pillars if need be perform a tie rod function. The actual press body is formed from a top and a bottom yoke and by machine frame plates, four machine frame plates being provided as a rule, these machine frame plates still having openings for stamping-strip feeding and discharge, tool-space operation and parts removal or installation openings. This results in a compact press in which control of the static and dynamic stresses is taken care of by the press body and the ram guide tasks are assigned to the guide pillars.
The ram guidance itself is effected via at least two spaced-apart guide bushes. In order to arrange them, the walls of the ram are preferably raised laterally, so that the actual working region of the tool lies between the two guide bushes. This achieves the effect that a neutral zone in terms of movement is produced in the working region of the tool, so that tilting of the ram has no adverse effects on the active elements of the tool.
Provided the press is a fine-blanking press, a V-ring cylinder unit is to be assigned to the one yoke. This V-ring cylinder unit normally sits in or at the top on the top yoke, the cylinder in turn being a double-acting cylinder with circulation.
The pressure force which acts on a corresponding piston is transmitted into the tool space via pressure pins and pressure plates which likewise sit in the yoke.
During the working travel, pressure fluid is displaced from the corresponding pressure space of the V-ring cylinder unit by means of the pressure pins and the pressure plate. This pressure fluid is transmitted to preferably four compensation pistons which are disposed on the bottom yoke and whose piston rods act on the underside of the ram. As a result, the ram drive force is assisted and the displacement work of the V-ring function is compensated for and need no longer be subtracted from the total force as in the known presses. Presses of this type of construction therefore have a useful press force about 30% higher at the same overall size. The displacement volume of the V-ring cylinder unit preferably corresponds to the volume of the compensation pistons.
Assigned to the ram itself is a counterholding-force cylinder unit, in which the cylinder is again a double-acting cylinder with circulation. The counterholding-force cylinder unit or its cylinder sits in or under the ram. Here, too, the force of the piston is transmitted into the tool space through the ram via pressure pins and pressure plates.
When the counterholding-force cylinder unit is working, the displaced pressure fluid, in a similar manner to the V-ring cylinder unit, is preferably directed to two to three compensation pistons which are preferably integrated in the cylinder of the counterholding-force cylinder unit and whose piston rods are supported against the bottom yoke. As a result, the displacement work of the counterholding-force function is compensated for and the ram drive force is assisted. Here, too, the displacement volume approximately corresponds to the volume of the compensation pistons. The displacement work of the counterholding-force function therefore no longer has to be subtracted from the total force of the press in this application either. Presses of this type of construction therefore have an overall useful press force about 40% higher than presses of known type of construction.
The V-ring cylinder unit and the counterholding-force cylinder unit, both as far as the force and thus the pressure are concerned and also with regard to the travel, can preferably be adjusted independently of one another.
This also ensures a controlled and/or regulated ram speed freely selectable at every operating point and thus ensures optimum quality of parts with at the same time optimum service life of the active elements of the tools.
Since the ram movements of the press according to the invention are only carried out by means of the ram-drive piston units, whereby the rapid-closing and rapid-return cylinders are dispensed with, any desired travel/time characteristic which corresponds to the capacity of the ram-drive piston units can be run over a stroke (ram cycle BDC-TDC-BDC). Since the “shakehands”, related to the control, between actuators and sensors of the ram drive and the rapid-traverse cylinder functions in the control are thereby dispensed with, the ram cycle time can be improved, which leads to higher production quantities and optimum tool life.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and details of the invention follow from the description below of preferred exemplary embodiments and with reference to the drawing which shows a cross section through a press according to the invention, an open position being shown in half section on the left side and a closed position being shown in half section on the right side.
DETAILED DESCRIPTION
The press P according to the invention has a flexurally rigid top yoke 1 and a flexurally rigid bottom yoke 2 . The top yoke 1 and bottom yoke 2 are firmly connected on the outside by machine frame plates 3 . 1 and 3 . 2 and form the press column.
Furthermore, the top yoke 1 and the bottom yoke 2 are connected to one another via guide pillars 4 . 1 and 4 . 2 , four guide pillars preferably being provided in the corner regions of the press. The connection to the guide pillars 4 . 1 and 4 . 2 may be fixed or mounted in an articulated manner as a tie rod.
A ram 5 is guided on the guide pillars 4 . 1 and 4 . 2 , this ram 5 having two spaced-apart guide bushes 6 . 1 and 6 . 2 per guide pillar. For this purpose, parts 7 of the ram 5 are also designed to be extended, so that a relatively large spacing of the guide bushes 6 . 1 and 6 . 2 is ensured.
The ram 5 is driven by a ram-drive piston unit 8 . Two ram-drive piston units 8 are preferably provided, which act as symmetrically as possible on the ram 5 . In the exemplary embodiment, however, only one ram-drive piston unit 8 is shown.
The ram-drive piston unit 8 is a double-acting preloaded cylinder 9 with circulation, a piston 10 separating two pressure spaces 11 and 12 from one another in said cylinder 9 . A piston rod 13 , which is connected to the ram 5 , leads out of the cylinder 9 .
Furthermore, a counterholding-force cylinder unit 20 is assigned to the ram 5 .
The counterholding-force cylinder unit 20 has a cylinder 21 which sits on an underside 22 of the ram 5 . In the cylinder 21 , a piston 23 again separates two pressure spaces 24 and 25 from one another, while a piston rod 26 leads out of the cylinder 21 from the piston 23 and is connected via pressure plates 27 to pressure pins 28 . 1 and 28 . 2 . These pressure pins 28 . 1 and 28 . 2 pass through the ram 5 and also through a tool-mounting plate 29 and engage in a bottom tool (not shown in any more detail), where they support a counterholder, as is known in the case of a fine-blanking tool.
Via a fluid connection (not shown in any more detail), the counterholding-force cylinder unit 20 is connected to a compensation piston 14 . Its piston 15 sits in the cylinder 21 and, here too, again separates two pressure spaces 17 and 18 from one another. Hose connections can be dispensed with due to the integration in the cylinder 21 .
Connected to the piston 15 is a push rod 19 which supports the cylinder 21 of the counterholding-force cylinder unit 20 and is supported against the bottom yoke 2 .
A V-ring cylinder unit 30 sits on the top yoke 1 . In the corresponding cylinder 31 , a piston 32 separates two working spaces 33 and 34 from one another.
A piston rod 35 leads from the piston 32 to a pressure plate 36 , which in turn is connected via pressure pins 37 . 1 , 37 . 2 and 37 . 3 , after passing through a tool-mounting plate 38 , to a V-ring plate of a tool (not shown in any more detail), as is likewise known from the prior art.
The V-ring cylinder unit 30 is fluidically connected to at least one further compensation piston 39 by fluid line 50 which sits on the bottom yoke 2 with a corresponding cylinder housing 40 . A piston 41 again separates two working spaces 42 and 43 , a piston rod 44 connected to the piston 41 leading out of the cylinder 40 and being connected to the underside 22 of the ram 5 .
The mode of operation of the present invention is as follows:
A tool, as shown, for example, in “Feinscheiden”, Handbuch für die Praxis, 2nd edition, 1977, pages 85 ff., essentially comprises a top tool part and a bottom tool part. The top tool part has a rear V-ring plate with a V-ring which encloses a fixed blanking punch. Assigned opposite the blanking punch in the bottom tool part is a flexible ejector (counterholder) which in turn is enclosed by a fixed die plate.
During a ram stroke (working cycle), in the course of which the top or the bottom tool part can be connected to the ram, the V-ring penetrates into the material of a punching strip and encloses the part to be cut out. After the penetration, the workpiece to be cut out is clamped in place between punch and ejector (counterholder). In this clamped state, the ram force now begins to cut out the workpiece, the V-ring plate at the same time being displaced back against the V-ring force, and the ejector being displaced against the counterholding force into the die by the material thickness of the workpiece. After the blanking operation has been carried out, during which the workpiece to be cut out is cut out of the punching strip and pushed into the die plate by the blanking punch, the V-ring force and the counterholding force are removed. The total force of the press in order to cut out the workpiece is therefore made up as follows:
F total =F blanking +F V-ring +F counterholder
Such a tool is preferably assembled outside the press on tool change plates 29 , 38 and pushed into the machine via cantilever beams. This is shown, for example, in WO97/35710. The cantilever beams are normally an integral part of the machine.
The tool change plates 29 , 38 are positioned via hydraulically actuated centering pins and clamped hydraulically via draw-in or swivel draw-in clamps. This operation can be started in a semiautomatic or fully automatic manner via the press control.
One possibility of fastening a tool to the two tool change plates 29 and 38 is shown, for example, in U.S Pat. No. 4,718, 339.
After the insertion of the tool pack and after the semiautomatic or fully automatic input of all tool- and workpiece-dependent process parameters, the semiautomatic or fully automatic punching operation can be started.
For a ram stroke nowadays, according to the prior art, as shown, for example, in “Feinschneiden”, Handbuch für die Praxis, 2nd edition, page 192, the V-ring cylinder and counterholder cylinder, in relation to the process, are set to the desired force by means of a pressure medium and are brought to a point just before material contact of the punching strip by means of quick-closing pistons of the ram. During this operation, a pressure medium is drawn or forced into the main working cylinder. After the inlet valve is closed, the pressure medium is compressed to the desired working pressure and thus the total force required is produced with the main working cylinder and the workpiece is cut out according to the sequence of operations described above.
In the press P according to the invention, the pressure spaces 11 , 12 ; 17 , 18 ; 24 , 25 ; 33 , 34 ; 42 , 43 are under a process-related working pressure at the start of a ram stroke. The closing movement of the ram 5 is now initiated in the sense that, for example, the valve is opened toward the pressure space 11 . Owing to the fact that pressure space 12 is still under the process-related working pressure, the closing movement starts immediately. By means of known physical laws, via the valve positions relative to the pressure spaces 11 and 12 , respectively, any desired travel/time diagram or velocity diagram can be run within the limits of the installed capacity. Therefore, according to the invention, for the required ram movement and the required ram force, the pressure medium is not brought to the required pressure, but rather the pressure space (e.g. 11 ) is specifically relieved and the pressure medium is circulated as useful pressure medium into the pressure space 12 .
According to the illustration, the ram 5 , guided on the guide pillars 4 . 1 , 4 . 2 , travels upward. For example, as soon as there is a punching strip between the bottom and the top tool, the V-ring is pressed into the material of the punching strip. In the course of the blanking operation now commencing, the V-ring plate runs back and displaces the pressure pins 37 . 1 to 37 . 3 and the pressure plate 36 upward. As a result, the piston 32 is likewise pushed upward, and the pressure medium is displaced in the pressure space 33 at constant pressure. The pressure medium is displaced from the pressure space 33 into the pressure space 42 of the compensation pistons 39 , so that the piston rod 44 is pressed against the underside 22 of the ram 5 and assists the ram drive force.
When the ejector or the counterholder gives way during the blanking operation, the pressure pins 28 . 1 and 28 . 2 and the pressure plate 27 are pressed downward by the workpiece thickness, as is the piston 23 of the counterholding-force cylinder unit 20 . As a result, pressure medium is displaced from the pressure space 25 at constant pressure into the pressure space 18 of the compensation pistons 14 , so that the push rod 19 presses against the bottom yoke 2 and likewise assists the ram drive force. In this case, the displacement volume of the V-ring cylinder unit and of the counterforce cylinder unit 20 in each case corresponds to the volume of the respective compensation pistons 14 and 39 .
As a result, the forces for the V-ring function and counterholder function are compensated for via the hydraulic pressure conversion. The press therefore only has to apply the blanking force and less percentage loss as total force.
F total =F blanking +F losses
A press P according to the invention can therefore fine-blank an analogous workpiece with about 40% of the capacity.
The machine is of course fitted with all possible automation components, such as, for example, inlet feed and outlet feed for a punching strip, lubricating device, parts-feeding device, parts-transfer device, scrap-removal device, etc.
The machine can be set up at floor level and requires no foundation pit. Due to the compensation pistons 14 and 39 according to the invention, the energy balance overall is optimal.
List of Item Numbers
1 Top yoke
2 Bottom yoke
3 Machine frame plate
4 Guide pillar
5 Ram
6 Guide bush
7 Part
8 Ram-drive piston unit
9 Cylinder
10 Piston
11 Pressure space
12 Pressure space
13 Piston rod
14 Compensation piston
15 Piston
16
17 Pressure space
18 Pressure space
19 Push rod
20 Counterforce cylinder unit
21 Cylinder
22 Underside
23 Piston
24 Pressure space
25 Pressure space
26 Piston rod
27 Pressure plate
28 Pressure pin
29 Tool-mounting plate
30 V-ring cylinder unit
31 Cylinder
32 Piston
33 Pressure space
34 Pressure space
35 Piston rod
36 Pressure space
37 Pressure pin
38 Tool-mounting plate
39 Compensation piston
40 Cylinder housing
41 Piston
42 Pressure space
43 Pressure space
44 Piston rod
P Press | A press, especially a precision cutting press, for producing precision cut parts from a metal strip or a preform by means of a tool, which is fixed to a top tool clamping plate and a bottom tool clamping plate, wherein a tappet is allocated to one of the tool clamping plates. The tappet is supported against an element fixed to the machine by means of at least one tappet drive piston unit, which is fixedly connected to an opposite element that is also fixed to the machine by means of at least two guide columns, the other tool clamping plate being disposed in said element, whereby the tappet can be displaced along the guide column. | 8 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application claims benefit under 35 USC 119(e) of U.S. provisional Application No. 61/446,704, filed on Feb. 25, 2011, entitled “PSEUDOMORPHIC WINDOW LAYER FOR MULTIJUNCTION SOLAR CELLS,” the content of which is incorporated herein by reference in its entirety.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] NOT APPLICABLE
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
[0003] NOT APPLICABLE
BACKGROUND OF THE INVENTION
[0004] 1. Field of Invention
[0005] The invention generally relates to photovoltaic solar cells and, more particularly, to high-efficiency multijunction photovoltaic solar cells based on III-V semiconductor compounds.
[0006] 2. Description of Related Art
[0007] Multijunction solar cells, based on III-V semiconductor compounds, have demonstrated high efficiencies for the generation of electricity from solar radiation. Such cells have reached 35.8% efficiency under the AMOG spectra (http://www.sharp-world.com/corporate/news/091022.html) and 43.5% (see M. A. Green et al., Progress in Photovoltaics: Research and Applications 19 (2011) 565-572) under concentrated sunlight equivalent to several hundred suns. Such efficiency and power achievements make it possible to apply this technology to the space and terrestrial energy markets. The solar cells with the highest efficiencies to date have employed three subcells having differing energy band gaps and arranged to permit each subcell to absorb a different part of the solar spectrum. Each subcell comprises a functional p-n junction and other layers, such as window and back surface field layers. These subcells are connected through tunnel junctions, with the layers either lattice matched to the underlying substrate or grown over metamorphic buffer layers.
[0008] Each subcell typically includes a window, emitter, base and back surface field (BSF) and may or may not include other layers. Those of skill in the art will also recognize that it is possible to construct subcells that do not contain all of the foregoing layers. The window and the BSF reflect minority carriers away from their interfaces with the emitter and base layers, respectively, and are well known to be critical to high efficiency carrier collection. The materials and doping levels used for windows are chosen such that the band alignment produces a large energy barrier for the minority carriers with a minimal barrier for majority carriers. This allows majority carriers to diffuse through the window, while minority carriers are reflected. It is critical that the interface between the window and the emitter be very high quality, to minimize the minority carrier surface recombination velocity. The window also typically has a higher band gap than the adjacent emitter in order to minimize its absorption of incident light.
[0009] For the top subcell, the window can be a major source of current loss. The window absorbs a fraction of the incident light in the solar spectrum that is above its band gap, and generates electron-hole pairs, or photocarriers. These photocarriers are not collected with high efficiency due to the high surface recombination velocity for minority carriers at the top of the window, and the low minority carrier diffusion lengths that are common in window materials. In subcells below the top subcell, the band gap of the window need not be as high as in the top subcell, because the top subcell will already have absorbed the higher energy photons. The window layer of lower subcells may be a source of loss if the upper subcell(s) do not absorb all light above the band gap of this window.
[0010] The intrinsic material lattice constant is defined as the lattice spacing a material would have as a free-standing crystal. When a semiconductor material has a substantially different intrinsic lattice constant than the substrate or the underlying layers on which is grown, the material will initially adopt the lattice constant of the underlying layers. The semiconductor material is strained, however, and the degree of strain is proportional to the difference in intrinsic material lattice constants between the material and the adjacent material on which it is grown.
[0011] As the thickness of such a semiconductor layer is increased, the accumulated strain increases until a critical thickness is reached, after which it becomes energetically favorable to relax and relieve strain through dislocation, i.e., departure of the atoms from their normal crystalline structures. The critical thickness depends upon many factors, including the materials involved, the substrate and/or underlying layers, growth technique and growth conditions. For a difference in intrinsic material lattice constants of about 1%, U.S. Pat. No. 4,935,384 to Wanlass et al. teaches that the critical thickness is around 15 nm. Below that critical thickness, Wanlass reports that the semiconductor layer is considered pseudomorphic, or fully strained, and the semiconductor layer holds the lattice constant of its substrate or underlying layer in the plane perpendicular to the growth direction. Typically, such a layer will have a different lattice constant in the direction of growth, with all lattice constants different from the material's intrinsic material lattice constant. The semiconductor layer is considered fully relaxed when sufficient dislocations have formed that the layer has been essentially restored to its intrinsic material lattice constants. In general, layers may be fully strained, fully relaxed, or partially strained and partially relaxed when grown on top of a substrate or layers with a substantially different lattice constant. This discussion has assumed that the materials have a cubic crystal structure in which the intrinsic material lattice constant is the same in all three crystal directions. An analogous discussion is appropriate for materials which are not cubic.
[0012] The prior art is primarily photovoltaic cells with window layers that have nominally the same intrinsic material lattice constants as the cell layers beneath them. For a given alloy system, choosing the lattice constant fixes the material composition and therefore its relevant properties such as its band-gap energy. For example, fully disordered Al x In 1−x P has substantially the same intrinsic material lattice constant as a GaAs substrate where x=0.52. This composition has an indirect band gap of 2.29 eV and a direct band gap of 2.37 eV at 300K. Strained, pseudomorphic window layers are mentioned by Wanlass et al. and King et al. (U.S. Pat. No. 7,119,271), but, as mentioned above, the teaching is that the critical thickness is 15 nm for a 1% difference in lattice constants. A thickness of 15 nm or less is too thin for practical use in many multijunction solar cells; hence, King et al. focus on window layers that are fully relaxed rather than pseudomorphic.
[0013] King et al. use a fully relaxed, high-band-gap window layer that incorporates dislocations to achieve relaxation in photovoltaic cells. While relaxation via dislocations have been claimed to improve interface quality and minimize defect transport, the greater body of work in the literature shows that dislocations are non-radiative recombination centers that degrade the quality of the material and reduce its current collection efficiency. In addition, defects at the interface of the emitter and window can increase the surface recombination velocity of the minority carriers and further degrade the solar cell efficiency. Thus, fully relaxed window layers are not ideal for high efficiency solar cells.
[0014] To improve the efficiency of high efficiency solar cells, it is desirable to maximize the band gap of the window layer of the top subcell, which typically reduces the light absorption in the window and increases the current of the solar cell, while avoiding dislocations that would be produced by relaxation.
SUMMARY
[0015] According to the invention, a photovoltaic solar cell with one or more subcells is provided, wherein at least one subcell has a wide-band-gap, pseudomorphic window layer of at least 15 nm in thickness and with an intrinsic material lattice constant that differs by at least 1% from an adjacent emitter layer. This window layer has a higher band gap than a window layer with substantially the same intrinsic material lattice constant as the adjacent emitter layer, which increases the light transmission through the window, thereby increasing the current generation in the solar cell. The quality of being a pseudomorphic material preserves a good interface between the window and the emitter, reducing the minority carrier surface recombination velocity, resulting in higher efficiency.
[0016] In a method according to the invention, a wide band gap, pseudomorphic (Al)In(Ga)P window layer of a photovoltaic cell is grown that has a lattice constant that differs by at least 1% from the adjacent emitter layer. The method utilizes growth temperatures of 300-550 degrees Celsius with growth rates of at least 0.1 microns per hour to deposit a layer of 15-60 nm of thickness that is fully strained. The elemental and molecular source material used to grow this layer has at least 99.9999% purity. Molecular beam epitaxy is a preferred technique for depositing the window layer, with a background pressure less than 10 −5 Torr. Relaxation, or the formation of dislocations to accommodate the change in lattice constant, is inhibited by the use of this growth method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows a schematic cross-section of an example of a single junction solar cell according to the invention.
[0018] FIG. 2A shows a schematic cross-section of a photovoltaic cell with three subcells, where each subcell comprises a window, emitter, base and back surface field connected by tunnel junctions.
[0019] FIG. 2B shows a schematic cross-section of one subcell of a multijunction solar cell, according to the invention.
[0020] FIG. 3 shows the measured external quantum efficiency (EQE), and internal quantum efficiency (IQE) of two GaInP solar cells with no anti-reflection coating (ARC).
[0021] FIG. 4 shows the measured reflectivity of two GaInP solar cell structures with no anti-reflection coating (ARC).
[0022] Table 1 shows the short-circuit current (J sc ) calculated using the external and internal quantum efficiency data for the two GaInP solar cells, and the difference in J sc between the two solar cells.
[0023] FIG. 5A shows the measured internal quantum efficiency (IQE) of the GaInP subcells of two multijunction solar cells.
[0024] Table 2 shows the short-circuit current (J sc ) calculated using the external and internal quantum efficiency data for the two GaInP subcells of multijunction solar cells, and the difference between in J sc between the two subcells.
[0025] FIG. 5B shows the measured external quantum efficiency (EQE) of the GaInP subcells of two multijunction solar cells.
[0026] FIG. 6 shows the measured reflectivity of the two multijunction solar cells.
[0027] FIG. 7 shows a triple axis x-ray diffraction scan of a triple junction solar cell with a fully strained AlInP window in the top subcell, according to the invention.
[0028] FIG. 8 shows a reciprocal space map along the asymmetric direction (224) of a triple junction solar cell on a GaAs substrate with one subcell having a fully-strained Al 0.73 1 n 0.27 P window according to the invention.
[0029] FIG. 9 shows a reciprocal space map along the symmetric direction (004) of a triple junction solar cell on a GaAs substrate with one subcell having a fully-strained Al 0.73 In 0.27 P window according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0030] According to the invention, a photovoltaic cell having one or more subcells is provided, wherein at least one of the subcells has a pseudomorphic window layer that has an intrinsic material lattice constant that differs by at least 1% from the adjacent emitter layer of the subcell. The window layer is on the order of between 15-60 nm in thickness. The window layer has a higher band gap than materials or compositions that have substantially the same intrinsic material lattice constant as the adjacent emitter layer. Having an intrinsic material lattice constant that differs by at least 1% from the adjacent emitter layer, rather than a smaller amount, maximizes the increase in band gap in the window layer. Higher band gaps are desirable because they produce a larger increase in solar cell efficiency, by reducing the fraction of the solar spectrum that can be absorbed by the window layer.
[0031] As an example, FIG. 1 shows a schematic cross-section of a photovoltaic cell with one subcell, also known as a single junction solar cell, according to the invention. Layers are not drawn to scale. The cell includes a thin window 12 (e.g., Al x In 1−x P), an emitter 13 (e.g., (Al)GaInP), a base 14 (e.g., GaInP) and back surface field 15 (e.g., AlGaInP), in addition to buffer layer(s) 16 , a substrate 17 and cap 11 and contact layers 10 . The back contact is not shown. The emitter, base and back surface field have substantially the same intrinsic material lattice constant as the substrate. The window layer has an intrinsic material lattice constant that differs from that of the adjacent emitter, as well as the substrate, by at least 1%. This means that subtracting the intrinsic material lattice constant of the window from that of the substrate and dividing this number by the intrinsic material lattice constant of the substrate yields an absolute value of at least 0.01 (or 1%). The window layer is fully strained with no relaxation via dislocations. In one embodiment, the window layer is Al x In 1−x P (x>0.65) of between 15 and 60 nm in thickness, and the substrate is GaAs or Ge. Al x In 1−x P with x>0.65 has a wider band gap than the composition of x=0.52 that has substantially the same intrinsic material lattice constant as the substrate, increasing the transmission of light to the emitter and base and increasing the photovoltaic cell efficiency. The current collection efficiencies in the emitter and base are higher than in the window layer, for reasons discussed above. Increasing the transmission of light to the emitter and base, and decreasing absorption in the window, will increase the solar cell's overall current collection and efficiency.
[0032] FIG. 2A shows a schematic cross-section of an exemplary photovoltaic cell consisting of three subcells (which may be identified as the top cell, middle cell and bottom cell, where the direction references proximity to the light source above), where each subcell consists of a window 23 , 28 , 33 , emitter 24 , 29 , 34 , base 25 , 30 , 35 , and back surface field (BSF) 26 , 31 , 36 layer. These subcells are connected by tunnel junctions 27 , 32 . The substrate 38 , buffer layer(s) 37 , cap 21 , top contact 20 and anti-reflection coating 22 (AR) are also shown. The back contact is not shown. FIG. 2B shows a schematic cross-section of a subcell of a photovoltaic cell corresponding to elements 23 , 24 , 25 and 26 , according to the invention. The pseudomorphic window layer has a thickness of at least 15 nm and an intrinsic material lattice constant that differs by at least 1% from that of the adjacent emitter layer. In a preferred embodiment of the invention, the window layer is comprised of Al x In 1−x P with x>0.65, where x=0.52 indicates the composition that has substantially the same intrinsic material lattice constant as the Ga 0.51 In 0.49 P emitter and base, and the GaAs or Ge substrate. Compared to x=0.52, the transmission of light to the emitter and base is increased with a window of Al x In 1−x P with x>0.65, which increases the photovoltaic cell efficiency.
[0033] In some embodiments, the subcell incorporating the invention will be the top subcell of a photovoltaic cell. In this case, the window may be directly adjacent to the anti-reflection coating, as illustrated by window 23 in FIG. 2A . In this case the window layer may also be considered part of the anti-reflection coating. For the example of an AlInP window, the Al x In 1−x P refractive index helps to reduce the difference between the low refractive indices of the anti-reflection coating layers and the rest of the semiconductor layers in the solar cell structure, which have high refractive indices.
[0034] The invention provides a method for producing a fully-strained Al x In 1−x−y Ga y P window layer in a photovoltaic cell, where the Al x In 1−x−y Ga y P material has a lattice constant that differs from the lattice constant of the adjacent emitter layer by at least 1%. For example, with a Ga 0.5 In 0.49 P emitter, an Al x In 1−x P window with x>0.65 has an intrinsic material lattice constant that differs from that of the emitter by at least 1%. According to the processing method, growth temperatures are between 300 and 550 degrees Celsius with a growth rate of at least 0.1 microns per hour. The source material for the window consists of elemental aluminum, elemental indium, elemental gallium and molecular phosphorus that are each of at least 99.9999% purity. The background pressure of the reactor is less than 10 −5 Torr. With these nonequilibrium growth conditions, dislocation formation is kinetically limited, so fully strained layers with thicknesses of 15-60 nm may be obtained. In a particular embodiment of the invention, molecular beam epitaxy is used to form the fully strained window layers.
[0035] FIG. 3 shows the measured external quantum efficiency (EQE), and internal quantum efficiency (IQE) of two photovoltaic cells with the structure shown in FIG. 1 . The cells have no anti-reflection coatings. The EQE is measured using calibrated detectors and it is verified with a standard reference solar cell. The Al x In 1−x P windows for these structures had thicknesses of approximately 35 nm and had x=0.52 and x=0.70, where Al 0.70 In 0.30 P is a fully strained layer according to the invention. The difference in intrinsic material lattice constant between the windows and the GaAs substrate is ˜0% (x=0.52) and 1.3% (x=0.70). The IQE is obtained from the EQE using the measured reflectivity shown in FIG. 4 for the two samples, respectively. The EQE response for the sample with x=0.70 is higher than for the sample with x=0.52 for the wavelength range 350 nm to ˜450 nm, because the transmission of light through the window is higher. This increase in the EQE translates to an increase in the cell current of 0.4 mA/cm 2 under the AM1.5D spectrum. However, the reflectivity for the sample with x=0.70 in the window is lower than the sample with x=0.70 (see FIG. 4 ). Thus, the improvement in current is lower when it is calculated using the IQE data (0.2 mA/cm 2 ) under the AM1.5D spectrum (Table 1).
[0036] FIG. 5A shows IQE and FIG. 5B shows the measured EQE for GaInP subcells of multijunction photovoltaic cells with anti-reflection coatings (ARC). The structure of the subcells is shown in FIG. 2B , and the GaInP and (Al)InGaP layers have substantially the same intrinsic material lattice constants as the GaAs substrate. The Al x In 1−x P windows for these structures had thicknesses of approximately 35 nm and had x=0.52 and x=0.70, where Al 0.70 In 0.30 P is a fully strained layer according to the invention. The difference in intrinsic material lattice constants between the windows and the adjacent emitter layers is ˜0% (x=0.52) and 1.3% (x=0.70). The IQE is obtained from the EQE with the measured reflectivity shown in FIG. 6 for the two samples, respectively. Again, there is an increase in the EQE and IQE for the short wavelength range, and a corresponding increase in the subcell current. The increase in subcell current is 0.5 mA/cm 2 under the AM1.5D spectrum, whether the current is determined from IQE or EQE (see Table 2). For a multijunction solar cell with three subcells, the bottom subcell often has higher current production than the upper and middle subcells, which may be current-matched. Thus, an increase in top subcell current may be split between the top and middle subcells by increasing the top subcell band gap or decreasing the top subcell thickness. Then the 0.5 mA/cm 2 gain in current according to this embodiment of the invention would increase the total multijunction cell current by 0.25 mA/cm 2 .
[0037] Reciprocal space maps and triple-axis rocking curves are well known high resolution, x-ray diffraction techniques for studying strain and relaxation in semiconductor epilayers. When a layer is pseudomorphically grown on a substrate that has a different intrinsic material lattice constant, the adoption of the layer's lattice to that of the substrate causes a tetragonal distortion in the film's unit cells. A Bragg reflection of the epitaxial film—substrate system will split into two reflection peaks, one due to the layer and one to the substrate. This is clearly seen in FIG. 7 , which shows a triple-axis x-ray diffraction scan of a multijunction solar cell with the top subcell having a fully strained AlInP window layer according to the invention. The Ga 0.51 In 0.49 P emitter that is adjacent to the AlInP window layer has substantially the same intrinsic material lattice constant as the GaAs substrate. The scan, taken in the (004) direction, shows the substrate peak at 0 arcsec and the Al 0.73 In 0.27 P layer peak near 4300 arcsec. The Al 0.73 In 0.27 P composition and thickness (42 nm) are determined for the fully strained layer from fitting the triple-axis x-ray diffraction scan using known lattice constants for GaAs and the AlInP alloy system. The difference in intrinsic material lattice constant between the AlInP film and the GaAs substrate is 1.5%.
[0038] In order to derive the degree of relaxation as well as the AlInP composition, more structural information is needed than is obtained from the measurement of a single triple-axis rocking curve. This is where a reciprocal space map is useful. Reciprocal space mapping is performed such that the Bragg reflection under investigation is fully mapped in a confined area in Q space. Reciprocal space maps may be obtained by joining together successive one-dimensional scans in Q space. A fully strained layer with a different intrinsic material lattice constant will have reciprocal lattice points along the vertical line that passes through the substrate. A fully relaxed layer will have reciprocal lattice points along a line connecting the substrate and the origin of the reciprocal space. For a fully relaxed epilayer on a substrate, the Qx for the epilayer will be different than that of the substrate.
[0039] FIGS. 8 and 9 show reciprocal space maps done along two orientations of the multijunction solar cell with the top subcell having a Al 0.73 In 0.27 P window with a thickness of 42 nm according to the invention, with an intrinsic material lattice constant that differs from the substrate and adjacent emitter by 1.5%. The maps show that the A 1 0.73 In 0.27 P window is pseudomorphic (i.e., fully strained). FIG. 8 shows the reciprocal space map along the (224) direction, which is the asymmetric scan. FIG. 9 is a representation along the (004) direction, which is the symmetric scan. For the space map along the (224) direction, the Q x for the substrate and the AlInP layer is the same, and the reciprocal lattice point of the AlInP layer lies along the vertical line normal to the surface. This means that the layer is fully strained and has the same in-plane lattice parameter as the substrate. In the case of symmetric scan, there is nonzero component of the scattering vector along the substrate normal. This means that the symmetric ⊖-2⊖ scan is along the y-axis in the reciprocal space while the rocking curve theta scan is along the x-axis in the reciprocal space. A ⊖-2⊖ originating from a set of planes which are not parallel to the substrate normal will be in the x-y plane. Thus, there is no indication of relaxation or tilt in the layer viewed with respect to the substrate.
[0040] The invention has been explained with reference to specific embodiments. Other embodiments will be evident to those of ordinary skill in the art. It is therefore not intended for the invention to be limited, except as indicated by the appended claims. | Photovoltaic cells with one or more subcells are provided with a wide band gap, pseudomorphic window layer of at least 15 nm in thickness and with an intrinsic material lattice constant that differs by at least 1% from an adjacent emitter layer. This window layer has a higher band gap than a window layer with substantially the same intrinsic material lattice constant as the adjacent emitter layer, which increases the light transmission through the window, thereby increasing the current generation in the solar cell. The quality of being pseudomorphic material preserves a good interface between the window and the emitter, reducing the minority carrier surface recombination velocity. A method is provided for building a wide band gap, pseudomorphic window layer of a photovoltaic cell that has an intrinsic material lattice constant that differs by at least 1% from the adjacent emitter layer. | 8 |
BACKGROUND OF THE INVENTION
Container refrigeration units are controlled by a microprocessor which receives inputs indicating the temperature, humidity, etc. in the conditioned space and controls the refrigeration system responsive to the inputs. Additionally, the microprocessor records the inputs such that the history of the load during the trip is recorded. Accordingly, it is possible to determine when and why a load is spoiled, thawed or the like. Perishable cargo such as fruit, vegetables and flowers produce, and are affected by, gases. Ethylene, for example, is produced in the ripening of bananas and its presence promotes ripening. It is therefore necessary to introduce some fresh air with the recirculating air, where perishable cargo is present, if spoilage or premature ripening of the load is to be avoided.
In a container, the load normally occupies all of the available space such that the flow paths for the conditioned air are located in the floor, ceiling and walls of the container and are often at least partially defined by the load. To minimize the wastage of conditioned space, only the expansion device, the evaporator, the evaporator fan, necessary ducting and sensors are located in the conditioned space. The rest of the refrigeration unit and its controls are located on the exterior of the container and are powered by an external power supply.
SUMMARY OF THE INVENTION
In the present invention a manually operated fresh air vent is provided to introduce some ambient/fresh air into the air circulating in the container and to exhaust some air from the container such as is done to provide some fresh air in commercial buildings. When the temperature setting is above freezing, or another temperature indicative of a perishable load, the condenser fan is run continuously independent of the operation of the refrigeration system when the fresh air vent is open. The fresh air vent position sensor of the present invention continuously senses the position of the fresh air vent in the refrigeration container unit. The microprocessor based controller of the refrigeration container unit automatically records the time and position of the fresh air vent as well as the evaporator fan speed. In a preferred embodiment, mechanically keyed tangs transfer mechanical movement of the fresh air door to a rotary electronic sensor such as a sealed Hall effect sensor. The rotary electronic sensor has a output voltage proportional to its mechanical position and its output voltage is used by the controller to determine the position of the fresh air vent door. Relative to the fresh air vent, the microprocessor stores the manual vent position change, the trip start vent position, the power on vent position and the midnight or other periodic logging of the vent position.
It is an object of this invention to monitor the opening, closing and position of a manually actuated vent.
It is another object of this invention to selectively provide a continuous supply of fresh air to a perishable cargo.
It is a further object of this invention to provide a sensor which cannot be improperly assembled as to its position and requires no mechanical calibration. These objects, and others as will become apparent hereinafter, are accomplished by the present invention.
Basically, a refrigeration container is provided with a manually operated fresh air vent with a position sensor which provides a signal to the microprocessor based controller indicative of the position of the fresh air vent. The fresh air vent controls both the providing of fresh air to the circulating air in the container and the exhausting of a portion of the circulating air. The evaporator fan is run continuously when the air vent is open to prevent the build up of gases produced by the perishable cargo.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the present invention, reference should now be made to the following detailed description thereof taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a simplified schematic diagram of a container and its refrigeration unit;
FIG. 2 is a simplified schematic representation of the fresh air vent structure;
FIG. 3 is a pictorial view of the assembled fresh air vent structure;
FIG. 4 is an exploded view of the fresh air vent structure of FIG. 3;
FIG. 5 is an enlarged view of a portion of the FIG. 4 structure partially assembled; and
FIG. 6 is an enlarged view of a portion of the FIG. 4 structure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, the numeral 10 generally designates a refrigeration unit which is mounted in a recess on a container 12 . Insulation 13 lines container 12 and separates the portions of refrigeration unit 10 which are located in container 12 from the portions located external to the conditioned area. Refrigeration unit 10 includes a fluid circuit serially including compressor 14 , discharge line 16 , condenser 18 , expansion device 20 , evaporator 22 and suction line 24 . Compressor 14 is driven by motor 15 under the control of microprocessor 100 responsive to inputs from sensors 102 which includes sensors for temperature, humidity, etc. The expansion device 20 , evaporator 22 , evaporator fan 22 - 1 and evaporator fan motor 22 - 2 are located within container 12 . Evaporator fan motor 22 - 2 operates under the control of microprocessor 100 and causes conditioned air from evaporator 22 to be distributed through container 12 and return air to be delivered back to evaporator 22 . Although evaporator fan motor 22 - 2 is controlled by microprocessor 100 , it is not powered by microprocessor 100 but, rather by a generator, or the like, as is conventional. To the extent that structure is illustrated in FIG. 1 and described it is generally conventional.
FIG. 2 is a more detailed depiction of a portion of the FIG. 1 system adding details of the fresh air vent structure which is collectively labeled 30 . As will be described in detail below, air vent structure 30 includes a pair of valves which control two restricted flow paths, 30 - 1 and 30 - 2 , between the interior of refrigeration unit 10 and the surrounding atmosphere. Restricted flow paths 30 - 1 and 30 - 2 are illustrated as open. As noted with respect to FIG. 1, evaporator fan motor 22 - 2 operates under the control of microprocessor 100 and causes conditioned air from evaporator 22 to be distributed through container 12 and to be delivered back to evaporator 22 . If the container 12 contains a perishable cargo that produces gas(es) the air circulating in the container will contain the gas(es).
While it is desirable to remove the gas(es) produced by the cargo to retard ripening etc., its exhausting represents a loss in that it is at a temperature typically less than ambient and within a very narrow temperature range in order to maximize the quality of the load. However, since a perishable load such as flowers or produce, typically, is kept at about 40° F. which is about mid-range for normally encountered ambient temperatures, the temperature difference between the load and ambient does not present a serious energy loss in the practice of the present invention. Fresh air vent structure 30 is manually adjusted to simultaneously open or close the two restricted flow paths 30 - 1 and 30 - 2 . The evaporator fan 22 - 1 is located in opening 22 - 3 a of fan deck 22 - 3 and when operating coacts therewith to separate chamber 22 - 4 from chamber 22 - 5 such that chamber 22 - 4 is at fan suction pressure and chamber 22 - 5 is at fan discharge pressure. Note that both chambers 22 - 4 and 22 - 5 are upstream of evaporator 22 . The first flow path 30 - 1 connects to the return air path just upstream of evaporator fan 22 - 1 and, when open, permits a selected portion of fresh air to enter chamber 22 - 4 . The supplying of a portion of atmospheric air through restricted flow path 30 - 1 is possible because the pressure in chamber 22 - 4 is less than ambient pressure. The second flow path 30 - 2 connects to the return air path just downstream of evaporator fan 22 - 1 and fan deck 22 - 3 and permits a selected portion of return air to be discharged into the atmosphere since chamber 22 - 5 is at fan discharge pressure which is above ambient. The degree of opening of the valves of fresh air vent structure 30 coacts with the speed of evaporator fan 22 - 1 to determine the amount of air being exhausted and supplied. Microprocessor 100 is connected to and controls evaporator fan motor 22 - 2 and is connected to the position sensor 50 of fresh air vent structure 30 and is therefore capable of recording the supplying of fresh air during a trip.
Referring specifically to FIGS. 3 and 4, fresh air vent structure 30 includes a cover 40 which is typically made of metal. A threaded shaft 41 is suitably secured to cover 40 and extends axially outwardly therefrom. A circular recess 40 - 1 is formed in cover 40 and two radially spaced openings or ports 40 - 2 and 40 - 3 are formed in recess 40 - 1 . A pin 42 is secured in recess 40 - 1 radially outward of port 40 - 3 . Foam insulation 44 has a central opening 44 - 1 and two ports 44 - 2 and 44 - 3 which correspond to ports 40 - 2 and 40 - 3 , respectively. Door, or disc, 46 has a central opening 46 - 1 for receiving threaded shaft 41 . Door, or disc, 46 has two ports 46 - 2 and 46 - 3 which correspond to ports 44 - 2 and 44 - 3 , respectively, of foam insulation 44 which is secured to door 46 such that ports 44 - 2 and 44 - 3 are in registration with ports 46 - 2 and 46 - 3 , respectively. Door 46 has a pair of arcuate slots 46 - 4 and 46 - 5 for receiving pin 42 . Taken together slots 46 - 4 and 46 - 5 extend over approximately 90° with slot 46 - 4 having a lesser arcuate extent than slot 46 - 5 .
With pin 42 in either slot 46 - 4 or slot 46 - 5 and threaded shaft 41 extending through openings 44 - 1 and 46 - 1 , foam 44 and door 46 are secured to cover 40 by nut 48 threaded on shaft 41 . Rotation of foam 44 and door 46 as a unit produces a valving action as ports 44 - 2 and 46 - 2 are moved into and out of registration with port 40 - 2 . A corresponding valving action takes place as ports 44 - 3 and 46 - 3 are moved into and out of registration with port 40 - 3 . Pin 42 coacting with either slot 46 - 4 or slot 46 - 5 limits the rotary movement of door 46 with respect to cover 40 . Slot 46 - 4 controls the movement of door or disc 46 between closed and partially open whereas slot 46 - 5 controls the movement of door 46 between partially open and fully open. Tub 60 is typically made of plastic and has a peripheral flange 60 - 1 to permit the attachment of cover 40 thereto as by bolts or other suitable fasteners 62 . Tub 60 has a recess 60 - 2 formed therein and two spaced, raised portions 60 - 3 and 60 - 4 , respectively, extending outwardly from the bottom of recess 60 - 2 . The outer portion of raised portions 60 - 3 and 60 - 4 define grilled openings 60 - 3 a and 60 - 4 a , respectively. When cover 40 is secured to tub 60 grilled openings 60 - 3 a and 60 - 4 a are in registration with ports 40 - 2 and 40 - 3 , respectively.
Referring specifically to FIGS. 4 and 6, Hall effect sensor 50 has a shaft 50 - 1 with a flat surface 50 - 1 a such that shaft 50 - 1 has a D-shape in section. Sensor 50 is suitably secured in rectangular box 54 by nut 51 and washer 52 . Box 54 has flanges 54 - 1 which are suitably secured to cover 40 as by rivets 55 . U-shaped member 56 has a base portion 56 - 1 with an opening 56 - 1 a therein having a flat portion 56 - 1 b corresponding to flat surface 50 - 1 a of shaft 50 - 1 . When shaft 50 - 1 is received in opening 56 - 1 a , U-shaped member 56 rotates with shaft 50 - 1 . Nut 58 secures U-shaped member 56 on shaft 50 - 1 . Arms 56 - 2 and 56 - 3 define tangs. Tangs 56 - 2 and 56 - 3 extend through arcuate slots 40 - 4 and 40 - 5 , respectively, in cover 40 so as to be freely movable with respect thereto, as best shown in FIG. 5 . Tangs 56 - 2 and 56 - 3 are received in openings 46 - 6 and 46 - 7 , respectively, of door 46 .
Shaft 50 - 1 of Hall effect sensor 50 has a rotational range of about 130° so that the 90° of the combined range of slots 46 - 4 and 46 - 5 is less than the rotational range of shaft 50 - 1 . In assembling air vent structure 30 , shaft portion 50 - 1 , threaded shaft portion 50 - 1 ′ and members 50 - 2 and 50 - 3 extend through bores 54 - 2 and 54 - 3 and a bore not illustrated such that sensor 50 is accurately located with respect to box 54 . Washer 52 is then placed on threaded shaft 50 - 1 ′ and nut 51 is threaded on shaft 50 - 1 ′ securing sensor 50 to box 54 . U-shaped member 56 is placed on shaft 50 - 1 with flat 50 - 1 a and flat portion 56 - 1 b coacting to angularly locate U-shaped member 56 with respect to shaft 50 - 1 . Nut 58 is then placed on shaft 50 - 1 to secure U-shaped member 56 thereon. Box 54 is riveted to cover 40 by rivets 55 as best shown in FIGS. 4 and 5. Hall effect sensor 50 has a plurality of leads 50 - 4 , 50 - 5 and 50 - 6 which are located on one side of sensor 50 . Grommet 64 is located in opening 60 - 5 of tub 60 . Electrical connection 70 is connected to leads 50 - 4 , 50 - 5 and 50 - 6 and passes through grommet 64 . The location of leads 50 - 4 , 50 - 5 and 50 - 6 on one side of sensor 50 , the location of opening 60 - 5 on one side of tub 60 and the limited rotation of shaft 50 - 1 ensure proper assembly.
Tangs 56 - 2 and 56 - 3 are inserted through arcuate slots 40 - 4 and 40 - 5 , respectively. Cover 40 is secured to tub 60 by bolts 62 . Foam insulation 44 is secured to door 46 such that ports 44 - 2 and 44 - 3 are in registration with ports 46 - 2 and 46 - 3 , respectively. Foam insulation 44 and door 46 are selectively and changeably located on cover 40 in accordance with the amount of fresh and exhaust air desired. If the desired range is from closed to partially open, foam insulation and door 46 are placed such that threaded shaft 41 extends through openings 44 - 1 and 46 - 1 , tangs 56 - 2 and 56 - 3 are inserted in openings 46 - 6 and 46 - 7 , respectively, and pin 42 is inserted through slot 46 - 4 . Nut 48 is then threaded onto threaded shaft 41 . If the desired range is from partially open to fully open, the only difference would be locating pin 42 in slot 46 - 5 . Because the mechanical assembly is relatively accurate, the only calibration required is electronic. Specifically, upon assembly in place the signal is measured and set at zero.
When fresh air vent structure 30 is assembled, box 54 containing Hall effect sensor will be located in the space between raised portions 60 - 3 and 60 - 4 , such that Hall effect sensor 30 is accurately located in fresh air vent structure 30 . With shaft 50 - 1 received in opening 56 - 1 a and tangs 56 - 2 and 56 - 3 received in openings 46 - 6 and 46 - 7 , respectively, shaft 50 , U-shaped member 56 and door 46 move as a unit. Hall effect sensor 50 is connected to the microprocessor 100 through connector 70 . Connector 70 is located in container 12 but extends therefrom to provide a signal to microprocessor 100 .
Preferably, when cover 40 is secured to tub 60 , the space is filled with foam for insulation. It is believed that illustrating the foam will only obscure details. When foam does fill the space, box 54 serves to isolate the Hall effect sensor 50 from the foam but box 54 is secured in place by the foam. Grommet 64 provides a leak tight seal to prevent foam from leaking from tub 60 .
In operation, refrigeration unit 10 will operate under the control of microprocessor 100 to maintain the conditions within a desired narrow range and to provide a history of conditions in container 12 , as is conventional. Superimposed upon the automatic control of refrigeration unit 10 provided by microprocessor 100 , a manual override is provided by fresh air vent structure 30 by exhausting a portion of the return air circulating in the container 12 and supplying fresh/ambient air as make up air. It should be noted that fresh air vent structure 30 would only be operated to provide fresh air when container 12 has a perishable cargo which produces gas(es). Fresh air vent structure 30 is opened by rotating door 46 and foam 44 which is secured thereto so that they rotate as a unit. Rotation of door 46 is limited by pin 42 which only permits movement of door 46 through the arcs defined by slots 46 - 4 and 46 - 5 . Rotation of door 46 and foam 44 in an opening direction from a closed position when pin 42 is received in slot 46 - 4 or when pin 42 is in slot 46 - 5 at apposition corresponding to the minimal opening will bring ports 46 - 2 and 44 - 2 into, or increase, registration with port 40 - 2 which is always in registration with grilled opening 60 - 3 a . The path serially defined by grilled opening 60 - 3 a , port 40 - 2 , port 44 - 2 and port 46 - 2 corresponds to the restricted path 30 - 1 illustrated in FIG. 2 between the return air and atmosphere. The position of door 46 will define the degree of registration of ports 44 - 2 and 46 - 2 with port 40 - 2 and grilled opening 60 - 3 a . Rotation of door 46 and foam 44 in an opening direction from a closed or minimally open position will also bring ports 46 - 3 and 44 - 3 into registration with port 40 - 3 which is always in registration with grilled opening 60 - 4 a . The registration between ports 46 - 2 and 40 - 2 will be the same as the registration between ports 46 - 3 and 40 - 3 . The path serially defined by port 46 - 3 , port 44 - 3 , port 40 - 3 and grilled opening 60 - 4 a corresponds to the restricted path 30 - 2 illustrated in FIG. 2 between ambient and the return air at fan discharge pressure for discharging a portion of the return air.
As door 46 is rotated to open or close fresh air vent structure 30 rotation of door 46 will be as a unit with U-shaped member 54 and shaft 50 - 1 of Hall effect sensor 50 . Rotation of shaft 50 - 1 of Hall effect sensor 50 produces an output voltage which is proportional to the mechanical position of shaft 50 - 1 and this information is used by microprocessor 100 to determine the position of door 46 . The position of door 46 determines the degree of opening and this information in combination with the speed of evaporator fan 22 - 1 permits the determining of the amount of fresh air being supplied as make up air.
From the foregoing it should be clear that the present invention permits the position of a fresh air vent to be sensed by an electronic position sensor and stored in a microprocessor 100 .
Although a preferred embodiment of the present invention has been illustrated and described, other changes will occur to those skilled in the art. It is therefore intended that the scope of the present invention is to be limited only by the scope of the appended claims. | A refrigeration container is provided with a manually operated fresh air vent with a position sensor which provides a signal to the microprocessor based controller indicative of the position of the fresh air vent. The fresh air vent controls both the providing of fresh air to the circulating air in the container and the exhausting a portion of the circulating air. The evaporator fan is run continuously when the air vent is open to prevent the build up of gases produced by the perishable cargo. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a variable damping force shock absorber for an automotive suspension system. More specifically, the invention relates to a variable damping shock absorber which can adjust damping characteristics for bounding stroke motion and damping characteristics for rebounding motion independent of each other.
2. Description of the Background Art
A of typical construction a variable damping force shock absorber has been disclosed in Japanese Patent First (unexamined) Publication (Tokkai) Showa 58-77943. The variable damping force shock absorber has a damping characteristics adjusting mechanism which adjusts damping characteristic of the shock absorber irrespective of the stroke direction. Such prior proposed variable damping force shock absorber is not yet complete for achieving satisfactorily level of riding comfort and vehicular driving stability.
Namely, as can be appreciated, the optimal damping characteristics of the bounding motion and rebounding motion is necessaily different from each other in most vibration modes. Therefore, in setting damping guidelines of common damping characteristics both for the bounding motion and the rebounding motion, difficulty arises to determined the optimal damping characteristics both for the bounding motion and rebounding motion, since the optimal damping characteristics for one of the bounding and rebounding motions cannot be the optimal damping characteristics for the other direction of motion. In other words, as long as the common damping characteristics for the bounding and the rebounding motion is to be set, the set damping characteristics can not be optimal for both the bounding and the rebounding motion.
SUMMARY OF THE INVENTION
In view of the drawback in the prior art, it is an object of the present invention to provide a variable damping force shock absorber which has a capability of independent adjustment of the damping characteristics of the bounding and rebounding motion to each other.
In order to accomplish the aforementioned and other objects, a variable damping force shock absorber, according to the present invention, has separate two bounding and rebounding fluid flow path, wherein the bounding fluid path is active for permitting fluid flow in the piston bounding stroke and the rebounding fluid path is active for permitting fluid flow in the piston rebounding stroke. A first flow restriction means is associated with the bounding fluid path for adjusting the fluid flow path area of the bounding fluid path, which first flow restriction means is variable to the magnitude of fluid flow restriction for adjusting the damping characteristics for the piston bounding stroke. A second flow restriction means is associated with the rebounding fluid flow path, which second flow restriction means is variable to the flow restriction magnitude for adjusting the damping characteristics for the piston rebounding stroke. The first and second flow restriction means are operable independently of each other.
According to one aspect of the invention, a variable damping force shock absorber comprises:
a hollow cylinder filled with a working fluid;
a piston disposed within the interior space of the cylinder for separating the interior space of the cylinder into first and second fluid chambers, the piston being connected to a piston rod for thrusting movement within the interior space in response to an input of vibration energy in the expansion and compression modes;
a first fluid path means for permitting fluid flow from the first fluid chamber to the second fluid chamber in response to a piston compression stroke;
a first variable orifice means disposed within the first fluid path for restricting fluid flow through the first fluid path means, the variable orifice means varying magnitude of the flow restriction;
a second fluid path means for permitting fluid flow from the second fluid chamber to the first fluid chamber in response to the piston expansion stroke;
a second variable orifice means disposed within the second fluid path for restricting fluid flow through the second fluid path means, the variable orifice means varying magnitude of the flow restriction;
a first control means, associated with the first variable orifice means, for operating the latter to adjust the flow restriction magnitude for the fluid flow therethrough; and
a second control means, associated with the second variable orifice means, for operating the latter to adjust the flow restriction magnitude for the fluid flow therethrough, the second control means being independent of the first control means for adjusting the flow restriction magnitude independently of the first control means.
At least one of the first and second variable orifice means may vary damping characteristics in a continuous fashion. The first and second control means are provided through the piston rod. The first and second control means comprise rotary shaft members coaxially arranged through the piston rod, which rotary shafts are driven by an externally applied driving force and converting means cooperating with the rotary shafts for converting rotation of the rotary shaft into a thrusting force for adjusting the path area of said first and second variable orifices.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given herebelow and from the accompanying drawings of the preferred embodiment of the invention, which, however, should not be taken to limit the invention to the specific embodiment but are for explanation and understanding only.
In the drawings:
FIG. 1 is a section of the first embodiment of a variable damping force shock absorber according to the present invention;
FIG. 2 is an enlarged section of the first embodiment of the variable damping force shock absorber of FIG. 1, showing the major part;
FIG. 3 is a chart showing the damping characteristics of the first embodiment of the shock absorber in various operational mode and vibration mode;
FIG. 4 is a section of the second embodiment of a variable damping force shock absorber according to the present invention;
FIG. 5 is an enlarged section of the second embodiment of the variable damping force shock absorber of FIG. 4, showing the major part;
FIG. 6 is a plan view of a piston employed in the second embodiment of the variable damping force shock absorber of FIG. 4;
FIG. 7 is an enlarged section showing detailed construction of a piston rod employed in the second embodiment of the variable damping force shock absorber of FIG. 4; and
FIG. 8 is a chart showing damping characteristics of the second embodiment of the shock absorber in various operational mode and vibration mode.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, particularly to FIGS. 1 and 2, the first embodiment of a variable damping force shock absorber, according to the present invention, has a hollow cylinder 1 defining an interior space filled with a working fluid. The interior space of the cylinder 1 is separated into upper and lower fluid chambers A and B by means of a piston assembly 2. As can be seen, in the shown embodiment, a free piston 4 is provided within the interior space of the cylinder 1 to define a gas chamber C beneath the lower fluid chamber B. The gas chamber C is filled with a pressurized gas for variation of the volume of the chamber C in terms of the pressure in the lower fluid chamber for establishing the force balance and thus serves as a pressure accumulator.
The open end of the cylinder 1 is closed by an upper plug assembly including an oil seal 1a, a rod guide 1b and a packing ground 1c. On the other hand, the bottom of the cylinder 1 is closed and is provided with a eye ring 1d to receive therethrough a wheel axle or spindle or the like.
The piston assembly 2 is mounted on the lower end of the piston rod 3. The piston assembly 2 includes a rebounding stopper 5, a washer 6, a first bounding side disc valve 7, a second bounding side disc valve 8, a piston body 2A, a second rebounding side disc valve 9, a first rebounding side disc valve 10, a washer 11, a first collar 12 and a second coller 13. The components of the piston assembly 2 are assembled in order on the lower end of the piston rod 3 and fixed in the assembled form by means of a fastening nut 14 which engages with the threaded lower end of the piston rod.
The piston body 2A is formed with a central opening 2a extending axially and adapted to receive the piston rod 3. The piston body 2A has an upper surface opposing the upper fluid chamber A. A pair of grooves 2b and 2c are formed on the upper surface. The pair of grooves 2b and 2c extend essentially in annular fashion in coaxial relationship to each other. Along the circumferential edge of the annular grooves 2b and 2c, essentially circular lands with valve seat surfaces 2d and 2e to mate with the second bounding side disc alve 8, so as to form inner and outer variable orifices. As can be seen, the diameter of the seat surface 2d corresponds to the outer diameter of the first bounding side disc valve 7. The inner annular groove 2b is communicated with the lower fluid chamber B via one or more bounding fluid path openings 2f which has lower end opening directly to the lower fluid chamber. The inner annular groove 2b is further communicated with the central opening 2a via a radial groove 2g and with the outer annular groove 2b via a radial groove 2h. One or more ports 3a are formed through the piston rod 3 for establishing fluid communication between the exterior and the interior space defined by the axial opening. Therefore, the central opening 2a of the piston body 2A is communicated with the interior space of the piston rod 3 via the ports 3a. The ports 3a are communicated with radial paths 18b formed through an outer rotary actuation rod 18 and an essentially annular groove 18c defined between the inner periphery of the outer rotary actuation rod 18 and an inner rotary actuation rod 19.
It should be appreciated that, the radial paths 18b include a plurality of sets of paths having mutually different diameters. One of the plurality of sets of paths are aligned with the radial path for adjusting flow restriction magnitude.
As result, the working fluid in the lower fluid chamber B may flow into the upper fluid chamber A via the bounding fluid path opening 2f, the inner groove 2b, the radial path 2g, the radial port 3a, the radial path 18b, the annular groove 18c, the radial port 3a, the radial groove 2h, during piston bounding stroke.
Similarly, essentially annular grooves 2j and 2k are arranged on the lower surface of the piston body 2A. Essentially annular lands with valve seat surfaces 2m and 2n extends along the respective peripheries of the inner and outer annular grooves 2j and 2k. The inner annular groove 2j is in fluid communication with the upper fluid chamber A via one or more rebounding fluid paths 2p which directly open to the upper fluid chamber.
The seat surfaces 2m and 2n mate with the second rebounding side disc valve 9. Similarly to the seat surface 2d, the seat surface 2m has a diameter corresponding to the outer diameter of the first rebounding side disc valve 7. In addition, a spring seat member 15, movable about the outer periphery of the first collar 12 and having an outer diameter corresponding to the diameter of the seat surface 2m, abuts against the first rebounding side disc valve 10 for transferring the spring force of a coil spring 16. The lower end of the coil spring 16 is seated on a spring seat member 17. The spring seat member 17 has a threaded bore engaging with a thread on the outer periphery of the second coller 13. With this construction, when the spring seat member 17 is driven to rotate, it causes axial displacement toward and away from the spring seat member 15 for causing variation of the spring force to be exerted on the first rebounding side disc valve 10.
The spring seat member 17 is formed with a cut-out 17a. The inner rotary rod 19 has an extension 19a extending from the lower end of the piston rod 3 and turned to engage with the cut-out 17a at the end thereof.
With the shown construction, when the piston strokes in a rebounding direction causing compression of the upper fluid chamber A, the pressurized fluid in the upper fluid chamber flows into the inner annular groove 2j via the rebounding fluid paths 2p. Therefore, fluid pressure is exerted on the second rebounding side disc valve 9 to cause deformation of the disc valves 9 and 10. Accordingly, the pressurized fluid in the inner annular groove 2j flows into the outer annular groove 2k via a gap formed between the seat surface 2m and the mating surface of the second rebounding side disc valve 9. Also, deformation of the second rebounding disc valve 9 permits fluid flow from the outer annular groove 2k to the lower fluid chamber B. During this fluid flow, the variation of the damping force generated by an inner variable orifice defined between the seat surface 2m and the associated portion of the second rebounding disc valve 9, is proportional to 2/3 power of the piston stroke speed. Similarly, the variation of the damping force generated by an outer variable orifice defined between the seat surface 2n and the associated portion of the second rebounding disc valve 9, is proportional to 2/3 power of the piston stroke speed. In addition, since the spring force exerted position of the second rebounding disc valve 9, associated with the seat surface 2m is greater than that exerted on the portion associated with the seat surface 2n, greater damping force can be generated by an inner variable orifice. That is to say, the inner variable orifice may provide harder damping characteristics than that of the outer variable orifice. In the shown embodiment, since the inner variable orifice with the harder damping characteristics and the outer variable orifice with the softer damping characteristics are arranged in series, lowering of the variation rate of the damping force at medium and high piston speed range can be compensated to provide essentially linear damping characteristics as shown in FIG. 3.
The damping characteristics in response to the piston rebounding motion can be adjusted by rotatingly driving the inner rotary rod 19. For driving the inner rotary rod 19, an operation dial or handle 19b is provided at the top of the rod. Rotation of the rotary rod 19 may cause rotation of the spring seat member 17 for adjusting the spring force to be exerted on the first rebounding disc valve 9. Namely, when the spring seat member 17 is oriented at the lowermost position to define the predetermined largest distance from the spring seat member 15, then the spring force to be exerted on the first rebounding disc valve 9 becomes minimal to initiate deformation of the first and second rebounding disc valves 9 and 10 at a lower pressure difference between the inner and outer annular grooves 2j and 2k and the lower fluid chamber B.
On the other hand, when the piston strokes in the bounding direction causing compression of the lower fluid chamber B, the pressurized fluid in the lower fluid chamber flows into the inner annular groove 2b via the bounding fluid paths 2f. Therefore, fluid pressure is exerted on the first bounding side disc valve 7 to cause deformation of the disc valves 9 and 10. Accordingly, the pressurized fluid in the inner annular groove 2b flows into the outer annular groove 2c via a variable orifice constituted of the radial path 18b. Then the pressurized fluid flows through a gap formed between the seat surface 2e and the mating surface of the second bounding side disc valve 8. Also, deformation of the second bounding disc valve 8 permits fluid flow from the outer annular groove 2c to the upper fluid chamber A. On the other hand, when the fluid pressure difference between the annular grooves and the upper fluid chamber becomes great enough to overcome the bias force of the bounding disc valves 7 and 8, the disc valves are deformed to form gaps between the associated seat surfaces 2d and 2e to permit the fluid flow therethrough.
During this fluid flow, the radial paths 18b serve as a fixed orifice which has variation characteristics of the damping force proportional to square of the piston stroke speed. On the other hand, the variation of the damping force generated by an inner variable orifice defined between the seat surfaces 2d and 2e and the associated portion of the second bounding disc valve 8, is proportional to 2/3 power of the piston stroke speed. In the combination of the damping characteristics of the fixed orifice and that of the variable orifice, essentially linear damping characteristics can be obtained as shown in FIG. 3.
The damping characteristics in response to the piston to bounding motion can be adjusted by rotatingly driving the outer rotary actuation rod 18. For driving the outer rotary actuation rod 18, an operation dial or handle 18d is provided at the top of the rod. Rotation of the rotary rod 18 may cause displacement of the radial paths 18b so that the different path areas of the radial paths 18b may be aligned with the port 3a.
As can be appreciated, the shown embodiment of the variable damping force shock absorber permits independent adjustment of damping characteristics for bounding and rebounding piston stroke.
FIGS. 3 to 5 show another embodiment of the variable damping force shock absorber according to the present invention. Similarly to the former embodiment, the shown embodiment of the variable damping force shock absorber has a hollow cylinder 101 defining an interior space filled with a working fluid. The interior space of the cylinder 101 is separated into upper and lower fluid chambers A and B by means of a piston assembly 102. As can be seen, in the shown embodiment, a free piston 120 is provided within the interior space of the cylinder 101 to define a gas chamber C beneath the lower fluid chamber B. The gas chamber C is filled with pressurized gas for variation of the volume in the chamber in terms of the pressure in the lower fluid chamber for establishing force balance and thus serves as a pressure accumulator. The open end of the cylinder 101 is closed by an upper plug assembly including an oil seal 101a, a rod guide 101b and a packing ground 101c. On the other hand, the bottom of the cylinder 101 is closed and is provided with a eye ring 101d to receive therethrough a wheel axle or spindle or the like.
A piston assembly 102 is mounted on the lower smaller diameter section 105a of a stud 105 which is, in turn, fitted onto the lower end of the piston rod 103. The piston assembly 102 includes a washer 106, a bounding side disc valve 108, a piston body 102A, a rebounding side disc valve 109, a washer 111 and a collar 112. The components of the piston assembly 102 are assembled in order on the lower end of the piston rod 103 and fixed in the assembled form by means of a fastening nut 113 which engages with the threaded lower end of the piston rod.
The piston body 102A is formed with a central opening 102a extending axially and adapted to receive the smaller diameter section 105a of the stud 105. The piston body 102A has an upper surface opposing to the upper fluid chamber A. A pair of grooves 102b and 102c are formed on the upper surface. The pair of grooves 102b and 102c extend essentially in annular fashion in coaxial relationship to each other. Along the circumferential edge of the annular grooves 102b and 102c, essentially circular lands with valve seat surfaces 102d and 102e to mate with the bounding side disc valve 108, so as to form inner and outer variable orifices. The inner annular groove 102b is communicated with the lower fluid chamber B via one or more bounding fluid path openings 102f which has lower end opening directly to the lower fluid chamber. The inner annular groove 102b is further communicated with the central opening 102a via a radial groove 102g and with the outer annular groove 102b via a radial groove 102h. One or more ports 105c are formed through the smaller diameter section 105a of the stud 105 at an axial orientation essentially corresponding to the radial groove 102g for establishing fluid communication between the exterior and the interior space defined by the axial opening. Therefore, the central opening 102a of the piston body 102A is communicated with the interior space of the smaller diameter section 105a of the stud 105 via the ports 105c. The ports 102a are communicated with the radial paths 114a defined between a rebounding side valve spool 114 and a bounding side valve spool 115. The lower end shoulder of the rebounding side valve spool 114 is cooperative with the upper end shoulder of the ports 105c for forming a variable path area throttling orifice variable of the path area corresponding to the axial position of the rebounding side valve spool 114. With the shown construction, a fluid path By1 is established.
As can be appreciated, the path area of the variable path area throttling orifice defined between the port 105c and the lower end shoulder of the rebounding side valve spool 114 can be varied continuously or at least in non-stepwise fashion.
As result, the working fluid in the lower fluid chamber B may flow into the upper fluid chamber A via the bounding fluid path opening 102f, the inner groove 102b, the radial path 102g, the radial port 105c, the radial path 114a, the radial port 115c, the radial path 102h, during piston bounding stroke.
Similarly, essentially annular grooves 102j and 102k are arranged on the lower surface of the piston body 102A. Essentially annular lands with valve seat surfaces 102m and 102n extends along the respective pheripheries of the inner and outer annular grooves 102j and 102k. The inner annular groove 102j is in fluid communication with the upper fluid chamber A via one or more rebounding fluid paths 102p which directly open to the upper fluid chamber.
The inner annular groove 102j is communicated with the outer annular groove 102k via a radial groove 102r. Also, the inner annular groove 102j is in fluid communication with the radial paths 102q. The radial paths 102q are in fluid communication with radial ports 105d. The radial ports 105d may communicated with an annular groove 115a defined on the outer periphery of the bounding side valve spool 115. Therefore, the fluid path By2 is established for permitting fluid flow from the upper fluid chamber A and the lower fluid chamber B.
Similarly to the rebounding side valve spool, the lower end edge of the annular groove 115a of the bounding side valve spool 115 forms a variable path area throttling path together with the upper edge of the radial port 105d (in FIG. 5, the throttling orifice is shown in a position fully blocking fluid communication). As can be appreciated, the path area of the throttling orifice defined between the annular groove 115a and the radial port 105d is variable depending upon the axial position of the bounding side valve spool 115.
The rebounding side valve spool 114 controls the axial position by a rebounding side valve control rod 116 coaxially arranged within the axial bore 103a of the piston rod 103. The rebounding side valve control rod 116 extends to the top end of the piston rod as shown in FIG. 7. On the other hand, the lower end of the rebounding side valve control rod 116 is connected to a rebounding side joint 117. The rebounding side joint 117 has a lower end mating with the top end of the rebounding side valve spool 114 for interengagement and for permitting the valve spool to shift in an axial direction. At this condition, the rebounding side joint 117 transmits the rotational torque on the rebounding side valve control rod 116 to the rebounding side valve spool 114. The rebounding side valve spool 114 has a threaded outer periphery meshing with the thread on the inner periphery of the bore 105e defined in the stud 105. Therefore, rotation of the rebounding side valve spool 114 as driven by the rebounding side valve control rod 116 causes axial shifting of the rebounding side valve spool 114 for causing variation of the path area in the throttling orifice between the valve spool 114 and the radial port 105c.
On the other hand, the axial position of the bounding side valve spool 115 is controlled by means of a bounding side valve control rod 118 coaxially arranged within the interior space of the rebounding side valve control rod 116. The bounding side valve control rod 118 also extends to the top end of the piston rod 103 for external connection with an external driving power source, such as an stepping motor. The lower end of the bounding side valve control rod 118 has a lower end connected to a bounding side joint 119. The bounding side joint 119 is formed into cylindrical construction to have the upper connected to the upper rod 118a of the bounding side valve control rod 118 and the lower end connected to the lower rod 118b of the control rod 118. The lower rod 118b is splined on the inner periphery of the bounding side joint 119 so as to be permitted axial movement relative to the upper rod but can be rotatingly driven together with the upper rod. Since the lower rod 118b is rigidly connected to the bounding side spool 115, rotational torque extered on the upper rod 118a is transmitted to the bounding side valve spool 115. The bounding side valve spool 115 has a threaded outer periphery meshing with the thread formed on the inner periphery of the smaller diameter section 105a of the stud 105. Therefore, by rotatingly driving the bounding side valve spool 115 via the bounding side valve control rod 118, the axial position of the bounding side valve spool relative to the radial port 105d can be adjusted to adjust the throttling rate at the throttling orifice between the annular groove 115a and the radial port 105d.
With the shown construction set forth above, the damping characteristics equivalent to that obtained in the former embodiment can be obtained as can be clear from FIG. 8 which shows damping characteristics at minimum and maximum throttling rate in the variation path area throttling orifices. In addition, since the shown embodiment may provide non-stepwise or continous variation of the throttling rate, optimal damping characteristics at respective bounding and rebounding modes of vibration can be obtained.
Therefore, the present invention fulfills all of the objects and advantages sought therefor.
While the present invention has been disclosed in terms of the preferred embodiment in order to facilitate better understanding of the invention, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments which can be embodied without departing from the principle of the invention set out in the appended claims. | A variable damping force shock absorber has a two separate bounding and rebounding fluid flow path, which the bounding fluid path is active for permitting fluid flow in a piston bounding stroke and the rebounding fluid path is active for permitting fluid flow in a piston rebounding stroke. A first flow restriction device is associated with the bounding fluid path for adjusting fluid flow path area of the bounding fluid path, which first flow restriction device is variable of magnitude of fluid flow restriction for adjusting damping characteristics for piston bounding stroke. A second flow restriction device is associated with the rebounding fluid flow path, which second flow restriction device is variable of flow restriction magnitude for adjusting damping characteristics for piston rebounding stroke. The first and second flow restriction devices are operable independently of each other. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority benefit under 35 U.S.C. Section 119(e) to U.S. Provisional Patent Ser. No. 61/184,930 filed on Jun. 8, 2009 the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to drilling lateral wells or sidetrack wells from a primary wellbore to enhance the efficiency and productivity of oil and gas wells.
BACKGROUND OF THE INVENTION
[0003] It is well known that hydrocarbons may be produced from subterranean formations through a well that has been drilled into a hydrocarbon bearing formation. In many circumstances, it is desirable to then drill one or more additional wellbores (often referred to as “laterals”) outward from the primary wellbore in an effort to increase the productivity of the well or to access additional hydrocarbons in adjacent formations. This can be an effective and economical way to substantially increase the profitability of a well and to increase the overall recovery of fluids from a single, primary well site and surface installation. These lateral wells may extend outwardly from the primary wellbore for substantial distances (e.g. 2000 feet or more) or may be relatively short “drainholes” which extend only a few feet (e.g. 100 feet or less) into the formation.
[0004] During the drilling of a well, it is often necessary, for various reasons, to alter, i.e., sidetrack, the direction of the wellbore. The challenge when drilling laterals is being able to drill precisely on target. Drill rigs are expensive and several extra days of rig time may substantially reduce the profitability of drilling additional laterals. Efficiently drilling laterals, which directly and precisely exit the primary wellbore at the desired location within the wellbore first, requires cutting an opening or a window through heavy casing or liner.
[0005] A conventional technique for drilling laterals may involve the setting of a kickoff plug, or the like, in a primary wellbore. A kickoff plug may have a length ranging from about 50 to 500 feet, and may comprise a cement composition. The kickoff plug typically is set in the wellbore by lowering a drillstring or open-ended tubing string to the desired depth and pumping a cement composition into the wellbore. The cement composition is allowed to cure to form a plug. After the cement plug has formed, a drillstring may be used to reinitiate drilling operations. The drillstring and drill bit use the plug to drill in a new direction, so as to thereby deflect the drill string and change the direction in which the drilling proceeds. However, the use of kickoff plugs may be problematic due to the prevention of access to further production of fluids from lower portions of the original wellbore because the cement seals the well at the deviation.
[0006] Another conventional method of forming a lateral wellbore uses a whipstock which is inserted into the main wellbore and fixed therein. The whipstock is typically a steel structure that includes a concave, slanted surface along its upper portion arranged to direct anything coming down the wellbore toward one side thereof. In particular, the whipstock forms a guide for gradually directing a cutting device from the main wellbore of the well into and through the wall of the existing wellbore where the new lateral wellbore will be formed or cut. Similar to the kick-off plug method, whipstocks are typically permanently installed. A conventional permanently installed whipstock prevents further access to lower formations below the installed whipstock. Furthermore, wells require some amount of workover to remain productive which is prevented to some degree by the installation of a permanent whipstock. Thus, a whipstock which allows access to further formations and/or production below the whipstock is preferred.
[0007] While most whipstocks are permanent, removable whipstocks have been developed, but have not been entirely satisfactory as the process of milling and drilling over the whipstock generally destroys or severely damages the whipstock. The process of removing a whipstock requires hooking the whipstock with a latching device that is accessible from above. The inherent topside location of the latching mechanism makes it vulnerable to the damage caused by the milling bit and it is not uncommon to have considerable delays in pulling out the temporary whipstock.
[0008] Furthermore, techniques for drilling windows through the side of a cased wellbore become particularly challenging when the production tubing is considerably smaller than the liner. With extra room in the liner, the milling drillbit tends to jump around on the whipstock and create extra damage to the whipstock and to other parts of the liner, slowing down progress and increasing the risk of problems, especially with respect to the recovery and removal of the whipstock. The issue of small production tubing in a large liner occurs, for example, when the window is well above the bottom of the original borehole and the production tubing is sized so to maintain liquid flow with the gaseous components. It is a significant advantage to use the gas in the production fluids to carry the valuable liquids to the surface and large diameter tubing is known to frustrate that benefit by allowing the gaseous components to bypass the liquids and leave them at the bottom of the tubing.
SUMMARY OF THE INVENTION
[0009] In one embodiment of the present invention, there is a process for drilling a sidetrack wellbore from a tailpipe through a liner pipe and into a desired formation, wherein the process comprises installing a permanent bypass whipstock assembly into a section of a length of the tailpipe as part of a production assembly wherein the permanent bypass whipstock assembly is an elongated, generally cylindrical body in close proximity to the liner with a primary path extending from a first end to a second end wherein the tailpipe is releasably connected to the first end and the second end of the primary path through the permanent bypass whipstock assembly and where the permanent bypass whipstock assembly further includes a deviating sidetrack path whereby the deviating sidetrack path diverges from the primary path at an incline for ultimately forming the sidetrack wherein the downhole end of the deviating sidetrack path is along a peripheral side of the permanent bypass whipstock assembly and the uphole end of the deviating sidetrack path is closer to the first end of the permanent bypass whipstock assembly whereby the uphole end of the deviating sidetrack path opens to the primary path of the permanent bypass whipstock assembly; installing the production assembly into a wellbore with the deviating sidetrack path of the permanent bypass whipstock assembly aligned in a predetermined direction with for forming the sidetrack well that may later be drilled; installing a diverter to close the primary path below the desired location of the sidetrack path wherein the diverter directs tools and other equipment from the primary path within the permanent bypass whipstock assembly to the sidetrack path of the permanent bypass whipstock assembly; installing a milling system, wherein the milling system includes a milling bit at the downhole end of a drill string whereby when the milling system reaches the diverter the path of the milling assembly is deflected onto the deviating sidetrack path whereby the milling system continues along the sidetrack path whereby the milling system forms a window in the liner; removing the milling system; installing a drill system, wherein the drilling system includes a drillbit located at the downhole end of a drill string whereby the drill system runs through the primary path through the permanent bypass whipstock assembly, being diverted onto the deviating sidetrack path by the diverter whereby the drill system reaches the window formed in the liner by the milling system; drilling a sidetrack wellbore with the drill system; removing the drill system; and installing a liner pipe casing into the sidetrack wellbore.
[0010] In another embodiment of the present invention, there is a permanent bypass whipstock assembly for forming a sidetrack wellbore, wherein the permanent bypass whipstock assembly comprises an elongated cylindrical body, wherein the elongated cylindrical body includes a first end connected to an uphole end of the tailpipe and a second end connected to a downhole end of the tailpipe, wherein the elongated cylindrical body includes: a primary path running through the elongated cylindrical body, wherein the primary path is slightly offset whereby the primary path is further defined by a thin-walled portion and a thick walled portion, a deviating sidetrack path for forming a sidetrack wellbore diverges from the primary path, wherein the deviating sidetrack path is below a stabilizing portion and above a deflector portion, wherein the deviating sidetrack path diverges at an incline whereby the uphole end of the deviating sidetrack path is closer to the first end of the permanent bypass whipstock assembly and opens to the primary path of the permanent bypass whipstock assembly whereby the downhole end of the deviating sidetrack path is along a peripheral side of the permanent bypass whipstock assembly, a thin-walled portion, wherein the thin-walled portion is elongated running entire downhole length of the permanent bypass whipstock assembly, whereby an interior surface defines the primary path and an exterior surface is in close proximity with the liner; and a thick-walled portion, wherein the thick-walled portion includes: a stabilizing portion, wherein the stabilizing portion is a wedge shaped inverted trough defined by the deviating sidetrack path, wherein an interior surface of the stabilizing portion defines the primary path and an exterior surface of the stabilizing portion is in close proximity with the liner, and a deflector portion, wherein the deflector portion is wedge shaped with an inclined surface defining the lower portion of the deviating sidetrack path, wherein an interior surface of the deflector further defines the primary path and an exterior surface of the deflector is in close proximity with the liner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention, together with further advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
[0012] FIG. 1 is a schematic diagram of a primary wellbore.
[0013] FIG. 2 is a cross-sectional portion of FIG. 1 .
[0014] FIG. 3 is detailed cross-sectional side view of a permanent bypass whipstock assembly inserted into a primary wellbore.
[0015] FIG. 4 is a cross-sectional view of the liner, tailpipe and permanent bypass whipstock assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not as a limitation of the invention. 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 scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations that come within the scope of the appended claims and their equivalents.
[0017] In the description which follows, like parts are marked throughout the specification and drawing with the same reference numerals, respectively. The drawing figures are not necessarily to scale and certain features are shown in schematic form or are exaggerated in scale in the interest of clarity and conciseness.
[0018] In a conventional drilling operation, a primary wellbore extends into an earth formation for the production of oil and gas. The primary wellbore includes a casing string which is inserted into the wellbore after the wellbore has been drilled. The casing string is generally installed in a wellbore when the well is drilled to target depth or when the sidewalls of the wellbore are in danger of collapsing. If the sidewalls of the wellbore collapse, the wellbore is cased and drilling continues with a smaller drillbit. Once the target is reached, a smaller diameter casing or liner is installed to prevent the sidewalls from collapsing. Typically, once the casing string is installed, cement is forced down the inside of the casing string and up the annulus to seal the casing to the wellbore and prevent fluids from transiting along the wellbore outside of the casing from one formation to another.
[0019] A liner is installed within the casing within the primary wellbore. Once a production zone has been reached, a production tubing string is installed within the liner to carry hydrocarbons to the surface where such hydrocarbons are recovered and transported to market. Near the downhole end of the production tubing string, a production packer assembly is installed to seal a production annular space between the liner and the production tubing string in order to prevent fluids from escaping into other parts of the wellbore or formations and to direct the produced fluids into production tubing. Additionally, the production packer assembly ensures the fluids do not flow by the tubing by liner annulus to lower portions of the wellbore.
[0020] Referring to FIG. 1 , at the downhole end of the production tubing string 15 a production packer assembly 24 is utilized to ensure fluids do not flow down liner 14 to lower portions of the wellbore. At the downhole end of the production tubing string 15 and below production packer assembly 24 is a tailpipe 26 .
[0021] As previously mentioned, it is sometimes desirable to drill a sidetrack well from within a wellbore. For clarity, it should be understood that conventional wells are drilled substantially vertically from the surface downward to or through the producing formation. However, wellbores may be drilled at a slanted or inclined orientation from the vertical axis. Likewise, deviation may produce a horizontal orientation. Sidetrack wells may extend in any direction from the original well and, in the case of a horizontal wellbore, may extend upward or downward.
[0022] Depicted in FIG. 1 , tailpipe 26 , located at the downhole end of a production tubing string 15 and running below production packer assembly 24 , is interrupted by the installation of a permanent bypass whipstock assembly 62 , which is utilized to assist in the efficient and economical formation of a sidetrack or lateral well. For demonstrative purposes only, and not by way of limitation, the present illustrated embodiments provide for the use of permanent bypass whipstock assembly 62 to form a sidetrack well which exits liner 14 to the right. Furthermore, for demonstrative purposes only the permanent bypass whipstock assembly is installed below the deepest production packer assembly, however, the permanent bypass whipstock assembly can be installed in the tailpipe below any production packer assembly.
[0023] In one embodiment, as shown in FIG. 2 which is a cross-section of FIG. 1 , permanent bypass whipstock assembly 62 generally has a cylindrical shape with a relatively straight primary path 64 slightly offset from liner axis 1 extending therethrough. Referring back to FIG. 1 , permanent bypass whipstock assembly 62 preferably includes a thick robust body constructed of a durable material, such as steel, around primary path 64 and potential sidetrack path 66 to resist forces and pressures, such as drill bits, rotating equipment and other downhole insults, likely imposed as equipment is inserted therethrough.
[0024] Permanent bypass whipstock assembly 62 is securely connected to tailpipe 26 at a desired location within the string such that a portion of tailpipe 26 is above permanent bypass whipstock assembly 62 and an additional length of tailpipe 26 extends below permanent bypass whipstock assembly 62 . Tailpipe 26 is assembled at the surface with permanent bypass whipstock assembly 62 installed in the desired location and the combined assembly is subsequently installed with the production assembly. In a preferred embodiment, permanent bypass whipstock assembly 62 replaces a section of tailpipe 26 by being screwed or otherwise secured in place. When installed, permanent bypass whipstock assembly 62 is completely open to the path of downhole production, thereby not interfering with the production from the wellbore below the installation of permanent bypass whipstock assembly 62 , as shown in FIG. 2 .
[0025] In an embodiment, permanent bypass whipstock assembly 62 includes several components, a thin-walled portion and a thick walled portion, as shown in FIG. 1 . In an embodiment of the present invention, thin-walled portion 102 is an elongated piece running the entire length of permanent bypass whipstock assembly 62 . The interior surface of thin-walled portion 102 defines primary path 64 , while the exterior surface is in close proximity with liner 14 .
[0026] In another embodiment of the present invention, thick-walled portion 104 is located along the peripheral surface opposite thin-walled portion 102 . Unlike thin-walled portion 102 , thick-walled portion 104 includes sidetrack path 66 , a whipstock portion 96 , and an optional stabilizing portion 94 . Sidetrack path 66 , located above whipstock portion 96 , provides an inclined path by a sidetrack well is ultimately formed. In an alternate embodiment of the present invention, sidetrack path 66 is located below optional stabilizing portion 94 and above whipstock portion 96 in an effort to provide a path for the formation of a sidetrack well. Sidetrack path 66 , as shown in FIGS. 1, 3 and 4 , appears to have an angle which is more substantial and dramatic than would perhaps be preferred. The exaggerated or more dramatic angle is drawn so that the angle may be more easily seen by the reader. In the preferred embodiment, the permanent bypass whipstock assembly is quite long and the sidetrack path is also relatively long compared to what is shown in FIG. 3 . The preferred angle is between 1.5 to 3 degrees.
[0027] Referring to FIG. 3 , whipstock portion 96 is a wedge shaped member with an inclined surface 95 defining the lower surface of sidetrack path 66 . The inclined surface of whipstock portion 96 follows the natural incline of sidetrack path 66 . The interior wall of whipstock portion 96 follows the natural slightly curved path of tailpipe 26 providing a guiding mechanism for the formation of sidetrack well 60 . Additionally, the interior wall of whipstock portion 96 defines primary path 64 of permanent bypass whipstock assembly 62 . The exterior wall of whipstock portion 96 is in close proximity to the wall of liner 14 .
[0028] In an alternate embodiment of the present invention, an optional stabilizing portion 94 , can be installed above sidetrack path 66 . Optional stabilizing portion 94 can have a wedge shape with an inverted trough defined by the upper surface sidetrack path 66 , which follows the natural incline of sidetrack 66 . The interior wall of stabilizing portion 94 defines primary path 64 , following the natural curvature of tailpipe 26 which tailpipe 26 would have followed had it not been interrupted by the insertion of stabilizing portion 94 . The exterior wall of stabilizing portion 94 is also in close proximity to the wall of liner 14 .
[0029] Referring to FIG. 3 , when it is desired to create sidetrack well 60 , a retrievable diverter 72 is inserted to block the primary path 64 of permanent bypass whipstock assembly 62 . Retrievable diverter 72 is designed to be installed by a simple wireline tool and recovered in a similar manner a latching mechanism, such as a keyhole 73 . Diverter 72 includes a sloped top surface which aligns with the desired location of the sidetrack via a sidetrack path 66 whereby tools inserted through tailpipe 26 are deflected onto sidetrack path 66 . Preferably, sidetrack path 66 is a gently sloped path with a circular cross section to provide stability for any tools or rotating equipment to be restrained while in sidetrack path 66 . It is important to recognize that retrievable diverter 73 and permanent bypass whipstock assembly 62 perform completely different functions in the present invention. For example, permanent bypass whipstock assembly 62 allows for complete downhole access when installed, while retrievable diverter 72 eliminates downhole access upon installation of the diverter.
[0030] After diverter 72 is inserted, a drill string is directed downhole with a milling bit suited for the slow process of milling through the steel liner 14 . Bit pressure should be concentrated on the whipstock surface recognizing that diverter 72 and the corresponding surface of sidetrack path 66 of permanent bypass whipstock assembly 62 will direct the milling drillbit against the location of liner 14 where a window is desired for sidetrack wellbore 60 . Once the milling bit has fully opened the window, the drillstring is withdrawn and re-installed with a conventional drillbit to drill sidetrack well 60 to its full depth. Again, diverter 72 and the corresponding surfaces of sidetrack path 66 of permanent bypass whipstock assembly 62 direct the conventional drillbit to and through the window to form sidetrack 60 . Likewise, bit pressure may be applied to the whipstock assembly. Any portion of the diverter that encounters drilling loads should be completely separate than the portion of the diverter containing the retrieval mechanism. In an embodiment, the diverter experience limited drilling loads. In another embodiment of the present invention, only the outer circumference of the diverter experience drilling forces.
[0031] Referring now to FIGS. 3 & 4 , when sidetrack well 60 is completely formed, the drillstring is withdrawn and a liner pipe 80 is installed into sidetrack 60 guided downhole by diverter 72 and the corresponding surfaces of sidetrack path 66 of permanent bypass whipstock assembly 62 .
[0032] Upon completion of formation of sidetrack well 60 , including insertion of liner pipe 80 and perforation, if necessary, all of the necessary tools and equipment are removed whereby diverter 72 is retrieved to more fully open up downhole path 64 for further work or production. It is important to recognize that several sidetrack (multilateral) wells can be formed in a single primary wellbore using this technique where several permanent bypass whipstock assemblies are installed at various points in the tailpipe string. Likewise, the sidetrack(s) and existing production can be produced selectively by including a packer and nipple below each permanent bypass whipstock assembly. In an embodiment of the present invention, the production from the sidetrack wellbore is selectively produced by including a packer above the permanent bypass whipstock assembly. In another embodiment, the packer is placed below the permanent bypass whipstock assembly. In yet another embodiment, a packer is placed above the permanent bypass whipstock assembly Furthermore, the production from the sidetrack well of the permanent bypass whipstock assembly may contain multiple exit points.
[0033] Permanent bypass whipstock assembly 62 is substantially larger in diameter than tailpipe 26 such that permanent bypass whipstock assembly 62 is in close proximity to liner 14 , thereby reducing the clearance between tailpipe 26 and liner 14 . As such, the permanent bypass whipstock assembly is essentially restricted from lateral movement inside liner 14 due to their relative diameters or sizes. The permanent bypass whipstock assembly reduces the clearance to no more than is necessary to run an additional permanent bypass whipstock assembly and/or packer assembly into the liner, thus eliminating the need for cement by placing the permanent bypass whipstock assembly in close proximity to the liner wall for a single string exit. Furthermore, by eliminating the need for cement, the original production below the tailpipe can be produced.
[0034] Finally, the scope of protection for this invention is not limited by the description set out above, but is only limited by the claims which follow. That scope of the invention is intended to include 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 part of the description and are a further description and are in addition to the preferred embodiments of the present invention. The discussion of any reference 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 present invention relates to drilling lateral wells or sidetrack wells from a primary wellbore to enhance the efficiency and productivity of oil and gas wells. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. application Ser. No. 10/360,040 filed Feb. 6, 2003, which is a continuation of U.S. application Ser. No. 10/072,433 filed on Feb. 8, 2002, which claims the benefit of priority of U.S. provisional application 60/267,912 filed Feb. 9, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates to methods of poultry production and more particularly to a method for enhancing poultry production.
BACKGROUND OF THE INVENTION
[0003] In various industries such as those involving agriculture, it is often necessary to circulate relatively large amounts of air through a building to help maintain the interior of the building within a desired temperature range, and to provide adequate ventilation. One such application where ventilation and control of the temperature within a building is extremely important is in connection with poultry houses. Such facilities are typically used to house chickens which are being grown for eventual slaughter or which are being used for egg production. Such facilities are also designed for manipulating the light that enters into the building. Light entering a poultry house may effect a chicken in two ways. Initially, the time frame by which a chicken becomes sexually mature is dependent upon the seasonal cycles the chicken experiences. Further, the psychological well being, and thus the physical development, of the chicken is effected by the quantity and concentration of light it is exposed to. Turkeys or other animals are also commonly kept in such houses, and may be equally as sensitive to light variation.
[0004] In a large scale poultry house, typically twenty thousand to twenty-five thousand chickens may be housed at a given time. If a poultry house is not properly ventilated, and the ambient temperature within it not properly controlled, the respiration of the chickens and the waste by-products within the poultry house can quickly give rise to a build up of ammonia and heat within the house which may be physiologically detrimental to the chickens. In extreme cases, such as where adequate ventilation and/or cooling is not provided on hot summer days, significant animal mortality may result. Even if mortality does not result, repeated lapses of proper ventilation and/or cooling can produce significant physiological stress on the chickens that results in inhibited growth, reduced egg production, and/or disease. Further, any concentrated areas of light shining into the poultry house will attract the chickens to that area, resulting in a crowd of chickens. This may be psychologically detrimental to the chickens which further inhibits their physical development. Any of the above conditions may result in significant financial losses to a poultry farmer.
[0005] In cases where the chickens are used for egg production, the sexual development of the chickens is a key aspect for production. Generally, chickens sexually mature during the onset of spring. In this way, nature provides for the eggs to be laid during appropriate climate conditions to ensure the survival of the offspring. Mass production of eggs, however, occurs throughout the year. As a result, poultry farmers seek to manipulate the maturity cycles of the chicken to enable the chickens to produce eggs year around. Manipulation of the maturity cycles is generally achieved through controlling the length of day the chickens experience. Through implementation of a light regulation program within the poultry house, the chicken's body can be manipulated into sensing the arrival of spring, regardless of the actual season. Thus, the chicken's body prepares to lay eggs in the upcoming weeks. This process holds significant financial advantages for poultry farmers.
[0006] In either of the above described cases, regulation of the amount of light entering the poultry house is a key element to ensure efficient poultry farming. Traditional poultry houses include a variety of features to ensure proper cooling, ventilation and the like. Such features create the opportunity for light to shine through small gaps where the features are mounted. Further, some features are themselves translucent, enabling a degree of light to pass therethrough and into the poultry house. The light that passes into the poultry house is detrimental to the efficient farming of poultry for the reasons discussed above.
[0007] It is therefore desirable in the industry to provide an improved method of poultry farming that eliminates the drawbacks resulting from light transmission into a poultry house.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a method for enhancing poultry production through the regulation of light the poultry is exposed to. The method of the present invention provides a poultry house for housing poultry therein. The poultry house further includes at least one exhaust fan for facilitating ventilation within the poultry house, wherein the exhaust fan includes light absorbing components for eliminating light transmitted into the poultry house. The method further provides a light regulation scheme for enhancing the growth characteristics of the poultry within the poultry house.
[0009] In a first preferred embodiment of the present invention, the sexual maturity of poultry is manipulated by providing a poultry house having at least one exhaust fan, wherein the poultry house is essentially impervious to light. To achieve this, the exhaust fan includes light absorbing components thereby prohibiting light to transmit through the material. A light regulating scheme is implemented for manipulating the day/night schedule that the chicken perceives. This regulating scheme includes a length of time where it is completely dark within the poultry house (i.e. night). The light absorbing components of the exhaust fan facilitate complete darkness within the poultry house. In this manner, the length of day the chicken perceives may be manipulated to stimulate egg production.
[0010] In a second preferred embodiment of the present invention, the psychological balance of the poultry is achieved by providing a poultry house having at least one exhaust fan, wherein the poultry house is designed to produce a dimming or “brown-out” effect during daylight hours. To achieve this, the exhaust fan includes light absorbent components thereby prohibiting light to transmit through the material. A light regulation scheme is implemented for regulating the intensity of light that the poultry experience throughout the day. Balanced, dimmed light effectively calms the poultry enabling their bodies to concentrate on proper development.
[0011] Accordingly, it is a general object of the present invention to provide a method for enhancing the production of poultry by regulating the light the poultry is exposed to during essential growth and developmental periods.
[0012] A further object of the present invention is to provide a method for manipulating the sexual maturity of poultry, year around, through implementation of a light regulating scheme. The quantity of eggs produced, and thus hatchlings born, by a group of poultry may be thereby enhanced providing significant financial gains for poultry farmers.
[0013] Yet another object of the present invention is to provide a method for psychologically balancing growing poultry through implementation of a light regulating scheme. Poultry that are not subject to psychological stress develop better, providing a better quantity and quality of meat. Again, significant financial gains may be realized by poultry farmers.
[0014] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limited the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0016] [0016]FIG. 1 is an elevational view of a structure in accordance with a preferred embodiment of the present invention forming a poultry house, with a roof thereon, shown in broken-away form to illustrate various components within the poultry house not visible from the exterior thereof;
[0017] [0017]
[0018] [0018]FIG. 2 is a perspective view of an apparatus for exhausting air from the poultry house of FIG. 1; and
[0019] [0019]FIG. 3 is an exploded perspective view of the apparatus for exhausting air, shown in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The following discussion of the preferred embodiments of the present invention is merely exemplary in nature. Accordingly, this discussion in no way is intended to limit the scope of the invention, the application of the invention or the use of the invention.
[0021] Referring to FIG. 1, an apparatus 10 is shown in accordance with a preferred embodiment of the present invention. The apparatus 10 described herein is the subject of commonly assigned U.S. Pat. No. 5,492,082, which is hereby incorporated by reference. The apparatus 10 is used for providing a facility 12 for housing animals within a well ventilated and temperature controlled environment. The facility 12 may be used to house a wide variety of animals such as chickens, turkeys, hogs or virtually any other animal requiring a relatively controlled temperature and light environment for adequate growth or production of food such as eggs. While the following description of the various preferred methods and apparatus of the present invention will be directed principally with reference to chickens, this is in no way intended to limit the application of the invention to such animals. Those skilled in the art will appreciate that the facility 12 described herein is readily adaptable with little or no modification for use with a wide variety of animals which may be sensitive to significant variations in ambient temperature.
[0022] With further reference to FIG. 1, the facility 12 includes a pair of opposing side walls 14 and 16 , a front wall 18 , a rear wall 20 , and a roof 22 shown in break-away form to illustrate the various components used therein to control ventilation, humidity, temperature and light within the confines of the facility 12 . The side walls 14 and 16 may vary greatly in length but, for a large scale poultry house, are typically approximately 400 ft. in length. The front wall 18 and rear wall 20 may also vary significantly in length but are typically approximately 40 ft. in length for a large scale poultry house. The front wall 18 typically includes a plurality of doors 24 for allowing access to the interior of the facility 12 . A side access door 26 is typically included in the side wall 16 preferably at about a mid-point of the length of the side wall 16 . Optionally included is a door 25 in the rear wall 20 .
[0023] The side wall 14 is typically about 8 ft.-10 ft. in height and includes a plurality of openings 28 , 30 , 32 and 34 over which motor-driven curtains are disposed. In the preferred embodiment illustrated in FIG. 1, opening 28 may be covered completely by a tunnel curtain 36 disposed thereover which is adapted to be raised (i.e., opened) by a suitable electrically driven motor (not shown). Openings 30 , 32 and 34 in the side wall 14 are each covered by a plurality of side wall curtains 38 , 40 and 42 respectively. Each of the side wall curtains 38 , 40 and 42 are capable of being controllably raised (i.e., opened) and lowered (i.e., closed) in conventional fashion by an electrically driven motor (not shown) associated therewith. It will be appreciated by those of ordinary skill in the art that the motors for each of the side wall curtains 38 , 40 and 42 may be electrically coupled such that the side wall curtains 38 , 40 and 42 will be raised and lowered simultaneously by an appropriate curtain controller (not shown). Such a controller is commercially available from the assignee of the present invention.
[0024] With further reference to FIG. 1, the side wall 16 also includes a plurality of openings 44 , 46 and 48 . The opening 44 has disposed thereover a second tunnel curtain 50 which, when fully lowered, completely covers the opening 44 . The opening 46 has disposed thereover a side wall curtain 52 while the opening 48 is covered by a side wall curtain 54 . It will be appreciated that each of the curtains 50 , 52 and 54 is motor-driven, each having its own motor adapted to controllably raise and lower it in response to drive signals from a suitable curtain controller such as that mentioned above. As with the side wall curtains 38 , 40 and 42 , the side wall curtains 52 and 54 may be driven simultaneously between completely lowered and completely raised positions provided their respective motors (not shown) are electrically coupled so as to be driven by an independent curtain controller. Similarly, the motors associated with each of the tunnel curtains 36 and 50 may be controlled by an independent curtain controller such as mentioned above to cause both of the tunnel curtains 36 and 50 to be raised and lowered together substantially simultaneously. It is also anticipated that the motors for the side wall curtains 38 , 40 , 42 , 52 and 54 may be controlled in various arrangements to cause substantially simultaneous opening and closing of various combinations of the side wall curtains.
[0025] With continued reference to FIG. 1, the side wall 14 includes a plurality of openings 56 , 58 , 60 and 62 within which are disposed side wall exhaust fans 64 , 66 , 68 and 70 , respectively. Each of the side wall exhaust fans 64 - 70 are further oriented so as to exhaust air out of the interior of the facility 12 .
[0026] Each of the side walls 14 and 16 include larger openings 72 and 74 positioned opposite each other. The opening 72 has mounted therein a plurality of exhaust fans 76 a - 76 d and the opening 74 has mounted therein a plurality of exhaust fans 78 a - 78 d . The exhaust fans 76 a - 76 d and 78 a - 78 d are oriented so as to draw air from inside the facility 12 and exhaust the air exteriorly with respect to the facility 12 . It will be appreciated that while a plurality of four exhaust fans have been shown as disposed in each of the side walls 14 and 16 , that one or more of the exhaust fans could optionally be disposed in suitable openings in the facility 12 as indicated in phantom in the drawing of FIG. 1. Alternatively, all of the exhaust fans 76 a - 76 d and 78 a - 78 d could be disposed in the front wall 18 . The important consideration is that all of the exhaust fans 76 a - 76 d and 78 a - 78 d are disposed at an opposite end of the facility 12 from the tunnel curtains 36 and 50 .
[0027] With reference to FIGS. 2 and 3, the exhaust fan construction will be described in detail. The exhaust fan described herein is generally that described in commonly assigned U.S. Pat. No. 5,567,200, which is hereby incorporated by reference, with modification. The exhaust fans each include a housing 100 that forms a flow path for air flowing through the exhaust fan. The housing 100 has a first end portion 102 that includes a generally rectangular flange 104 . The flange 104 is operable to be mounted on the interior of the corresponding wall 14 , 16 , 18 of the facility 12 , while the remainder of the housing 100 extends through the wall 14 , 16 , 18 to the exterior of the facility 12 . The housing 100 further includes a generally conically shaped central portion 108 which serves to channel the flow of air between the interior of the facility 12 and a second end portion 110 of the housing 100 . The second end portion 110 of the housing 100 includes an annular wall 112 which defines an opening 114 in the housing 100 and has a surface feature such as an annular groove 116 . As will be more fully described below, the annular groove 116 is used to receive and position a motor mount within the housing 100 .
[0028] The housing 100 may be made from any suitable material. Preferably, the housing 100 is fiberglass, however, it will be understood that any other suitable materials may be used including ABS, polyethylene, polypropylene, vinyls, nylons, metal and so forth. As will be discussed in further detail hereinbelow, the material selected should be of a type that holds its integrity after long term exposure to ultra-violet (UV) light. In addition, the thickness of the material forming the housing 100 may be relatively thin. In this regard, the thickness of the housing 100 may be approximately 0.125 inches when the diameter of the annular wall 112 is approximately 24 inches.
[0029] The housing 100 further includes a generally conically shaped cone 118 that mechanically communicates with the annular wall 112 of the housing 100 . The cone 118 serves as a static regain cone which is used to improve the efficiency of the exhaust fan. The cone 118 may be rotomolded from a polymeric material such as polyethylene, however, other suitable materials may be used including ABS, polypropylene, vinyls, nylons, metal and so forth may also be used. As will be discussed in further detail hereinbelow, the material selected should be of a type that holds its integrity after long term exposure to ultra-violet (UV) light. Furthermore, it will be appreciated that the cone 118 may be of different shapes. For example, the cone 118 may be a blow-out cone in which the cone covers the opening 114 of the housing 100 when no air is flowing through the housing 100 , and then swings open when air is driven through the housing 100 . In such a case, the mountings for such a blow-out cone can be integrally formed in the housing 100 . As will be appreciated by those skilled in the art, one purpose of such a blow-out cone is to prevent air from flowing into the facility 12 through the exhaust fan when the fan, which is described below, is not operating. In accordance with the preferred embodiment of the present invention, a significant purpose of the cone 118 is to limit the amount of direct and indirect sunlight that would otherwise be able to shine through the exhaust fan.
[0030] The exhaust fan further includes a fan 120 as well as a motor 122 that is operable to drive the fan 120 . The fan 120 includes a plurality of integrally formed blades 124 that are connected to the centrally located hub assembly 126 . The hub assembly 126 includes an aperture 128 that is operable to receive the shaft 130 of the motor 122 . Upon rotation of the shaft 130 of the motor 122 , the fan 120 rotates so as to cause the blades 124 to drive air through the housing 100 . Each of the blades 124 of the fan 124 includes an end portion 132 which is located in a spaced relationship with respect to the annular wall 112 of the housing 100 as will be more fully described below. In this regard, the end portions 132 of the blades 124 are within about 0.375 inches from the annular wall 112 . As an alternative it is anticipated that the fan 120 may a belt-driven fan of a type commonly known in the art.
[0031] To provide means for mounting the motor 122 to the housing 100 , the exhaust fan further comprises a motor mount 134 . The motor mount 134 is operable to substantially maintain the spaced relationship between the annular wall 112 of the housing 100 and the end portions 132 of the blades 124 of the fan 120 . This spaced relationship is maintained because movement of the annular wall 112 during operation of the fan 120 is restricted by the motor mount 134 . The motor mount 134 comprises a generally first circular member 136 and a plurality of radial support members 138 . The first circular member 136 is generally circular in cross-section and is operable to be disposed within the annular groove 116 of the housing 100 . The radial support members 138 are preferably secured at approximately 90° intervals around the periphery of the first circular member 136 by a suitable means such as by welding. It will be understood, however, that the radial support members 138 may be secured at any suitable location around the periphery of the first circular member 136 so as to provide support for the motor 122 . The radial support members 138 extend from the first circular member 136 radially inward and each terminate with circular mounting end portions 140 .
[0032] Disposed proximate to the circular mounting end portions 140 is a second circular member 142 . The second circular member 142 is secured to the radial support members 138 by suitable means such as by welding and serve to maintain a generally planar relationship between the radial support members 138 during operation of the exhaust fan. As those skilled in the art will appreciate, the second circular member 142 may be of any other suitable shape that is able to generally maintain a planar relationship between the radial support members 138 .
[0033] When the motor 122 and fan 120 have been attached to the motor mount 134 , the motor mount 134 is inserted into the housing 100 in such a manner that the first circular member 136 engages the annular groove 116 of the housing 100 . It will be appreciated, however, that the motor mount 134 can also be inserted first into the housing 100 and then the motor 122 attached to the motor mount 134 .
[0034] The assembly of the exhaust fans will now be described. The housing 100 is formed so as to define the generally annular wall 112 which is proximate to the end portions 132 of the blades 124 . In addition, the housing 100 is formed so that the housing 100 has an internal surface contour which defines a surface feature such as the annular groove 112 . It will be appreciated, however, that other types of surface features, such as a raised channel contour, may also be used.
[0035] The motor mount 134 is then formed by initially forming the substantially first circular member 136 and then forming the plurality of radial support members 138 . The radial support members 138 are then secured to the first circular member 136 by a suitable means such as by welding. The motor 132 is then secured to the motor mount 134 by means of bolts 144 that extend through the circular mounting end portions 140 of the radial support members 138 . The motor mount 134 is then inserted into the housing 100 so as to cause the motor mount 134 to engage the annular groove 112 . It will be appreciated, however, that the motor mount 134 may also be initially secured to the housing 100 , after which the motor 120 is secured to the motor mount 130 .
[0036] A light trap 146 is optionally provided for eliminating direct light that would otherwise shine through the opening 114 . The light trap 146 is of a type commonly available in the market and includes a plurality of contoured baffles 148 that allow airflow while prohibiting light to pass therethrough. The baffles are spaced apart from one another, thereby creating a plurality of gaps therebetween for enabling airflow. The contouring of the baffles 148 , as seen in the cut-away portion of the light trap 146 , bends the light as it travels through the gaps. The light is bent at least three times by the baffles 148 , thereby prohibiting the light to travel completely through the light trap 146 . The light trap further includes a frame piece 152 for mounting the light trap 146 directly to the housing 100 at the end portion 102 . A more detailed description of the baffle plate 146 is forgone as the details of which are beyond the scope of the present invention.
[0037] A further option is the addition of a shutter 160 for selectively prohibiting the flow of air through the exhaust fan. The shutter 160 includes a frame 162 , across which, a series of vanes 164 are pivotally supported. The shutter 160 is mounted to the exhaust fan, whereby the frame 162 is mounted to the housing 100 . Further, the shutter 160 is preferably made from a plastic, including a gray resin. During periods of non-operation of the exhaust fan, the vanes 164 are closed, hanging downward from their pivot points with the frame 162 due to gravitational pull. In this manner, airflow is prohibited into the facility 12 , through the exhaust fan. During periods of exhaust fan operation, a pressure difference occurs between the exhaust fan side (low pressure side) and the facility side (high pressure side) of the shutter 160 , thereby causing the vanes 164 to pivot upward to an open position. With the vanes 164 in the open position, air flow is enabled through the exhaust fan. It is further anticipated that the shutter 160 is concurrently implemented with the light trap 146 described above. In this situation, the shutter 160 is mounted to the housing 100 and the light trap 146 is mounted to the facility side of the shutter 160 .
[0038] Again referencing to FIG. 1, each of the side walls 14 and 16 further include a plurality of relatively thin, elongated openings 80 and 82 , respectively. Preferably, the openings 80 and 82 are spaced along substantially the entire length of the side walls 14 and 16 . The openings 80 and 82 are preferably relatively small in height, and more preferably about one-half inch in height. Optionally, the openings 80 and 82 may also include a slat or louver--like elements adapted to open in relation to the degree of static pressure drop within the facility 12 caused by the side wall exhaust fans 64 - 70 . In this case the height of the louver-like assemblies may be four to six inches.
[0039] With further reference to FIG. 1 and turning now to the interior of the facility 12 , several of the cooling and heating devices used to control temperature, humidity and ventilation therein can be seen. A plurality of fans 84 , commonly known in the industry as “stir” fans, may optionally be included to provide an additional level of minimum air movement within the facility 12 . The stir fans 84 preferably comprise 220 volt, one-half horsepower, 36″ diameter fans and are preferably suspended from a truss or other similar structure supporting the roof 22 so as to be positioned relatively close to a floor 86 of the facility 12 . More preferably, the fans are suspended so that the bottom of each is disposed generally between about 3 ft. to 5 ft. from the floor 86 . Also suspended from the structure supporting the roof 22 is a pair of optional heaters 88 and 90 . The heaters 88 and 90 are also suspended so as to place them preferably about two and one-half ft.--three ft. from the floor 86 . It will be appreciated that typically a plurality of heaters greater than two will be included in the facility 12 to sufficiently warm the interior of the facility at various times. A plurality of temperature sensors in the form of thermistors 92 a - 92 f are also suspended to preferably within about eighteen inches from the floor 86 . An optional pair of temperature sensors 93 a and 93 b in the form of thermistors may also be suspended or otherwise mounted exteriorly of the facility 12 , such as from a portion of the roof 22 or on one or more of the walls 14 - 20 .
[0040] Optionally, an evaporative cooling system such as that generally known in the industry as a “fogger” 94 may be suspended from the structure supporting the roof 22 . The optional fogger 94 shown in FIG. 1 includes 4 elongated, tubular water lines 96 (only one being shown), although it will be appreciated that a greater or lesser number of lines 96 could be used to suit the needs of specific applications. Each line 96 has a plurality of spaced apart nozzles 98 coupled in series in the line 96 . Water is supplied to each of the lines 96 via a suitable pump and suitable electrically controlled valving which is well known in the art. The nozzles 98 each emit a very fine mist which also helps to cool the interior of the facility 12 .
[0041] An electronic control system 99 is fixedly mounted on one of the walls 14 - 20 within the facility 12 . The controller system 99 controls operation of the tunnel curtains 36 , 50 , the side wall curtains 38 - 42 and 52 , 54 , the side wall exhaust fans 64 - 70 , the tunnel fans 76 a - 76 d and 78 a - 78 d , the optional stir fans 84 , the optional heaters 88 , 90 and the optional fogger system 94 . Additionally, the electronic control system 99 is electrically coupled to the indoor temperature sensors 92 , as well as the external temperature sensors 93 . This enables the controller system 99 to monitor the temperatures at various internal areas of the facility 12 as well as at one or more areas exterior of the facility 12 .
[0042] The preferred embodiment of the present invention provides a method for enhancing poultry production. According to the method of the present invention, a facility is provided, such as the facility 12 described hereinabove, for housing poultry. At least one exhaust fan, of the type described hereinabove, is further provided for enabling ventilation of the facility 12 . The amount of light entering the facility 12 is regulated according to a predetermined schedule during a growth period of the poultry housed therein. In accordance with the present invention, efficient light regulation is assisted through the exhaust fans of the present invention, as described in further detail hereinbelow. The light regulation results in enhanced characteristics of the poultry thus, providing more efficient poultry production.
[0043] In accordance with a first alternative embodiment, the present invention provides a method for raising chickens to sexual maturity for enhancing egg production. In accordance with a second alternative embodiment, the present invention provides a method for raising chickens for more efficient production of desired meat portions. Each of the preferred embodiments utilizes light regulation, as discussed above and described in further detail hereinbelow. In order to limit the amount of natural light that enters the facility 12 each potential opening of the facility 12 must be covered. Hence, the various curtains described herein function to close the corresponding openings. Further, any of the materials and components that comprise facility 12 must be made to be light absorbent, thereby prohibiting the transmission of natural light therethrough.
[0044] To achieve this, the exhaust fans of the present invention are manufactured to eliminate their transparency, thus prohibiting transmission of natural light therethrough. Accordingly, an inside surface 150 of the housing 100 of each exhaust fan is coated with a dark paint. The dark paint is preferably black in color, however, it is anticipated that other dark colors may be substituted therefore. Further, the dark paint is preferably gel-coat paint applied to the inside surface 150 in layers. Again, it is anticipated that other coating methods may be substituted therefore. Coating only a single side of the housing 100 provides cost savings, in both manufacture and material, over coating multiple sides of the housing 100 . The cone 118 is manufactured from a dark polyethylene material. The material is preferably black in color, however, it is anticipated that another dark color may be substituted therefore. In this manner, the dark paint of the housing 100 and the dark cone 118 absorb light, thereby prohibiting the transmission of natural light through the otherwise partially translucent exhaust fans. Further, the cone 118 limits the amount of direct sunlight that would otherwise be able to shine through the exhaust fan.
[0045] In accordance with the first alternative embodiment of the present invention, the method of raising chickens to sexual maturity generally focuses on poultry raised to produce eggs. The physiological and sexual development of a chicken is a natural process that is a function of the length of day a chicken experiences. The method of the present invention accelerates this process by manipulating the day and night schedule the chicken experiences. In general, chickens are raised over a 21-week period in a facility, such as the facility 12 . For the first two weeks, the chickens are given all of the natural light that normally shines into the facility 12 . In this manner, the chickens are able to acclimate themselves to life in the facility 12 , learning where food and water are available, where warmth is available and becoming accustomed to living sociably with the other chickens in the facility 12 . Beginning in the third week and extending over the next eighteen weeks, a lighting program ensues whereby the light the chicken is exposed to gradually becomes longer. Initially, the lighting program limits the length of the “day” the chicken experiences, simulating winter days. Gradually, these “days” become longer, simulating the approach of spring. The gradually longer “days” cause the chicken's natural clock to anticipate the approach of spring, thus preparing the chicken sexually for laying eggs in “spring” (i.e. what the chicken's body thinks is spring). However, during the spring and summer months, the natural days are already longer. Therefore, in order for the chickens to experience a gradual lengthening of the day, and thus initiate sexual development, light entering the facility 12 must be restricted for a portion of the longer spring and summer days. Further, the light restriction must be to the point of complete darkness within the facility 12 . To achieve this, each potential opening of the facility 12 must be light restricted, as discussed above. The dark components of the exhaust fans of the present invention, as well as the baffle plate 146 , enable complete darkness to be achieved and therefore enable implementation of the lighting program in accordance with the method of the present invention.
[0046] In accordance with the second alternative embodiment of the present invention, the method of the present invention generally focuses on poultry raised to produce meat or eggs. Poultry raised for meat production are commonly referred to as “broilers” while poultry raised for egg production are commonly referred to as “layers”. The psychological well being of the broiler plays an important role in the quality and quantity of meat the broiler produces. Similarly, the psychological well being of the layer plays an important role in the quantity of eggs the layer produces. In general, chickens that are uncomfortable or have other psychological difficulties with their environment do not eat, drink or thus grow, as well as desired, resulting in less efficient poultry production. A significant influence on the psychological well being of a chicken is the light the chicken is exposed to. For example, if an opening of the facility 12 is not properly light restricted and light shines into the facility 12 unabated, that light will be concentrated in a particular area. As a result, the chickens, which are attracted to the light, tend to congregate in a confined space, around the light. This crowd of chickens has a detrimental psychological effect on the chickens, thus inhibiting their physical development.
[0047] To alleviate the psychological stress a chicken may experience during its growth, the second preferred embodiment functions in a two-fold manner through the regulation of light into the facility 12 . Due to the dark components of the exhaust fans of the present invention, light that would pass through the otherwise translucent exhaust fans is prohibited from entering the facility 12 , thus avoiding light concentrations within the facility 12 . In this manner, crowding of chickens in a confined space is avoided. Additionally, the limited light into the facility 12 creates a “brown-out” effect, dimming the overall light the chickens are exposed to. This has the effect of calming the chickens, making them more comfortable in the facility 12 . In this manner, the psychological well being of the chickens is enhanced, further enhancing their physical development.
[0048] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | A method is provided for raising poultry, such as chickens, for food production. In a first preferred embodiment, the method includes the steps of: providing a facility for housing the poultry, providing at least one light-absorbing ventilation fan associated with the facility for ventilating the facility, exposing an interior of the facility to natural light cycles of an outside environment for a first period and regulating light cycles of the interior for a second period, thereby mimicking daylight duration variation representative of seasonal changes for stimulating sexual development of the poultry. In a second preferred embodiment, the method includes the steps of: providing a facility for housing the poultry, providing at least one light-absorbing ventilation fan associated with the facility for ventilating the facility, limiting exposure of an interior of the facility to light to produce a brown-out effect therein for enhancing physical development of the poultry. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/FR 2014/051349, filed on Jun. 5, 2014, which claims the benefit of FR13/55279, filed on Jun. 7, 2013. The disclosures of the above applications are incorporated herein by reference in their entirety.
FIELD
[0002] The present disclosure relates to a thrust reverser for an aircraft nacelle receiving a turbojet engine, as well as an aircraft nacelle equipped with such a thrust reverser.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] The motorization assemblies for aircrafts generally include a nacelle forming a globally circular external casing, comprising inside a turbojet engine disposed along the longitudinal axis of this nacelle.
[0005] The turbojet engine receives fresh air coming from the upstream or front side, and discharges from the downstream or rear side the hot gases coming from the fuel combustion, which provide a certain thrust. For the dual flow turbojet engines, fan blades disposed around this turbojet engine generate an important secondary flow of cold air along an annular stream passing between the engine and the nacelle, which adds a high thrust.
[0006] Some nacelles include a thrust reversal system which at least partly closes the annular stream of cold air, and discharges the secondary flow towards the front in order to generate a braking thrust of the aircraft.
[0007] A known type of thrust reverser, in particular presented by Document EP 0321993 A2, includes rear mobile cowls which can axially slide towards the rear as a result of actuators, by deploying shutters in the annular stream for closing this stream at least partially. These shutters send back the cold air flow radially towards the outside by passing via cascades uncovered during this sliding, comprising vanes which direct this flow towards the front.
[0008] When the thrust reverser is closed, the cascades are integrated within the thickness of the mobile cowls, the shutters being folded below these cascades, under their lower faces turned towards the axis of the nacelle.
[0009] Each cascade is secured by an articulation to the front frame being upstream of the mobile cowls. Telescopic cylinders disposed longitudinally in the annular stream, have their front ends secured to the inside of the front frame, and their rear ends secured to the inside of a shutter.
[0010] When the mobile cowls retreat the telescopic cylinders start by extending, and when arrived at the end of travel pull the shutters towards the inside of the nacelle so as to deploy them in the annular stream.
[0011] The issue posed with this type of thrust reverser, is that the cylinders remaining in the annular stream during the normal operation of the turbojet engine, inhibit the cold air flow and increase consumption.
[0012] Another type of known thrust reverser, presented in particular by U.S. Pat. No. 5,228,641, includes cascades secured to the front frame, which are integrated in the thickness of the mobile cowls when the thrust reverser is closed. The shutters disposed below the cascades, include a front end connected to the mobile cowl by an articulation, and a rear end connected by a coupling link starting from the rear, to a connecting arm which returns to the front so as to be secured on the front frame.
[0013] The retreating of the mobile cowls causes the coupling links and the shutters thereof to tip over and descend into the annular stream in order to close it. These types of thrust reversers comprising cascades as well as the shutters with their control systems, integrated in the mobile cowls when the thrust reverser is closed, pose encumbrance issues which require reducing the size of the cascades in order to be able to insert them in these cowls. However, the aerodynamic performance of these cascades is lacking.
SUMMARY
[0014] The present disclosure includes a thrust reverser of a turbojet engine nacelle, comprising mobile cowls which retreat with respect to a front frame while causing via cylinders the tipping of the shutters initially folded inside these cowls, so as to substantially close the annular stream of cold air, and the opening of cascades disposed around this stream which receive the cold air flow in order to send it towards the front, characterized in that the cascades are secured to the mobile cowls and slide therewith.
[0015] An advantage of this thrust reverser is that since the cascades are outside the mobile cowls, cowls can be easily produced comprising a reduced radial thickness, which receive in an integrated manner the shutters as well as their control mechanisms comprising the cylinders. Thereby, these control mechanisms with the cylinders do not surpass in the annular stream of cold air, this stream may include a good aerodynamic profile providing the performances of the propulsion system. In addition, the cascade disposing of a less limited space, may include a shape which is better suited for the deflection of the flow.
[0016] The thrust reverser according to the present disclosure may in addition include one or several of the following features, which may be combines together.
[0017] According to one form, the shutters include a front end connected by an articulation to a mobile cowl, and a cylinder comprising a front end secured to the frame, and the other end secured to the rear of this shutter.
[0018] Advantageously, the cylinder is at the boundary of the external surface of the annular stream, the shutter being connected to the mobile cowl by an articulation which is distant from this cylinder radially towards the outside. Thus, by this distance it is obtained when the shutter is folded, a thrust of the cylinder providing a torque force on this shutter which maintains it pressed on its end of travel stop.
[0019] Advantageously, the cylinder disposed in the longitudinal axis of the shutter, is integrated in a longitudinal hollow of the face of the shutter turned radially towards the inside of the nacelle, thus inhibiting this cylinder surpassing in the annular stream.
[0020] Advantageously, the cylinder includes below a closing plate secured flat along the length, which is adjusted on the face of the shutter when it is folded so as to substantially close the longitudinal hollow of this shutter. This plate improves the aerodynamic surface of the annular stream.
[0021] Advantageously, the closing plate has its rear end secured to the rear part of the rod of the cylinder and its front end slidably secured onto the body of this cylinder by a linear guiding. In thrust reversal, this plate is spaced apart from the air flow so as not to inhibit it.
[0022] Advantageously, the rear part of the shutter radially bears outwards when the thrust reverser is closed, on an adjustable end of travel stop which allows adjusting the alignment of this shutter with the adjacent surfaces.
[0023] Advantageously, the rear end of the cascades is secured to a spoiler found at the front of the mobile cowls, a sealing member bearing on the front frame, which is radially inside the cascades.
[0024] Advantageously, the thrust reverser includes at the front of the mobile cowls, a seal member bearing on the front frame. This seal provides a pressure balance facilitating the opening or closing of the cowls.
[0025] Advantageously, the front ends of the cascades are connected together by a circular structure which is upstream of the front frame, this structure providing strong stiffness with a reduced mass.
[0026] Another object of the present disclosure is a turbojet engine nacelle including a thrust reverser comprising any one of the previous features.
[0027] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0028] The present disclosure will be well understood and other features and advantages will also appear more clearly upon reading the following description, given by way of example with reference to the accompanying drawings in which:
[0029] FIG. 1 is a partial view in axial section passing via the center of a shutter, of a thrust reverser according to the present disclosure which is closed;
[0030] FIG. 2 is a transversal sectional view of this shutter;
[0031] FIG. 3 is a longitudinal detailed sectional view showing the sealing system of the mobile cowls;
[0032] FIG. 4 shows the thrust reverser at the start of the opening, comprising the cylinder being extended;
[0033] FIG. 5 shows the thrust reverser more open, comprising the cylinder in complete extension;
[0034] FIG. 6 shows the thrust reverser even more open, comprising the shutter being deployed;
[0035] FIG. 7 shows the thrust reverser completely open, comprising the shutter entirely deployed; and
[0036] FIGS. 8 and 9 show the thrust reverser respectively closed and entirely open, comprising a sliding cylinder fairing.
[0037] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
[0038] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0039] FIGS. 1 and 2 show a rear part of a turbojet engine nacelle, comprising a front frame 2 secured onto the structure which is upstream of this part, and mobile cowls 10 adjusted behind this frame.
[0040] The rear part of the nacelle is covered by two mobile cowls 10 , each forming a half-circle in a transversal plane. Each cowl 10 is axially guided by longitudinal guiding means which allow a sliding towards the rear as a result of non-represented actuators, bearing on the stationary structure upstream of the mobile cowls 10 . The cowls 10 include a locking system in closed position, which is not represented.
[0041] In a variant, the nacelle may include a single annular mobile cowl 10 , which similarly slides towards the rear to open the thrust reverser.
[0042] The secondary annular stream 4 includes a radially outer contour comprising shutters 8 adjusted inside the mobile cowls 10 so as to give an aerodynamic continuity, and a radially inner contour formed by the stationary inner structure 6 .
[0043] Cascades 12 disposed flat around the annular stream 4 , form a crown entirely integrated within the front frame 2 when the thrust reverser is closed.
[0044] The rear end of the cascades 12 is secured to a spoiler 14 found at the front of the mobile cowls 10 , which forms a fold-back from the external surface of these cowls, towards the center of the nacelle. The cascades may slide freely through openings of the front frame 2 , so as to follow the movement of the cowls 10 when the thrust reverser opens.
[0045] The system for driving the cowls 10 comprising the actuators may be secured on the upstream part of the cascade structure 12 , to displace the assembly comprising the cascades and the cowls. This disposition entirely releases the passage of the air in the cascade structure 12 in thrust reversal, but encroaches on the front cowl of the engine.
[0046] In a variant the cowl driving system 10 may be secured on the cascades 12 , either in the plane of the cascades, or radially above or below the structure thereof. The cowl driving system 10 may also be secured on the upstream part of the structure of these cowls, by being integrated between two cascade elements 12 . In these two variants the drive system is in the passage of the air in thrust reversal mode.
[0047] Each shutter 8 includes an arm extending towards the front inside the mobile cowl 10 , terminating at the front end thereof by an articulation 16 connected to this mobile cowl, which is disposed just behind the fold-back spoiler 14 .
[0048] The rear part of the shutter 8 radially bears towards the outside on an end of travel stop 18 , which positions this shutter so as to adjust the face thereof in the continuity of the internal surfaces of the front frame 2 and the mobile shutter 10 . The end of travel stops 18 may be adjustable, so as to refine the position of the shutters 8 in the aerodynamic flow.
[0049] Each shutter 8 includes a telescopic cylinder 20 disposed in the longitudinal axis of this shutter, which is entirely integrated in a longitudinal hollow of the face of the shutter turned towards the inside of the nacelle, so as to be adjusted on the external surface of the annular stream 4 without surpassing in this stream. The front end of the cylinder 20 is secured by a pivot to the front frame 2 , the rear end is also secured by a pivot, to a rear part of the shutter 8 .
[0050] Each telescopic cylinder 20 includes a body containing on the front side a helical compression spring, which exerts pressure on the front end of the rod 22 thereof, in order to push it backwards so as to put this cylinder in extension.
[0051] A closing plate 32 secured flat under the cylinder 20 along the length thereof, forms a slidable fairing adjusted on the face of the shutter 8 when it is folded, forming the longitudinal hollow of this shutter so as to improve the external aerodynamic profile of the annular stream 4 . This closing plate 32 mounted as an option, is shown on FIGS. 8 and 9 .
[0052] It is worth noting that the shutters 8 are maintained under tension by the pressure of the cylinder springs 20 which tend to push them on their end of travel stops 18 , with a certain torque depending on the radial distance between the axis of this cylinder and the articulation 16 of the shutters. This pressure inhibits the floating of the shutters 8 which would inhibit the output rate of secondary air.
[0053] FIG. 3 shows a cowl 10 in its forward position, the thrust reverser being entirely closed.
[0054] The radially internal end of the fold back spoiler 14 bears forward on a sealing member 30 , which itself bears on the front frame 2 , radially inside the cascades 12 . The disposition of the cascades 8 integrated upstream of the mobile cowl 10 structure, allows this disposition of the seal which achieves a pressure balance facilitating the opening or closing of these cowls.
[0055] FIG. 4 shows the thrust reverser at the start of the opening, the mobile cowls 10 having started to retreat as a result of the actuators thereof. The cascades 12 start coming out of the front frame 2 .
[0056] The cylinders 20 are extending. Their rods 22 having not entirely come out, these cylinders 20 may continue to be deployed without exerting a retaining force on the rear part of the shutters 8 which do not tip over, and remain pressed inside the mobile cowls 10 .
[0057] FIG. 5 shows the thrust reverser more open, with the mobile cowls 10 which continue to retreat. The cylinders 20 reach their complete extension with the rods 22 entirely out, but the shutters 8 still do not tip over.
[0058] FIG. 6 shows the thrust reverser even more open, the rod 22 which can no longer retreat, has started to make the shutter 8 tip over by pulling the rear part thereof downwards.
[0059] FIG. 7 shows the thrust reverser entirely open, the mobile cowls 10 are in their maximum rear positions, the shutters 8 are completely lowered when arriving near the inner stationary structure 6 .
[0060] During these different steps shown by FIGS. 5 , 6 and 7 , the cascades 12 come further and further out of the front frame 2 , to end up completely out so as to clear their entire surfaces, which allow deflecting the secondary flow.
[0061] Advantageously, the front ends of the assembly of cascades 12 are connected together by a continuous circular structure which is found upstream of the front frame 2 , thus allowing in a simple manner with a reduced mass to obtain a particularly stiff assembly of cascades. The length of the cascades 12 is suited accordingly, so that their front ends remain upstream of this frame 2 when the thrust reverser is entirely open.
[0062] For the closing of the thrust reverser, the compression of the cylinder springs 20 as well as the air flow in the secondary stream 4 , push the shutters 8 backwards. There are the reverse movements with first a folding of the shutters 8 inside the mobile cowls 10 , prior to the compression of the springs.
[0063] It is thereby obtained a simple inexpensive system, disposing of mobile cowls 10 which may include a reduced thickness as on the one hand the cascades 12 , and on the other hand the shutters 8 with their maneuvering systems comprising the cylinders 20 , are axially one after the other without being superimposed. In addition it is not necessary to provide a space in these mobile cowls 10 for housing the cascades 12 .
[0064] With the cylinders 20 integrated in the shutters 8 , which do not surpass in the annular stream 4 , the internal and external aerodynamic profiles of this stream may be improved, and the fuel consumption is improved.
[0065] It is worth noting that the space available in the mobile cowls 10 having no cascades 12 , allows to adjust the position of the front articulation 16 of the shutters 8 , which may be near the external surface of these cowls in order to obtain with the choice of the anchoring points of the cylinders 20 , good kinematics for deploying the shutters. Particularly a rather important radial spacing between the cylinders 20 and the front articulation points 16 of the shutters 8 , allows these cylinders to maintain a strong torque on the folded shutters. A good distribution of forces and a better maneuvering reliability is also provided.
[0066] Furthermore, it is easier for the mobile cowls 10 which do not have a free internal volume for the cascades, to have a stiff structure produced.
[0067] FIGS. 8 and 9 show the closing plate 32 having the rear end thereof secured to the rear part of the cylinder rod 22 , and the front end thereof slidably secured on the body of this cylinder by a linear guiding, such as a guiding rail.
[0068] In direct jet mode for the propulsion of the aircraft, shown by FIG. 8 , the longitudinal hollow of the shutter 8 is closed by the plate 32 forming a fairing for improving aerodynamic performances.
[0069] In reverse jet mode for the braking, shown by FIG. 9 , the body of the cylinder 20 is globally released from the closing plate 32 which slides towards the front with the rod 22 , allowing a better circumvention of the reversal flow, and thereby an improvement as regards the reversal performances. | A thrust reverser of a turbojet engine nacelle includes mobile cowls which retreat with respect to a front frame while causing via cylinders the tipping of the shutters initially folded inside these cowls, so as to substantially close an annular stream of cold air, and cascades disposed around the annular stream which receive the cold air flow in order to send it towards the front. In particular, the cascades are secured to the mobile cowls and slide. | 5 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to an educational entertainment apparatus which comprises drum instrument set. More particularly, the present invention is directed to an educational entertainment apparatus for allowing players to play drum instrument set which generates acoustic sound and for evaluation and grading the accuracy and skillfulness of drum play.
BACKGROUND ART OF THE INVENTION
[0002] The musical instrument called drum instrument set comprises a snare, base, tomtom, hihat, and cymbal. The tomtom is divided into a large tomtom and a small tomtom. Large tomtom is often referred to as a floor tomtom. Small tomtom is composed of two ones. Drum instrument set may further comprises various metallic percussion instruments called symbal, if needed. Also, traditional Korean drums, so called “buk”, Japanese or Chinese folk drums may be added to the composition of the drum instrument set.
[0003] All kinds of drum mentioned in above and metallic percussion instrument, irrespective of both the East and the West genre of drums, can be employed in the drum instrument set of the present invention.
[0004] At present, an electronic drum game apparatus emulating drum play are commercialized in video game arcade. These electronic drum game apparatus is composed of monitors, foot pedals emulating bass drum play and hit spots imitating drum and cymbals, instead of using actual acoustic drums and cymbals. Players of this game apparatus can emulate the drummer's motion by stepping on the pedals or hitting the hit spots thereby, and enjoy the electric sounds generated from the above electronic game apparatus.
[0005] In the above electronic drum game apparatus, a player hits the designated hit spots with the stick according to the visual signal represented in the monitor, and emulates the motion of drum play. Consequently, the drum game apparatus only produces electric sounds according to signal which is made by hitting the hit spots.
[0006] Due to these aspects, the drum game apparatus commercialized only serves as an electronic game apparatus for entertainment without the function as a musically educational entertainment apparatus. That is, it had rather negative effect on the musical education since the sound generated from the electronic drum game apparatus is electronically synthesized sound, thus these game apparatus were never served as an entertainment apparatus for musical education.
[0007] The hit spots which imitates of the electronic drum game apparatus are not actual acoustic drums. Thus, it cause rather a negative effect on the emotional peace(equilibrium). The emotional peace (equilibrium) was generated by beautiful harmonious sounds, beats, and rhythm which is the essence of musical education. However, the computer-synthesized sounds generated from the said game apparatus has no educational effect on players.
[0008] In addition, the operation technique of the electronic drum game apparatus differ greatly from that of actual drum instrument set and thereby, even though a person who get mastery of the operation of electronic drum game apparatus would not become an experts in play of actual acoustic drum.
[0009] Therefore, no effect on musical education can be expected from the electronic drum game apparatus and consequently, it can not function as educational entertainment apparatus, which is new trend of the latest market for entertainment apparatus throughout the world.
[0010] Also, the object of electronic drum game entertainment apparatus is not musically aspirated, but only for recreational purposes. In electronic drum game apparatus, the beat which are not used in actual drum play, are usually employed in order to adjust the degree of the difficulty of game, thus, it can not contribute to musical education.
[0011] Furthermore, the technique of operation of electronic drum game apparatus require minimal amount of physical motions, whereas the actual acoustic drums require forceful and repetitive strikes which needed strenuous physical strength. Consequently, the electronic drum game apparatus which needs minimal physical exercise, has little effect on the physical health of players.
[0012] In order to overcome the above problem of the electronic drum game apparatus, the inventor of the present invention has developed a drum educational entertainment apparatus which comprises a soundproof enclosed space wherein actual acoustic drums and metallic percussion instruments were installed. The drum educational entertainment apparatus of the present invention enable the player to evaluate the accuracy of drum play and to enhance the skill of drum play.
[0013] Therefore, the object of the present invention is to provide a drum educational entertainment apparatus for allowing the player to enjoy the actual acoustic sounds and for evaluating skills of drum play for him/herself by computer. Furthermore, the drum educational entertainment apparatus of the present invention is to allow the player to feel the accomplishment of playing, and to provide the player with the beneficial effect on musical education through the play of the drum educational entertainment apparatus.
SUMMARY OF THE INVENTION
[0014] Therefore, the object of the present invention is to provide an apparatus of drum educational entertainment apparatus, which comprises:
[0015] a box which forms enclosed space;
[0016] an entrance door of said box;
[0017] an accounting unit for accounting coin or paper currency insert thereto;
[0018] a drum instrument set which is integrated into one body and fixed on the floor of said box;
[0019] a control box which is equipped within the said enclosed space and controls operation of the present apparatus through electric signals;
[0020] a monitor which develops visual signals forwarded from said control box;
[0021] a speaker which develops the sound signals forwarded from the control box.
[0022] The present invention may further comprises a sound sensor for detecting the sound signals generated from the said drum instrument set and forwarding the signals thus collected to the control box.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The above objects and other advantages of the present invention will become more apparent by describing in detail a preferred embodiment thereof with reference to the attached drawings, in which:
[0024] [0024]FIG. 1 is the perspective view of the drum educational entertainment apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Hereinafter, an apparatus of the present invention will be described in detail with reference to the accompanying drawings. However, the drum educational entertainment apparatus explained in below is given only for the explanation of the embodiment of the present invention and not intended to limit the scope of the present invention.
[0026] The drum educational entertainment apparatus of the present invention which comprises:
[0027] a box 1 which forms enclosed space;
[0028] an entrance door 2 of said box 1 ;
[0029] an accounting unit 3 for accounting coin or paper currency insert thereto;
[0030] a drum instrument set 4 which is integrated into one body and fixed on the floor of said box 1 ;
[0031] a control box 5 which is equipped within the said enclosed space and controls operation of the present apparatus through electric signals;
[0032] a monitor 8 which develops visual signals forwarded from said control box;
[0033] a speaker 9 which develops the sound signals forwarded from the control box 5 .
[0034] Preferably, the present invention may further comprises a sound sensor 7 for detecting the sound signals generated from the said drum instrument set and forwarding the signals thus collected to the control box.
[0035] In the drum educational entertainment apparatus of the present invention, sound sensor 7 can be mounted to the drum and/or cymbal, or on the control box and when necessary, the sound sensor may be placed anywhere within the interior of the enclosed box.
[0036] An accounting unit 3 for inserting coin or paper currency need not be placed on the entrance door nor on the control box, but it can be placed anywhere within the interior of the enclosed box.
[0037] [0037]FIG. 1 is the perspective view of the drum educational entertainment apparatus of the present invention.
[0038] As illustrated in FIG. 1, the apparatus of the present invention comprises a box 1 which forms enclosed space, the entrance door 2 formed on the box, drum instrument set 4 which is integrated into one body and fixed on the floor of said box 1 , the control box 5 which regulate the operation of this apparatus under the control of program which is divided into various steps according to degree of difficulty, and regulate forwarding the results of grading, various melodies and visual signals into the monitor, the sound sensor 7 which detects sound generated by the player's hitting, a monitor 8 which develops the scores, music melodies, and visual signals which are developed and forwarded from the control box 5 , and an accounting unit 3 for inserting coin, which placed either on the entrance door 2 or the control box 5 in order to control the on/off of the entrance door and the power supply of the control box.
[0039] Therefore, the drum educational entertainment apparatus of the present invention comprises a box, an entrance door, drum set, control box, monitor, speaker and an accounting unit.
[0040] The box which forms enclosed space in the drum educational entertainment apparatus, is soundproof regular hexahedron, perfect hexahedron, cylindrical, conical(cone) and et al. Shape of the box does not matter, however, the space thereof ought to be large enough to install a drum instrument set, a control box and a monitor.
[0041] Therefore, the internal volume of the drum educational entertainment apparatus of the present invention, is 1M 3 to 20M 3 , and regardless of the shape of the box, the minimum floor area is 0.5M 2 to 10M 2 , and the box should be large enough for the forming of an entrance door.
[0042] The external shape of the box which forms the enclosed space of the present invention, may be in form of various kinds of animals or house form, cars or airplane form, or drum instruments form for considering the visual enjoyment of user and usage thereof as an entertainment. The external shape of the box that forms the soundproof enclosed space of the present invention is not a essential part of the drum educational entertainment apparatus. In consideration of the esthetic taste of user, a person skilled in the art, may change the shape appropriately.
[0043] Regardless of neither shape nor the different possible functions of entrance door of the present invention, whether the shape is rectangular, square, or cylindrical, or the functions be sliding way, cover way, junction way, the dimension ought to be at minimum 0.2M 2 , enough for a person to pass through.
[0044] The drum instrument set may be installed in the said enclosed space, generally comprises Korean traditional drum, buk, a changku, a gong, cymbal, tambourine, timpani, western drums and et al., various types of wooden and metallic percussion instruments. Therefore, the drum instrument set employed in the present invention, comprises various types of percussion instruments such as big drums, small drums, various types of drums and cymbal, metallic tub, wooden tub, and wooden drums of which can generate sound by beating or scratching.
[0045] The control box of the present invention functions to gather sound signals from sound sensors continuously, allows the player to know whether he/she is playing the drums accurately in accordance with the visual signals illustrated on the monitor.
[0046] The control box of the present invention comprises three kinds of memory set. The first memory set stores music scores which are divided into tens of different levels according to the degree of difficulty. The second memory set stores the sounds through the speakers and the melodic signals with background images while drum set is being played. The third memory set stores visual signal and audio signal to educate the player the skill of drum play through monitor and/or speaker for one(1) to ten(10) minutes. The control box of the present invention comprises the central processing unit wherein the computer program which controls and adjusts the function of control box, is installed.
[0047] The conventional singing machine, so called “KARAOCHE” instrument can be employed as the control box of the present invention, if necessary. A person skilled in the art can operate the control box to adjust, the melody sound's octave, tone, and beat. Therefore, the said control box of the “KARAOCHE Room” can be used as the control box of the present invention.
[0048] The drum educational entertainment apparatus of present invention may optionally comprises the sound sensor that is selectively chosen from the conventional sound sensors for gathering signals to be used in grading the player's skill and for forwarding the date to the central processing unit of the control box.
[0049] An accounting unit of the present invention may be mounted on the entrance door or the control box. It controls the entrance door and the power supply of the control box. The accounting unit of the present invention is alike that of the general video arcade machine. It is connected to the entrance, the interior lighting inside the drum room, and the power switch of the control box and the monitor, therefore controlling the start or end of operation.
[0050] The accounting unit of the present invention is composed of a slot for inserting money and paper currency, change slot. It functions as a calculator and storage of received money. The money insert unit of the present invention functions alike that of the general money inserts, therefore, may be used as the component of the present invention.
Industrial Applicability
[0051] The drum educational entertainment apparatus of the present invention is a musical educational entertainment apparatus using the actual acoustic drum.
[0052] The apparatus of the present invention allow the player to enjoy acoustic sound by playing the actual drum instrument set and to evaluate the skill of drum play for him/herself. Therefore, the apparatus of the present invention function as the musical education apparatus, along with entertainment function.
[0053] In addition, the drum educational entertainment apparatus of the present invention have a good role for reducing the body weight and stress level due to the fierce playing work of drum instrument set.
[0054] While the present invention has been particularly shown and described with reference to particular embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be effected therein without departing from the spirit and scope of the invention as defined by the appended claims. | The present invention relates to an educational entertainment apparatus which comprises drum instrument set. More particularly, the present invention is directed to an educational entertainment apparatus for allowing players to play drum instrument set which generates acoustic sound and for evaluation and grading the accuracy and skillfulness of drum play. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to enclosures for cable splices for mechanical protection of the splice and for providing a barrier against water and moisture intrusion into the splice.
A variety of enclosures for cable splices are presently in use, including electrical and optical cables with a plurality of conductors. After the conductor interconnections are completed and the appropriate insulation or other protection has been applied, a housing is positioned around the splice with some form of sealing compound in the housing. The sealing compound usually is a gel which functions to reduce penetration of moisture into the splice. The housing itself provides mechanical protection for the splice and is normally designed to be removable for reentering the splice.
In one type of enclosure, the housing is partially filled with the sealing compound before it is positioned around the splice. Some form of end seal is provided to close the open ends of the housing around the cables which extend from each end of the splice. In another type of enclosure, an opening is provided in the wall of the housing for pouring the sealing compound into the interior of the housing after it is positioned around the splice. This type of construction, usually referred to as gravity encapsulation, tends to leave many openings and paths in the sealing compound through which moisture can penetrate.
In another type of encapsulation, a bag or wrap of some nature is positioned around the splice and filled with a sealing compound by pouring or the like. Then the encapsulated splice is tightly wrapped with overlapping turns of tape to apply pressure to the sealing compound within the bag to force the sealing compound into the interstices to provide a more effective barrier against moisture. While this type of encapsulation is reasonably effective, it is not easy to install, requiring considerable time and considerable skill to achieve a highly moisture-resistant closure.
Another approach for a quality encapsulation is to utilize a caulking gun or the like for injection of sealing compound into the interior of the housing after it is positioned around the splice with the end seals in place. With this system, considerable pressure can be exerted on the sealing compound to urge the compound into the various spaces. However, this method requires an extra tool and space for operating the tool.
The current designs for cable splice enclosures are shown in greater detail in the publications of the manufacturers, including AT&T, 3M, Raychem, Thomas & Betts and Communications Technology Corporation.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a new and improved enclosure for a cable splice which provides compression of the sealing compound for forcing the compound into all the cavities and crevices within the housing and into the core of the cable. Another object is to provide such an enclosure which can be installed without requiring special tools or heating or wrapping. An additional object is to provide such an enclosure which is simple, easy and quick to install without requiring any high level of skill or extensive practice to achieve quality sealing.
It is a further object of the invention to provide such an enclosure which is suitable for buried cable and which utilizes a durable housing providing mechanical protection while at the same time being easily opened for reentry of the cable splice.
In its preferred form, the enclosure of the invention includes a housing for positioning around the splice with a plurality of presser arms carried in the housing and positioned between the housing and the splice. Bosses are provided on the presser arms projecting through the housing for engagement with a compression member, typically a band or tape passing through slots in the bosses so that when the tape is tightened, the presser arms are urged inward to engage the wrap, moving the compound into the various cavities.
Preferably, the presser arms are arcuate in cross section and extend along the length of the splice, typically with three or four such arms shaped so as to substantially surround the splice when the arms are compressed inward. The housing may be formed as a one-piece molding with appropriate hinges for positioning around the splice or may be formed of two pieces with connecting flanges. Seals of some form are provided for closing the ends of the housing around the cables, and mechanical supports for the cables within the housing may be utilized, with the end seals and mechanical supports being conventional in design.
Other objects, advantages, features and results will more fully appear in the course of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a cable splice with a wrap being filled with a sealing compound;
FIG. 2 is a perspective view of a housing for positioning around the splice and incorporating the presently preferred embodiment of the invention;
FIG. 3 is a view similar to that of FIG. 1 with the housing of FIG. 2 in place;
FIG. 4 is an enlarged sectional view taken along the line 4--4 of FIG. 3;
FIG. 5 is a sectional view similar to that of FIG. 4 showing an alternative embodiment of the invention;
FIG. 6 is a view similar to that of FIG. 3 showing an alternative form of end seal;
FIG. 7 is a view similar to that of FIG. 1 showing an alternative form of cable splice using a spout for introducing the sealing compound;
FIG. 8 is a view of the splice of FIG. 7 with a housing in place;
FIG. 9 is an enlarged sectional view taken along the line 9--9 of FIG. 8; and
FIG. 10 is a sectional view similar to that of FIGS. 4 and 5 showing another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A conventional splice 11 of cables 12, 13 is shown in FIG. 1. After the interconnections of the various conductors of the cables have been completed and appropriately insulated, a wrap 14, typically a flexible plastic, is applied around the splice. The edges of the wrap are tightly bound around the cables in the conventional manner at 15, 16. A sealing compound 19 is poured into the interior of the wrap 14 through an open mouth, after which the open mouth is closed, as by an adhesive and/or folding over at 20. The closed mouth may be held in place by an adhesive tape or loosely tied with a string or with cable ties.
Next a housing 22 is positioned around the splice to produce the structure shown in FIG. 3. The housing 22 is shown in greater detail in FIG. 2 and typically comprises two segments which may be joined by a flexible hinge 23 as shown in FIG. 2 and FIG. 5, or may be formed separately with flanges 24 for joining with bolts and nuts or other form of fasteners 25 as shown in FIG. 4. Alternatively, the housing may be made in three or more segments, as desired.
In the embodiment shown in FIGS. 1-4, four presser arms 26 are positioned inside the housing, with each presser arm having one or more bosses 27 projecting outward through openings in the housing. While cylindrical bosses are illustrated, the shape of the boss is not critical and bosses with square cross-sections or other shapes may be used. Three bosses per presser are shown in the drawing figures. Preferably the presser arms are arcuate in cross section as shown in the drawing figures, and extend substantially along the length of the splice. The presser arms with bosses and the housing segments typically are molded of a relatively rigid plastic, but may be made of metal if preferred.
Means are provided for applying inward pressure to the presser arms via the bosses. In the specific embodiment illustrated, slots 30 are provided through the bosses near the outer ends, and a cable tie 31 is threaded through the corresponding bosses of the four presser arms. The cable tie is then pulled tight in the conventional manner, urging the pressure arms inward against the wrap of the splice to apply a compression force to the sealing compound and move the compound into the various spaces within the splice.
In an alternative arrangement, a metal band or hose clamp 32 with screw-type connector 33 is used to apply the compression force. The cable tie configuration is shown in FIG. 4 and the hose clamp is shown in FIGS. 2 and 5. The embodiment of FIG. 5 utilizes three pressure arms, in contrast to the four arms shown in the embodiment of FIG. 4. Of course, a structure with only two presser arms, or more than four, could be utilized if desired.
In the embodiment illustrated in FIG. 3, seals 35 are positioned at the each end of the housing to provide a seal around the cables. In the embodiment illustrated in FIG. 6, a different form of seal 36 is utilized. These end seals are conventional in nature. Typically, the cone-like seal 36 is formed as part of the housing 22.
Also, it is preferred to provide some form of mechanical support adjacent each end of the splice to provide cable strain relief, and this support may also be conventional in nature. However, the embodiment illustrated in FIGS. 2 and 3 is preferred. Cable engaging members 37 with bosses 38 are positioned in the housing and are clamped in place by clamping members 39. The various forms of boss and clamping members used with the presser arms may be used here also. With this novel arrangement, there is no need to adjust the cable engaging members to the diameter of the cable prior to installation, as required in the prior art. With the present design, the positioning of the members 37 occurs automatically as the clamping member is tightened.
Another alternative embodiment of the invention is shown in FIGS. 7-9 with a provision for introducing the sealing compound into the splice under the wrap before or after the housing is positioned around the splice. A spout 42 has a flange 43 positioned under the wrap 14, with an outer end 44 of the spout projecting outward. One of the presser arms is provided with an opening 45 for the spout, and a corresponding opening 46 is provided in the housing providing access to the spout from the exterior of the housing.
In this arrangement, before or after the housing is in position but before the compression clamping members have been tightened, the sealing compound is introduced under the wrap around the splice. This may be done by pouring, but does not require any pressure by a caulking gun or the like. After the desired quantity of sealing compound has been introduced, the spout may be closed by a threaded cap or the like.
Then the clamping members are tightened to apply compression forces to the sealing compound around the splice, as with the previously described embodiments.
In the alternative embodiment of FIG. 10, the presser arms 26 are molded as a single piece, with the arms joined by thinner, flexible, accordion-like sections 26A. Also the bosses 27 have slots or grooves 30A rather than the slots 30 shown in FIG. 4, as passages for the compression bands or ties.
As the clamping members 31, 32 are tightened, the free floating presser arms 26 and cable engaging members 37 are moved inwardly separately and are automatically positioned to exert uniform pressure on the splice and cables, thereby reducing strain on the assembly while achieving the desired sealing. | An enclosure for a cable splice having a sealing compound inside a wrap, and including a housing for positioning around the splice, a plurality of presser arms in the housing positioned between the housing and the splice, with each of the arms having a boss projecting outward through the housing, and a clamp or strap or the like for engaging the bosses and pressing them regularly inward to apply pressure to the sealing compound by the presser arms engaging the wrap. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for detecting foreign matters in a gas sealed electrical apparatus.
One of the problems associated with sealed type gas insulated electrical apparatus is the presence of foreign matters, such as metallic particles, in the electric apparatus. Such foreign matters may be produced by friction or sliding at the contacting surfaces of metallic parts during assembly in the factory or in the site at which the electrical apparatus is installed. The foreign matters may also be introduced while the interior of the electrical apparatus is exposed to the atmosphere before the electrical apparatus is sealed. The presence of the foreign matters in a circuit breaker, a disconnecting switch or a grounding switch is also attributable to local fusion of the movable and stationary contacts due to frictional heat or arcing. If a high voltage is applied to the electrical apparatus with metallic foreign matters contained therein, insulation breakdown occurs at a voltage several times lower than the insulating strength of the apparatus free from any metallic foreign matters or at even lower voltages. With large sized electrical apparatus, it is impossible to accuratily locate the portion of the apparatus where the initial breakdown has occurred. In order to locate the portion of initial breakdown, the whole electrical apparatus must be disassembled, which is time-consuming and laborious.
The insulation breakdown thus caused of course leads to disturbance in the power transmission system. Moreover, the parts damaged by the breakdown need to be disassembled and repaired.
In general, metallic particles contained in sealed type gas insulated electrical apparatus move under electric field and gravity at the bottom of the grounded tank portion in a manner described below. In FIG. 1, an electrical apparatus is shown in a simplified form for brevity of description. The electrical apparatus comprises a cylindrical grounded casing or tank 3 constituting an electrode and a central conductor 1 constituting a second electrode. The space between the casing 3 and the central conductor 1 is filled with an insulating gas 2. Present at the bottom of the tank 3 is a needle-shaped metallic particle 4. When no voltage is applied to the central conductor 1, the metallic particle 4 is at rest, as shown at (a) in FIG. 1. As a voltage is applied to the central conductor 1, electrostatic force is exerted on the metallic particle. As the voltage is increased the electrostatic force is increased. As the electrostatic force overcomes the force of gravity, the metallic particle is made to stand as shown at (b) and (c) in FIG. 1. When the voltage is increased further, the metallic particle moves up, and floats in the gas and reaches the central conductor 1 as shown at (c), (d), (e) in FIG. 1. When the electrostatic force becomes smaller than the force of gravity, or when the direction of the electrostatic force is reversed, the metallic particle 4 falls down as shown at (e), (f) and (g) in FIG. 1 and, upon collision with the bottom of the grounded tank 3, generates elastic waves, essentially consisting of ultrasonic waves. With a needle-shaped metallic particle, the electrostatic force is proportional to the square of the length of the particle, whereas the force of gravity is directly proportional to the length of the particle, so that the longer the particle is, the more active the movement of the particle is, and the greater the generated elastic waves arc. With a globular metallic particle, the electrostatic force is proportional to the square of the radius of the particle, whereas the force of gravity is proportional to the cube of the radius of the particle, so that larger the radius of the particle is, the less active the movement of the particle is. In any case, the metallic part 4 actively moves about in the space between the central conductor 1 and the grounded tank 3, and during the up-and-down movement of the metallic particle insulation breakdown occurs at a voltage much lower than the breakdown voltage in the absense of the metallic particle.
The elastic waves, including the ultrasonic waves, are also caused by corona discharge which occurs at a lower voltage than if no metallic particles are present.
FIG. 2 shows an example of electrical apparatus which may be affected by the presence of metallic particles. A central conductor 1 is supported by a grounded casing 3 through insulating spacers 9 which contain joints 9a for interconnecting adjacent sections of the conductor 1. If globular metallic particles 10 or needle-shaped metallic particles 4 are present, insulation breakdown occurs at a low voltage.
Similar problem also occurs in gas filled circuit breakers.
SUMMARY OF THE INVENTION
An object of the invention is to provide a method and apparatus for detecting metallic particles present in gas sealed electrical apparatus.
Another object of the invention is to enable location of metallic particles present in gas sealed electrical apparatus.
According to one aspect of the present invention, there is provided a method for detecting foreign matters present in gas sealed electrical apparatus including a tank at the ground potential and containing an insulating gas and a high voltage live part disposed in the tank, characterized by the steps of applying a voltage to the high voltage live part for causing generation of ultrasonic waves and propagation thereof through the tank, sensing the ultrasonic waves propagated through the tank, and discriminating between the magnitudes of the sensed ultrasonic waves to determine the shape of the foreign matters.
According to another aspect of this invention there is provided apparatus for detecting foreign matters present in gas sealed electrical apparatus including a tank at the ground potential containing an insulating gas and a high voltage live part disposed in the tank, characterized in that said detecting apparatus comprises sensing means located on said tank for sensing ultrasonic waves generated by foreign matters present in said tank and propagating through the tank, and indicating means responsive to the output of said sensing means for indicating the presence of said foreign matters.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 shows a longitudinal section of an electrical apparatus schematically illustrating how a needle shaped metallic particle moves in the electrical apparatus under electric field and gravity;
FIG. 2 shows a longitudinal section of a gas filled bus bar with metallic particles contained therein;
FIG. 3 shows an embodiment of a detection apparatus according to the invention, attached to an electrical apparatus;
FIG. 4 is a graph showing the magnitudes of the output of the sensing element in relation to the applied voltage;
FIG. 5A shows the detection apparatus of FIG. 4 attached to a gas filled bus bar;
FIG. 5B shows the detection apparatus of FIG. 4 attached to a gas filled circuit breaker;
FIG. 6 shows another embodiment of the invention with two sensing elements at different positions;
FIG. 7 shows a further embodiment of the invention with two sensing elements of different polarities mounted at the same positions;
FIG. 8 shows a further embodiment of the invention with a simplified measurement device, and
FIGS. 9 and 10 respectively show different variations of the simplified measurement device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now more particularly to FIG. 3, there is shown detection apparatus embodying the invention. A high voltage central conductor 1 is built in a grounded casing or tank 3, which contains an insulating gas 2. A needle-shaped metallic particle 4 and globular metallic particles 10 are present in the casing 3. When a voltage is applied to the central conductor 1, metallic particles 4 and 10 move up and down, and produce elastic waves, essentially consisting of ultrasonic waves, upon collision with the grounded casing 3. The elastic waves are also produced by corona discharge which occurs at a lower voltage than if no metallic particles are present. An ultrasonic wave sensing element 5, such as a piezo-electric element, is mounted to the exterior of the grounded casing 3 to sense the ultrasonic waves propaged through the casing 3, and converts the ultrasonic waves into an electrical signal. A cable 6 connects the sensing element 5 to an amplifier 7, whose output is fed to an indicating device 8, such as a synchroscope or a digital memory device, to enable observation. Thus presence of the metallic particles in the grounded casing 3 can be detected by the indication of the indicating device 8.
FIG. 4 shows the output produced by the ultrasonic sensing device 5. The plots grouped by a bracket A are those obtained when the needle shaped metallic particles are present. The plots grouped by a bracket B are those obtained when the globular metallic particles are present. With the presence of the needle shaped metallic particles, the output voltages are at about or over a level of 1 V. Longer metallic particles are found to result in greater output voltages. With the presence of the globular metallic particles, the detected voltage are at about or below a level of 0.5 V. It is therefore possible to discriminate between the magnitudes of the waves to determine whether the metallic particles present are needle shaped ones or globular ones. In other words, one may judge that the particles present are needle shaped if the output of the sensing device is above a certain level (0.75 V, for example), and that the particles present are globular if the output of the sensing device is below the level.
FIGS. 5A and 5B respectively show ultrasonic sensing devices 5 attached to gas filled bus bar and circuit breaker. In the circuit breaker shown in FIG. 5B, relatively movable contacts 11 are contained in a gas filled casing 12 and these contacts are connected to gas filled bus bars 13. In each case, the indicating device 8 permits observation of the ultrasonic waves due to the presence of the metallic particles 4 and 10 in a grounded casing 3 and 12. By the use of the detecting apparatus, dielectric breakdown can be prevented.
In FIG. 6, at least two sensing elements 5 are mounted at different positions on the same grounded casing 3 (or to the different casings 3, 15), and a single indicating device 8 is connected to both sensing elements for simultaneously indicating two input voltages. The time lag T 1 of one voltage wave behind the other is measured, and, used together with the propagation velocity of the ultrasonic wave through the grounded casings 3 and 15 for calculation necessary to locate the metallic particles. If a differential amplifier 16 is employed, external mechanical low-frequency noises transmitted to the grounded casings 3 and 15 and sensed by the sensing elements 5 can be removed. Thus, accuracy of the measurement is improved.
As shown in FIG. 7, differential sensing elements 14 a and 14 b of different polarities are mounted at the same positions and adapted to perform an additional differential operation. By the additional differential operation, the sensitivity of the measurement is improved.
The detecting apparatus illustrated in FIG. 5A, 5B, 6, 7 and 8 are relatively bulky and require an AC power source. These are disadvantageous in certain applications. Also, to conduct detection of metallic particles in an electrical apparatus placed at a high spot, a special support may be required.
FIG. 8 shows another embodiment of the invention. The output of an ultrasonic sensing element 5 is supplied via a cable 6 to an amplifier 22 and is amplified there to a sufficient level. The output of the amplifier 22 is detected by a detector 23 to be transformed to a waveform suitable for driving a direct-reading indicator such as a pointer type meter 24. The meter 24 may be a crest meter or a mean value meter. The amplifier 22, the detector 23 and the meter 24 form a simplified measurement device 21 and are all energized by a portable type source such as a battery (such as dry cells or cadmium cells) and hence do not require an AC power source. If the reading on the meter 10 is greater than a specific value, presence of metallic particles is assumed.
Terminals 25 are provided at the output of the amplifier 7 to permit connection of a synchroscope, by which the waveform of the voltage can be observed so that it can be determined whether the metallic particles present are needle shaped or globular and what the size of the metallic particles is.
As shown in FIG. 9, a bandpass filter 26 may be inserted between the detector 23 and the meter 24 so that only the detected voltage of a preselected frequency is fed to the meter 10. Such insertion of the bandpass filter 26 is useful for suppressing noises, to supply the meter 24 with a signal indicative of the ultrasonic waves having noises removed.
FIG. 10 shows a further embodiment of the invention. The pointer type meter 24 of FIG. 10 is replaced by an analog to digital converter 27 and a digital indicator 28. | In a method for detecting foreign matters present in gas sealed electrical apparatus including a tank at the ground potential and containing an insulating gas and a high voltage live part disposed in the tank, a voltage is applied to the high voltage live part causing generation of ultrasonic waves and the ultrasonic waves propagated through the tank is sensed by a sensing element mounted on the tank. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a divisional application of Ser. No. 11/326,929, filed Jan. 6, 2006 now abandoned, and entitled Turbine Element Repair Fixture, now abandoned, the disclosure of which is incorporated by reference herein in its entirety as if set forth at length.
BACKGROUND OF THE INVENTION
The invention relates to repair of turbine engine components. More particularly, the invention relates to fixtures for repairing turbine engine blades.
Turbine engine blades (including fan, compressor, and turbine section blades) are subject to wear and damage (e.g., foreign object damage (FOD)). Repair of such damage may include coating removal, machining of a wear/damage site, and/or the attachment of a scaffold material. The scaffold material may be externally attached, inserted, or in situ formed. The scaffold surface may define an external or internal surface of repair material built-up atop the scaffold. Exemplary build-up may be by welding (including laser cladding), brazing, or deposition. During repair, the blade may be held in a fixture. An exemplary fixture is a vise-like structure having drawers configured to grasp pressure and suction side surfaces of the blade airfoil.
SUMMARY OF THE INVENTION
One aspect of the invention involves a fixture for processing a blade. The fixture has first and second jaws. The second jaw is movable relative to the first jaw from a disengaged position for accepting a root of the blade. The blade is accepted in a receiving area between the first and second jaws. The second jaw is movable to an engaged position clamping the blade between the first and second jaws. A gas flow path extends from an inlet port to an outlet port. The outlet port is positioned to introduce gas to a blade inlet port when the blade is installed. In various implementations, at least one of the jaws may be removable and replaceable with a structurally different jaw to permit the fixture to accommodate a structurally different blade. The fixture may be used in a build-up repair on the blade. During the repair, a suitably non-reactive gas may be introduced through the fixture to limit or avoid adverse reaction (e.g., oxidation) of a scaffold element, the blade parent material, and/or the deposition material.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a blade processing station.
FIG. 2 is a side view of a fixture from the station of FIG. 1 .
FIG. 3 is a front view of the fixture of FIG. 2 .
FIG. 4 is a bottom view of the fixture of FIG. 2 .
FIG. 5 is a top view of the fixture of FIG. 2 .
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 1 shows a station 20 for processing (e.g., repair) of a turbine element 22 (e.g., a gas turbine engine compressor or turbine section blade). The blade 22 is held by a fixture 24 .
An exemplary processing of the blade involves adding material (e.g., a build-up of material in a repair or restoration process). The processing may also or alternatively include removing material (e.g., preparatory or finish machining). An exemplary build-up of material may be by a welding process such as laser cladding. Accordingly, to apply the material, the station 20 may include a welding head 30 . To position the head 30 relative to the blade 22 , one or both of the head 30 and fixture 24 may be movable. For example, the fixture 24 may be mounted to an automatically controlled reference such as a five-axis rotary table 32 . An exemplary head is a laser cladding head having a nozzle 34 and metal powder feed lines 36 .
FIG. 2 shows further details of an exemplary blade 22 and fixture 24 . The blade has an airfoil 40 . The airfoil 40 extends from an inboard end 42 at a platform 44 to an outboard tip 46 . In an exemplary repair situation, the tip may have been damaged and the blade is shown having been machined along a surface 48 . A convoluted fir-tree attachment root 50 depends from an underside of the platform 44 . The root 50 has first and second longitudinal ends and first and second circumferential sides 52 and 54 . For reference, “longitudinal”, “circumferential”, and “radial” directions 500 , 502 , and 504 defined relative to the orientation that the blade assumes when the root 50 is installed in a complementary slot in a disk of a turbine engine. A scaffold element 56 has a first portion extending into a passageway or compartment in the airfoil below the surface 48 . The scaffold 56 has a second portion protruding from the surface 48 for re-forming an end portion of the passageway or compartment when a deposition material is applied atop the surface 48 and scaffold 56 . An exemplary scaffold is a refractory metal-based (e.g., molybdenum) core element.
The exemplary fixture 24 includes a base 60 for mounting the fixture to the table 32 . An exemplary base 60 is formed as a metal plate (e.g., of an aluminum alloy or steel). In the exemplary base 60 , a pair of metal (e.g., steel) dowel pins 62 ( FIG. 3 ) have upper portions press fit into associated apertures 64 in the base and have lower portions protruding below an underside 66 of the base. The pins 62 may be received by complementary holes or slots in the table to register the fixture relative to the table. The fixture may be secured to the table by means such as clamps (not shown).
The upper surface 68 of the exemplary base 60 carries a root-engaging clamp structure 70 . The exemplary clamp structure 70 ( FIG. 2 ) includes a fixed jaw 72 and a movable jaw 74 . The fixed and movable jaws 72 and 74 cooperate to define a channel-like receiving area 76 for receiving the blade root 50 .
The exemplary fixed jaw 72 includes the unitary combination of a bottom portion 80 along the base 60 and a wall portion 82 opposite the moving jaw 74 and extending away from the base 60 . The exemplary fixed jaw is mounted to the base by means of registering pins 84 and screws 86 ( FIG. 4 ).
A screw or other means are provided for tightening the moving jaw 74 . An exemplary screw assembly 90 includes a threaded shaft 92 passing through a bore 93 in the jaw 74 and into threaded engagement with a bore 94 of the fixed jaw 72 . The exemplary screw 90 further includes an actuator 96 (e.g., a knob). The exemplary knob 96 has a bore 98 receiving an outboard portion of the screw. Tightening/loosening of the knob 96 may do one or both of tightening/loosening of the shaft relative to the knob or the shaft relative to the screw fixed jaw to shift the moving jaw 74 toward/away from an engaged condition.
The exemplary screw assembly 90 has a central axis of rotation 510 at an angle θ off-parallel to the base underside 66 . Exemplary θ is 5-30°. With the radial direction 504 essentially normal to the underside 66 , the axis 510 is off-normal to the radial direction by θ. The exemplary bottom portion 80 has a front face 120 oriented normal to the axis 510 . The fixed jaw bottom portion 80 has a generally horizontal upper surface 122 . With the blade installed and the jaws in the engaged condition, an underside 124 of the root contacts the bottom portion upper surface 122 . A shoulder 130 of the fixed jaw wall portion 82 engages an associated neck region 132 of the adjacent side of the root. An upper rear edge portion 140 of the moving jaw 74 engages a neck portion 142 of its adjacent side of the root. The off horizontal angle of the axis 510 helps cause the moving jaw 74 to exert a downward force to the blade root, clamping the blade root both against the fixed jaw wall portion 82 and bottom portion 80 .
The exemplary fixture includes additional means for precisely registering the blade relative to the fixture. Exemplary registering means include a projection at least partially captured in an aperture of the blade. In the illustrated embodiment, the projection is formed by the upper end of a pin 150 ( FIGS. 3 and 5 ). The exemplary pin 150 (e.g., steel) has a pin upper portion protruding from the fixed jaw bottom portion 80 upper surface 122 and a pin lower portion received in press-fit relation in an associated bore in the fixed jaw bottom portion 80 .
A channel 160 ( FIG. 5 ) is formed in the fixed jaw bottom portion upper surface 122 . The exemplary channel 160 extends elongate in the blade longitudinal direction 500 (i.e., transverse also to the axis 510 ). The exemplary channel 160 is obround and may be formed by milling. A bored port 162 extends downward from a base 164 of the channel. The port meets a transverse bore 170 (e.g., extending approximately in the blade circumferential direction 502 ) from an inlet port 172 on the backside 174 of the fixed jaw. The bore 170 may include pipe threads for engaging a fitting (not shown) to couple the fixture to a source 180 ( FIG. 1 ) of inert gas (e.g., argon or other noble gas or a gas essentially non-reactive in the welding process). For example, otherwise desirable materials for scaffold elements may be subject to oxidation or other chemical degradation. These may include refractory metal-based cores for forming/reforming internal passageways. The gas may be effective to limit such degradation to a tolerable amount or essentially eliminate it.
One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, details of the particular turbine elements to be worked upon and details of the work station may influence details of any particular implementation. Accordingly, other embodiments are within the scope of the following claims. | A blade processing fixture has first and second jaws. The second jaw is movable relative to the first jaw from a disengaged position for accepting a root of the blade. The blade is accepted in a receiving area between the first and second jaws. The second jaw is movable to an engaged position clamping the blade between the first and second jaws. A gas flow path extends from an inlet port to an outlet port. The outlet port is positioned to introduce gas to a blade inlet port when the blade is installed. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to artificial joints, and more particularly to techniques for securing artificial joint prostheses to bones.
One serious problem which is receiving greater attention in orthopedic meetings is that of the loosening of prostheses which are employed in such artificial joints. Up to the present time, a number of techniques have been undertaken to enhance fixation. Some of the methods and apparatus which have been proposed include the use of special techniques to denude the inner cancellous bone surfaces to which the prosthesis are to be cemented, by the use of Water Pik type apparatus, bottle brushes, or hydrogen peroxide; the use of rubber dams around the opening in the bone, to facilitate the packing of cement; and the use of special arrangements similar to a "grease gun" for the injection of the cement prior to prosthesis insertion.
However, while such techniques are probably improvements over prior procedures, no substantiating data is as yet available, and it is considered probable that the results will show improvement, but that the problem of loosening of prostheses will not have been fully solved by these techniques.
A principal object of the present invention is to reduce the loosening of prostheses, by improving the bond between the prosthesis and the cement and more specially between the cement and the bone structure.
SUMMARY OF THE INVENTION
In accordance with the present invention, it has been determined that greatly improved bond strength between prostheses and the enclosing bone may be obtained by supplying the cement to the space between the prosthesis and the enclosing bone under pressure, and maintaining the pressure for a sufficient period of time to permit hardening or polymerization of the cement.
In accordance with one aspect of the invention, the prosthesis may be provided with apertures through which the cement may be supplied under pressure to the space between the prosthesis and the enclosing cancellous bone.
In addition, the periphery of the prosthesis may be provided with a rim or edge for making a tight seal with the mating surfaces of the bone, to facilitate the maintenance of elevated pressure within the space between the prosthesis and the bone so that pressure may be maintained while the cement sets.
In accordance with another feature of the invention, exit apertures may be provided through the prosthesis to permit the forcing out of blood and other substances within the intramedullary space, prior to completely filling the space between the prosthesis and the closing bone with cement, and the maintenance of high pressure within this space until the cement hardens.
Other collateral features of the technique of the invention include the preliminary placement of a plug in the central channel of the bone, to prevent undue penetration of the cement along the length of the bone when the pressurized joint is being prepared; the use of a clamp to hold the prosthesis in place while pressurized cement is being forced through it; the location of the apertures through the prosthesis on non-bearing surface areas of the prosthesis when such areas are available; the use of disposable plastic cylinders for supplying the cement, which may be somewhat more fluid than that which is conventionally employed; and the maintenance of pressures which are substantially above atmospheric pressure during the entire period of polymerization and setting up or hardening of the cement.
Advantages of the present method include significantly increased penetration and better engagement of the cement with the cancellous bone surface, as well as a decreased porosity of the solidified cement with a resultant increase in the mechanical tensile strength of that cement, and hence a greatly increased mechanical strength of the resultant interface between the artifical joint and the bone. More specifically, the average percent improvement for paired specimens, in which a comparison was made between the pressurized specimens prepared in accordance with the invention, and control specimens prepared by normal techniques were as follows: a 388% increase in fracture strength, a 198% higher shear modulus, and 420% greater energy required for fracture.
Other objects, features, and advantages of the invention will become apparent from a consideration of the following detailed description and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic showing of a prosthesis being cemented into place in the end of bone in accordance with principles of the present invention;
FIG. 2 is a diagrammatic showing of the complete system for supplying cement under pressure to the prosthesis of FIG. 1;
FIG. 3 shows an alternative arrangement providing separate inlet and outlet ports through the prosthesis;
FIG. 4 is an isometric view of a knee joint prosthesis provided with inlet and outlet apertures for the implementation of the present invention;
FIGS. 5A and 5B are comparative showings indicating the penetration of cement in accordance with the principles of the invention and in a control sample, respectively; and
FIGS. 6A and 6B are comparative photomicrographs showing the interface between the cancellous bone and the cement for the technique of the present invention, and for the control sample, respectively.
DETAILED DESCRIPTION
Before embarking on a detailed description of the drawings, it is useful to review a few of the medical terms which will be employed in the present description. Although the present invention is applicable to other types of artificial joints, it will be described in terms of a knee joint. The lower leg includes two bones, the larger of which is the tibia and the smaller bone along the outer portion of the lower leg being the fibula. The thigh or the upper leg bone is the femur. In the normal human knee joint, the lower end of the femur is provided with two rounded projections. In medical terminology a rounded projection on a bone is known as a "condyle", and one type of artificial knee joint is known as a "condylar" replacement. Various types of total knee replacement prosthesis have been used by orthopedic surgeons, and these range from relatively unconstrained models to fully constrained arrangements. A good survey article is "A Comparison of Four Models of Total Knee-Replacement Prostheses" by J. N. Insall, M.D., et al, The Journal of Bone And Joint Surgery, Vol. 58-A, No. 6, September 1976, Pages 754 through 765. Other medical terms which may be usefully be employed in describing the present invention include the terms "distal" and "proximal" which refer to the "far", and "near" portions of the anatomy on a limb such as the leg; and with reference to the application of a prosthesis to the end of a bone, the end of the bone to which the prosthesis is being secured is referred to as the proximal end, and the other end of the bone is the distal end. Other useful medical terms include the term "cannula" which is defined as a tube for insertion into the body, and the corresponding verb "cannulate", which involves penetration with a cannula. The term "cortex" and the associated adjective "cortical" which refer to the outer layer of a body structure and with regard to bone it is the hard or dense outer portion of the bone, as compared with the inner or "cancellous" bone structure which is normally of a reticular, spongy, or lattice-like structure. Incidentally, the central portion of an elongated bone, such as the tibia, normally has a central channel or canal known as the "medulary" channel, which is free of bone and only includes marrow and other soft tissue.
Now, referring to FIG. 1 of the drawings, the upper end of a tibia 12 is shown provided with an implant 14 which includes a protruding edge or lip 16 which may be provided with an O-ring 17, or other deformable gasket, and which acts to seal the implant 14 onto the surgically shaped transverse planar surface 18 of the bone. The deformable gasket should be formed of latex or other medically inert resilient material. The implant 14 includes a series of passages or multiply bifurcated cannula 20 which permit the application of medical cement to the space between the implant 14 and the inner surface of the tibia 12. The cement is supplied to the cannula 20 through the detachable threaded inlet coupling 22 and the flexible inlet tubing 24 through which the pressurized liquid medical cement is supplied.
A clamp 26 is provided with a series of threaded screws 28 which grip the superficial edge of the tibia and, through the larger hand-operated screw 30 applies a rigid fixation and immobilization force to the implant 14. This clamp 26 serves to keep the prosthesis 14 located securely and tightly on the bone surface while the space within the bone is filled with pressurized medical cement. Incidentally, shown at 32 is a plug of medical cement which had previously been inserted and hardened so that there will not be undue penetration of the pressurized cement along the length of the medulary canal when the implant 14 is being cemented into place.
Following full polymerization or hardening of the medical cement, the threaded inlet port 22 is detached by unscrewing it. The prosthesis clamp 26 is then removed from the bone and the prosthesis and the in situ pressurized fixation technique is now complete.
The medical cement which is employed is normally polymethylmethacrylate. This is available from Howmedica as "Simplex-P" and as Zimmer Bone Cement from Zimmer, and under other trade names in England and Europe. It is supplied as a mix with a liquid monomer and a powdered polymer. Following mixing of the two components there is usually about 10 minutes within which the material may be employed, before it polymerizes and hardens. In some cases, barium sulfate is added to the medical cement so that it is visible in X-ray photographs.
As mentioned above, it normally takes in the order of 10 minutes for the medical cement to fully polymerize and harden. It is a feature of the present invention that pressure is retained on the cement for this entire period of time to insure firm engagement both of the prosthesis and also of the cancellous bone which encloses it.
Referring back to FIG. 1, the implant 14 may, if desired, be provided with one or more fixation ribs or grooves 34 for locking the implant in place and for reducing the likelihood that it will be loosened.
FIG. 2 is an overall schematic showing of one technique for implementing the present pressurized medical cement fixation procedure. In this example, a high pressure nitrogen gas source 38 such as is commonly found in the present day operating room, is employed to drive a pneumatically powered system, or gas pressurized piston arrangement 40. A disposable plastic cylinder 42 is filled with liquid polymethylmethacrylate, and the gas flow control valve 44 is actuated under the control of a time measuring and shut-off control arrangement 46. Connected to the flexible inlet tubing 24 at the over-pressurization safety release valve 48 is a pressurization monitor and recorder 50. In connection with the showing of the implant 14 and the tibia 12, the clamp 26 as shown in FIG. 1 would of course be present, but has been omitted from FIG. 2 for simplicity.
FIG. 3 shows a slightly modified form of implant 62 for the implementation of the present invention. In accordance with the arrangements shown in FIG. 3, the medical cement is supplied through the flexible tubing 64 and the fitting 66 to a single cannula 68 which extends to the lower end of the implant 62. As mentioned hereinabove, there is considerable blood and other fluids which may accumulate within the recess in the end of the bone 12. In accordance with the embodiment shown in FIG. 5, the pressurized cement as it flows through the cannula 68 forces these fluids and body materials up through one or more exit cannula 72 and 74. Then, the space between the implant 62 and the inner wall of the tibia 12 is filled with cement. After all of the extraneous fluids flow through the cannula 72 and 74, and cement starts to emerge from them, they may be closed either by pressing a gloved finger over each of the holes or in any other suitable manner. In the arrangement of FIG. 3, a sharper edge 76 is shown engaging the surgically prepared proximal end 78 of the tibia 12, which may, if desired, by grooved to match the rim of the prostheses.
FIG. 4 is an isometric view of a so-called duocondylar prosthesis, in which, again, an implant 82 for the tibia is shown. Between the two bearing surfaces 84 and 86, which receive the metal prosthesis which is secured to the femur, are shown the inlet opening 88, and one of the two outlet openings 90. The other outlet opening 90 is concealed behind the central ridge of the upper surface of the implant, in the showing of FIG. 4. Incidentally, it may be noted that the inlet and the outlet openings are preferably not included in the bearing surfaces 84 and 86.
Incidentally, the present orthopedic techniques for joint replacement normally involve the use of one component of medically inert stainless steel, and the other being of high density polyethylene. In the present illustrative example, the implant employed at the distal end of the tibia is of the high density polyethylene type. However, the principles of the present invention are applicable to the securing of the metal implants in place, and to implants of other materials.
Tests have been conducted relative to the present method, using unembalmed, frozen and then thawed cadaver tibias. A total condylar tibial prosthesis was cannulated and fitted with plastic tubing connected to a disposable plastic cylinder into which a pneumatic piston could be driven. The proximal tibia was prepared as for a total condylar knee replacement. A polymethylmethacrylate (PMM) plug was placed distally, as shown for example, at 32 in FIGS. 1 and 3. Liquid PMM was added to completely fill the tibial cavity, the prosthesis was inserted, clamped to the tibia, and a fixation clamp as shown at 26 in FIGS. 1 and 3 was applied. Concurrently, a second portion of the PMM medical cement was placed in the plastic cylinder attached to the pneumatic piston. Compressed nitrogen was applied to the piston which in turn pressurized the liquid PMM in the cylinder until an experimental intramedullary pressure of 100 pounds per square inch was obtained. The acrylic in the cylinder was applied under pressure through the prosthesis as the liquid polymer partially penetrated the cancellous bone, and it was maintained at 100 pounds per square inch until complete polymerization occurred. The opposite tibia was used as a control with initial plugging of the distal intramedulary canal and subsequent manual packing of the medical cement followed by the insertion by hand of a non-modified tibial implant otherwise conforming to that which was employed using the principles of the present invention.
The clamped prosthesis prevented leaking of the acrylic cement proximally. At an experimental intermedulary pressure of 100 psi, it was possible to inject up to an additional 30 cc. of cement into the already filled marrow cavity. This indicates that much lower intramedulary pressures or shorter times of pressurization might be used while still achieving adequate PMM penetration.
The results of the tests are shown visually in FIGS. 5A and 5B, and in the second set identified as FIGS. 6A and 6B, with the "A" designating the pressurized sample and "B" representing the control or non-pressurized sample. FIGS. 5A and 5B are low power photomicrographs and FIGS. 6A and 6B are higher power photomicrographs showing the interface between the bone and the acrylic cement. In FIG. 5A and FIG. 5B, the central light colored circular area is a section through the stem of the high density polyethylene prosthesis, and the extended light colored areas in FIG. 5B, at the interface between the PMM and the bone indicate areas of no mechanical chemical contact. In FIGS. 6A and 6B, the photomicrographs are of different density, giving the cement and bone different appearances in the two figures, but the bone in each case is located at the bottom of the figure. With the same enlargement power being employed, the extended areas where there is little or no contact in FIG. 6B clearly show the reason for the much greater strength of the pressurized sample of FIG. 6A.
The conventional specimens from the hand-inserted side showed an average radial penetration of the PMM of 67% from the center of the intramedulary canal, while the average penetration of the pressure-injected side was 80% of the specimen radius.
Strength of materials testing of paired right and left experimental (pressurized) and control (unpressurized) specimen cross-sections were performed on a standard materials testing instrument of the type known as an "Instron Model TM-M" at a strain rate of 10 mm. per minute. In the tests, successive 1 centimeter sections were taken perpendicular to the longitudinal axis of the tibia, the bone cortex was clamped, and the central hardened PMM was mechanically shifted relative to the bone. The statistical mean or average of the results for 30 specimens are shown below in terms of the peak fracture shear stress (in Newton's per square meter), the energy to fracture (in Newton-meters), and the linear range shear modulus (in Newton's per square meter).
______________________________________ New Technique Hydraulic Control pressurization Hand insertion______________________________________Fracture ShearStress (N/m.sup.2) 4.17 × 10.sup.6 1.55 × 10.sup.6Energy toFracture (N-m) 1.20 0.59Linear ShearModulus (N/m.sup.2) 12.1 × 10.sup.6 4.62 × 10.sup.6______________________________________
The pressure fabricated prosthetic units consistently showed a statistically significant increase in shear stress for fracture, fracture energy, and shear stiffness. In analyzing the data, it was interesting to note that a pooled averaging of all the data, as set forth in the foregoing table, had the occasional effect of understating the advantages of the new technique. When the percentage improvement was compared on a sample by sample basis, and the percentages were averaged, however, much more surprising and dramatic results are shown. In particular, the average percent improvement for paired pressurized specimens taken from equivalent cross-sectional levels were as follows: a 388% increase in fracture strength, a 198% higher shear modulus, and 420% greater energy required for fracture (involving average ratios of 4.88, 2.98, and 5.20, respectively). Concerning the pressure to be employed in the securing of prosthesis, it was mentioned hereinabove that a (calculated) pressure of approximately 100 psi (gauge pressure) was employed. It was also noted that the penetration of the cement extended through much of the cancellous bone, approaching the very hard outer cortex of the bone. It is considered possible that somewhat lesser pressures might advantageously be employed to provide a balance between firm securing of the implant to the bone, while permitting somewhat greater flow of bodily fluids to nourish and maintain the strength of the bone.
For completeness, reference will be made to certain additional articles providing background on orthopedic procedures of the type to which the present invention relates. These articles include "Polycentric Total Knee Arthroplasty", by Dr. Matthew D. Skolnick, the Journal of Bone and Joint Surgery, September 1976, Vol. 58-A, No. 6, pages 743 through 748; and "Geometric Total Knee Arthroplasty", by Dr. Matthew D. Skolnick, The Journal of Bone and Joint Surgery, Vol. 58-A, No. 6, pages 749 through 753, September 1976. Attention is also directed to R. S. M. Ling and A. J. C. Lee, U.S. Pat. No. 3,889,665, granted June 17, 1975, which relates to an apparatus for initially inserting medical cement into an intramedulary canal, using peripheral sealing while pressurizing the cement which is being inserted. The Ling patent is apparently solely related to the initial application of cement under pressure, in the absence of the prosthesis, and it is presumed that the prosthesis is later applied to the cement manually and no pressure is employed to seal the implant to the previously located cement, nor is pressure applied while the medical cement is hardening.
In closing, it is noted that the present invention has been described and illustrated in connection with a tibial prosthesis. However, the principles disclosed herein are clearly applicable to other types of artificial joints, such as hip and shoulder joint prostheses, by way of specific example, and to the pressurized cementing of prostheses for such other joints to insure a firm bond. Also, instead of the specific apparatus disclosed herein, other arrangements may be provided for supplying the liquid cement and for holding and sealing the prosthesis in place while the pressurized medical cement is being applied. Accordingly, the present invention is not to be limited to that precisely as shown and disclosed herein. | In order to reduce the incidence of artificial joint failure at the interface where the prosthesis is bonded to the bone by cement, the artificial prosthesis is provided with openings, and is clamped in place to provide a peripheral seal around the end of the bone to which it is being secured. Then the cement is applied through the prosthesis under pressure, and the pressure is maintained until the cement hardens. The prosthesis may be provided with both input and output openings so that, as the cement is forced into the space between the prosthesis and the cortical bone structure, material including blood and marrow contents will be forced out the exit apertures and the pressurized cement will thereafter make good direct contact with both the bone and the prosthesis, to insure a lasting bond. The rim of the prosthesis and the matching bone surfaces may be specially prepared to provide a good pressure tight seal. | 0 |
This application is a divisional of application Ser. No. 07/481,556, filed Feb. 15, 1990, now U.S. Pat. No. 5,079,657.
FIELD OF THE INVENTION
This invention relates to the field of magnetic head systems. More particularly, the present invention relates to improvements for reducing stiction in a magnetic head system. More particularly, the present invention relates to an improved technique for reducing stiction by texturing the surface of the air bearing on the magnetic head slider which supports the magnetic head and lies opposite the disk surface.
BACKGROUND OF THE INVENTION
In conventional magnetic head systems, the magnetic head consists of an electromagnetic arrangement for writing, reading or erasing data on a magnetizable storage medium, movable relative thereto, such as a magnetic disk. Known kinds of magnetic head arrangements include ring electromagnets with an air gap, Hall effect components, magneto-resistive components and inductive electromagnetic arrangements. Typically, for use with a magnetic disk, the magnetic head is attached to a slider and lies opposite the disk surface.
Rotating magnetic disks of the type in which the magnetic head is in contact with the disk surface when the disk is at rest and flies above the disk surface when the disk is rotating at its operating speed are well known in the field. In such types of rotating magnetic disks, the magnetic head, which is supported on a slider, rides on a cushion or bearing of air above the disk surface when the disk is rotating at its operating speed. The slider is movable radially on the disk to be positioned over a selected one of a group of concentric recording tracks. The slider is carried on a suspension assembly connected ultimately to an actuator. The slider and its suspension during normal operation are relatively rigid, but are somewhat fragile when subjected to tangential forces.
Typically, in these conventional magnetic disks, the slider is biased against the disk surface by a small force from the suspension when the disk is not rotating. The slider is in sliding contact with the disk surface from the time that rotation of the magnetic disk is initiated, until the disk reaches a rotational speed sufficient to cause the slider to ride on the air bearing. The slider also contacts the disk surface when the rotation of the disk is slowed to a stop and the rotational speed of the disk falls below that necessary to create the air bearing.
In such magnetic disks, a lubricant is often maintained on the disk surface to prevent damage to the head and the disk during starting and stopping of the disk. An existing problem with such magnetic disks is that after the slider has been in stationary contact with the disk surface for just a short period of time, the slider tends to resist translational movement or stick to the disk surface. This adherence or "stiction" is known to be caused by a variety of factors, including static friction and viscous shear forces. However, "stiction" is aggravated by the presence of the lubricant material on the disk surface which tends to puddle up between the disk surface and the slider when the disk is not in motion and the slider rests on the disk surface. Even in those magnetic disks which have disks with extremely smooth unlubricated disk surfaces, stiction may occur because of the strong intermolecular attraction at the interface between the smooth disk and slider surfaces. "Stiction" causes severe damage to the head or disk when the slider suddenly breaks free from the disk surface, once disk rotation is initiated. Additionally, as the disk begins rotation, substantial forces, caused by "stiction," can be applied tangentially on the suspension, resulting in damage to or destruction of the suspension and possible damage to the disk surface.
In one known technique to overcome the stiction problem in such rotating disk systems, disk rotation is started very slowly so that the slider gradually breaks free from the disk surface. This approach is undesirable because it requires a relatively long period of time to bring the magnetic disk up to operating speed and additionally imparts tangential forces to the suspensions, which is the direction in which they are structurally weakest. In accordance with another technique, the slider and its suspension structure are moved a slight amount in each disk radial direction, a number of times, prior to applying power to rotate the disks at start up. This controlled micromotion has been found to be effective only in a few cases.
It is recognized that higher magnetic recording density requires correspondingly reduced head-to-disk spacing (flying height). At times, the head-to-disk spacing is so decreased that the magnetic head slider comes into contact with the magnetic disk surface frequently during the starting and stopping operation. Furthermore, the flying height may be so decreased that, even during the flying period, if the magnetic disk has flaws, such as tiny projections or dust on the surface, the magnetic disk may be contacted. Under these circumstances, the reliability of a magnetlc recording device greatly depends on the sliding characteristics of the magnetic head slider.
To prolong system life, many approaches to the stiction problem have been proposed. Most of the proposals apply impregnation or coating of lubricating materials to the magnetic disk surface and may improve the slidability. However, with the impregnation of the lubricant in the porous voids in the magnetic disk surface, although an improvement in the slidability results, the head still adheres to the recording medium. If an excessively large amount of a liquid lubricant is applied on the top of the magnetic disk, stickiness between the head slider and the surface of the disk may actually increase. Consequently, not only the number and size of the porous voids in the slider must be controlled purposely, but also the viscosity and quantity of the liquid lubricant must be selected. This requires the use of extremely sophisticated manufacturing techniques.
Another approach addresses the stiction problem by scribing minute circumferential grooves on the magnetic disk substrate. However, this method limits maximum recorded densities by increasing media defects and noise production (spacing modulation) and results in increased manufacturing costs.
U.S. Pat. No. 4,549,238 describes a texturing technique for alumina-titanium carbide thin film heads using a CF4 plasma etching process to selectively remove the surface layer titanium carbide particles. The intention of this process is to reduce the effective hardness of the slider instead of reducing stiction, and thereby reduce wear of the disk upon landing and taking off.
SUMMARY OF THE INVENTION
The present invention relates to an improved technique to reduce stiction which retards take-off and displaces critical lubricants in a magnetic head system. The present invention reduces stiction by texturing the surface of the magnetic head slider. With such texturing, the reliable life of both the disk and the magnetic head are significantly increased, while the data density, in bits per area unit of magnetic storage disks, increases since the distance between the magnetic head and disk surface may be reduced.
In accordance with one embodiment, the present invention utilizes nonuniform etching of chemically identical components of a ferrite slider material due solely to random crystal orientation relative to the exposed air bearing surface. This embodiment may also include the use of nonuniform etching of an inhomogeneous slider material such as that used in composite sliders.
In accordance with another embodiment, the present invention utilizes a photoresist, such as utilized in making printed micro-circuits, to form a pattern. The surface may then be etched to texture it according to the pattern to form the anti-stiction properties. Many controlled and reproducible patterns are possible, as well as controlled etching depth.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the present invention are illustrated in and by the following drawings in which like reference numerals indicate like parts and in which:
FIG. 1 is a perspective view of one example of a head core slier for a rigid magnetic disk drive illustrating the air bearing.
FIG. 2 is a magnified perspective view of a portion of the textured air bearing surface of the slider of FIG. 1 after undergoing the etching process in accordance with a first embodiment of the present invention.
FIG. 3 is a plan view of the magnetic head slider illustrating a pattern created on the air bearing surface, in accordance with a second embodiment of the present invention.
FIG. 4 is a plan view of the magnetic head slider illustrating an alternate pattern created on the air bearing surface, in accordance with the second embodiment of the present invention.
FIG. 5 is a plan view of the magnetic head slider illustrating another alternate pattern formed on the air bearing surface, in accordance with the second embodiment of the present invention.
FIG. 6 is a plan view of the magnetic head slider illustrating a pattern varied on different regions of the air bearing surface, in accordance with the second embodiment of the present invention.
FIG. 7 is a graphical representation illustrating the extent by which the stiction is reduced by patterning the slider air bearing surface in accordance with the present invention.
FIG. 8 is graphical representation illustrating a relationship between the concentration of a phosphoric acid solution and the etching rate, in accordance with a preferred etching technique. The illustrated relationship is for an exemplary plane (110) of the surface of a ferrite single crystal.
FIG. 9 is a graphical representation illustrating a relationship between the rate of etching with the phosphoric acid and the etching temperature in accordance with a preferred etching technique. The illustrated relationship is for an exemplary plane (110) of the surface of a ferrite single crystal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates generally a magnetic slider 10. The slider 10 may be either a monolithic slider composed of polycrystalline ferrites or a single crystal material such as ferrite. In addition, the slider 10 may also be formed of a composite material such as calcium-titanate with alumina. Any of the before-mentioned type sliders 10 are exemplary of bulk type core sliders utilized by a floatingtype magnetic head in a rigid magnetic disk drive. The slider 10 is integrally formed comprising a slider body 12 and a yoke portion 14. The yoke portion in cross section is C-shaped. A recording medium such as a magnetic disk rotates adjacent one surface 16 of the slider body 12. On the surface 16 are formed a pair of parallel air bearing portions 18a, 18b which are spaced apart and extend in the rotating or sliding direction of the magnetic disk. The sliding surfaces of the air bearing portions 18a, 18b have a predetermined height as measured from a recessed portion therebetween. The core slider 10 has a center rail 20 which is formed between the air bearing portions 18a, 18b. The center rail 20 serves as a track portion whose surface has the same height as the air bearing portions 18a, 18b. This track portion includes the magnetic gap 19 used for recording purposes. The magnetic gap 19 and yoke 14 may of course be located in any suitable position. For example, the center rail of the core slider 10 which carries the yoke 14 and the gap 19, may alternatively be omitted and the yoke 14 and gap 19 integrated with one of the side rails. In such a configuration, the side rails would continue to be air bearing surfaces.
Referring now to FIG. 2, in accordance with one preferred embodiment of the present invention, the surfaces of the air bearing portions 18a, 18b, which are formed of either polycrystalline ferrites for monolithic sliders or calcium-titanate with alumina for composite sliders, are textured by utilizing conventional etching techniques such as either chemical etching, reactive-ion etching or ion milling. By etching the surface of the air bearing portions 18a, 18b, the natural inhomogeneity and the mechanical anisotropy of the slider material produces randomly-shaped height variations 22 in random locations relative to the plane of the surface of the air bearing portions 18a, 18b. In an exemplary embodiment, typically for a material such as ferrite, the variations may advantageously be about 1 to 10 microinches in height from the average plane. Generally, the variations are preferably 0-100% of the grain size of the material. The textured surface results from the non-uniform etching rate of chemically identical components of ferrite slider material due solely to random crystal orientation relative to the exposed surface of the air bearing portions 18a, 18b . This embodiment may also include the use of the nonuniform etching rate of an inhomogeneous slider such as is used in composite sliders.
Referring now to FIGS. 3, 4, 5, and 6, a second embodiment of the present invention utilizes the uniform etching characteristics of single crystal material such as ferrite. Patterns which are enlarged for clarity in FIGS. 3, 4, 5, and 6, are created on the surface of the air bearing portions 18a, 18b, using conventional photolithographic techniques. An etching mask is formed of a positive or negative type photoresist, or formed of a suitable masking material such as Cr or SiO or SiO 2 , by vacuum vapor deposition, sputtering, chemical vapor deposition (CVD), or other techniques known to those skilled in the art. This method of forming a mask and the material of the mask are suitably selected in terms of ease and cost of formation and the adhesiveness of the mask to the surface. The ferrite material partially covered by the etching mask is then subjected to an etching process to remove a suitable amount of stock from the non-masked portions of the surface. One such preferred method is described in greater detail at a later point in this application.
The ferrite material is usually etched by an ordinary electrolytic etching or chemical etching method, such as chemical etching, laser-assisted chemical etching, reactive ion-milling, etc. A variety of controlled and reproducible patterns are possible. It is also possible to control the depth of the pattern. FIGS. 3, 4, 5 illustrate the surface of the air bearing portions 18a, 18b patterned in four different exemplary patterns. The second embodiment advantageously produces carefully controlled patterns of predetermined height with minimum material removal, with complete protection of the region around the gap 19, relatively independent of slider material composition and crystallographic variations.
As shown in FIGS. 3 and 4, the etched patterns are preferably formed as repetitions of non-circular curves, as shown at 21 and 23. The surface may be textured with any pattern whereby a recessed area 28 of the pattern forms a continuous boundary connecting the edges of the air bearing and thus forming a path to facilitate fluid communication across the surface of the air bearing to distribute ambient pressure. For example, in accordance with the etched pattern shown in FIG. 3, at 21, the recessed portion 28 preferably extends continuously from an outer edge 30 to an inner edge 32. Alternatively, as shown in FIGS. 5 and 6, the etched patterns are preferably formed as regular geometric shapes of varying size, such as shown at 25 and 27. Furthermore, as shown in FIG. 6, at 27 and 34, it is possible that the pattern may vary in different regions of the air bearing surface. The etched pattern must advantageously provide a maximum reduction of stiction at a leading edge 36 as well as provide stability at a trailing edge 38. In accordance with this principle, the etched pattern may also have smaller geometric shapes at the leading edge and larger geometric shapes at the trailing edge. In the illustrated embodiment, the patterns are chosen to emulate a random variation. Although such randomness is advantageous, even uniform geometric patterning of the air bearing surface is advantageous in reducing stiction.
Referring now to FIG. 7, exemplary values of stiction in grams along the x-axis are graphically represented versus CSS (contact-start-stop) cycles x 1000 along the y-axis. Line 24 represents the extent of stiction as experienced by conventional sliders with untextured air bearing surfaces. Line 26 represents reduced stiction achieved by the textured surfaces of the air bearing portions 18a, 18b. The results shown in FIG. 7 were achieved using the embodiment shown in FIG. 2 with a variation in height from the average plane of 2 microinches. This height variation was created using ion milling.
Although the reasons for the significant reduction in stiction, as shown in FIG. 7, are not completely understood, it is believed that at least some of the benefit is derived from:
A) limited-area contact between the air bearing surface and a static disk;
B) the tendency of the air bearing to wear in a way that causes different portions of the air bearing surface to contact the static disk over repeated use cycles; and
C) the tendency of the interface between the slider and disk to quickly achieve ambient air pressure by virtue of proximity of ambient pressure to the interface.
Referring now to FIGS. 8 and 9, a preferred method of etching, which is both economical and provides an improved degree of dimension accuracy, is described in greater detail. Such a preferred etching technique makes it possible to form minute recesses, grooves or holes that cannot be formed by a conventional machining operation. In accordance with such a method, the surface of an exemplary Mn-Zn ferrite single crystal may be exposed to a solution which contains an amine compound, prior to forming the etching mask on the surface of the ferrite single crystal. Preferably, this preliminary treatment is carried out after the surface is cleaned with an organic solvent or pure water. The Mn-Zn ferrite single crystal may also preferably be annealed prior to the preliminary treatment. The amine compound is preferably selected from alkanol amines such as ethanol amine, diethanol amine or triethanol amine. However, it is also possible to use other amine compounds for example: aliphatic primary amines such as ethyl amine, propyl amine and butyl amine; aliphatic secondary amines such as diethyl amine and dipropyl amine; aliphatic tertiary amines such as triethyl amine; aliphatic unsaturated amines such as allyl amine; alicyclic amines; diamines; triamines; or aromatic amines such as aniline, toluidine and benzyl amine. The selected amine compound is generally used as an aqueous solution. The monocrystalline surface of the Mn-Zn ferrite is immersed in the aqueous solution and cleansed. The concentration and temperature of the amine compound and the immersion time are determined based on the specific amine compound used and the cleaning result desired. The above steps assure increased adhesion between the etching mask and the relevant surface of the Mn-Zn ferrite single crystal, thereby enhancing the dimensional accuracy of the texturing.
This method of etching may be applied to both a single crystal of ferrite or a monocrystalline portion of a Mn-Zn ferrite material. Where a monocrystalline portion of a Mn-Zn ferrite is used, an exposed monocrystalline surface is usually mirror-ground to a desired smoothness with a diamond abrasive grain, in a conventionally known manner. The diamond abrasive used preferably has a grain size of four microns or less. This preliminary surface treatment of the monocrystalline surface is advantageous because a rough monocrystalline surface prior to the etching process produces undesirable effects even if the chemical etching process occurs uniformly over the entire surface area.
A strain adjacent to the surface of the ferrite single crystal to be chemically etched lowers the etching rate of the surface and degrades the dimensional accuracy of the etched crystal. Therefore, it is recommended to remove such a strain prior to the chemical etching process. This may be accomplished by preliminary chemical or ion-beam etching, or annealing (heat treatment) in an inert atmosphere such as N 2 . Advantageously, both the preliminary etching and the annealing are performed for improved results. The annealing operation is generally carried out at a temperature between 200° C. and 600° C., advantageously, between 250° C. and 550° C., for at least 30 minutes. In cases where the Mn-Zn ferrite bar has a glass filler at a magnetic gap or other portions, the upper limit of the annealing temperature is below the melting point of the glass filler.
Alternatively, the preliminary treatment with the amine compound solution may be replaced by a preliminary treatment with a solution of phosphoric acid, which is also effected prior to the application of the etching mask to the surface of the Mn-Zn ferrite single crystal. By this preliminary etching, the Mn-Zn ferrite surface on which the etching mask is formed is etched to a depth of at least 10 angstroms. The phosphoric acid concentration, the etching temperature and the immersion time are determined in accordance with the desired etching depth.
After the monocrystalline surface of the Mn-Zn ferrite is subjected to a preliminary treatment with a solution containing an amine compound or phosphoric acid, the appropriate etching mask is formed on the treated surface, by any known method such as screen printing, or the like. Such a method is selected according to the patterning accuracy and cost required. In accordance with one method, the etching mask may advantageously be formed by exposing a layer of a photo resist to radiation through an appropriate photomask. The photo resist may be either a positive type or a negative type. The etching mask may be formed of a suitable metal such as Cr, or SiO or SiO 2 , by vacuum deposition, sputtering or CVD. The degree of adhesion of the mask to the ferrite surface, the ease and the cost of forming such a mask are contributing factors which determine the type of material and method used in forming such a mask.
The monocrystalline surface of the Mn-Zn ferrite with the appropriate etching mask is then subjected to a chemical etching process. The chemical etching process to form the pattern is carried out, most preferably by using an aqueous solution consisting of water and mainly phosphoric acid. A small amount of other acids such as sulfuric acid may also be used in addition to phosphoric acid. If the content of phosphoric acid is 80% or more with respect to the entire amount of the acids contained in the aqueous solution, the balance is considered to be mainly of phosphoric acid.
Referring now to the graph of FIG. 8, there is shown a relationship, at 40, between the concentration of phosphoric acid in the aqueous solution and the etching rate for a surface in the (110) plane, as an example. As clearly shown in the graph, the etching rate is very high when the phosphoric acid concentration exceeds 80%. It can also be noted that when the concentration exceeds 80% the rate of increase is exponential. In such cases, it is rather difficult to accurately control the etching amount. The etching rate is also influenced by the etching temperature, as indicated at 42, in the graph of FIG. 9. It is desireable to maintain the etching time at a minimum because where the etching mask is formed of a photo resist, the adhesion between the etching mask and the ferrite surface is decreased due to expansion of the photo resist during the period that it is immersed in the etching solution. Additionally, it is also desireable to minimize the etching time, for improved dimensional accuracy of the etched portion.
If the etching temperature exceeds 90° C., the amount of an aqueous component of the etching solution containing phosphoric acid changes to an appreciable extent, and the temperature distribution within the etching solution becomes uneven, whereby the etching amount considerably differs at the local areas of the ferrite surface. For this reason, the etching temperature should be 90° C. or lower, preferably ranging between 50° C. and 90° C.
Since the etching rate is very low when the phosphoric acid concentration is 5% or lower as indicated in FIG. 8, the concentration of phosphoric acid in the etching solution should preferably be maintained between 5-80%. However, the etching temperature and the phosphoric acid concentration of the etching solution may not be limited to those indicated above, particularly when the amount of etching is comparatively smaller and when the etching mask has a high degree of adhesion to the ferrite surface. In this case, other factors also contribute to achieve optimum etching conditions.
Although the invention has been described in terms of the preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of the invention. Accordingly, the scope of the invention is intended to be defined only by reference to the appended claims. | The present invention discloses texturing of the slider air bearing surfaces of the magnetic heads in disk drives to reduce stiction that retards take-off and displaces critical lubricant in a magnetic head system. One embodiment of the present invention utilizes nonuniform etching of chemically identical components of a ferrite slider material due solely to random crystal orientation relative to the exposed surface. Another embodiment of the present invention utilizes a photoresist of a type used in making printed circuit boards, to form a pattern. Subsequently, the surface may be etched to form the antistiction properties. A variety of controlled and reproducible patterns as well as a controlled depth of pattern may be utilized. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims priority of Japanese Patent Application No. Hei 11-14554, filed, the contents being incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a solder bonding method, and an electronic device and a process for fabricating the electronic device, more specifically to a solder bonding method using a solder material containing Sn as a main component, and an electronic device and a process for fabricating the electronic device.
[0003] Recently, in view of the high-speed operation of semiconductor devices, techniques for short wiring lengths have been required. What is noted is flip chip bonding in which specifically solder bumps formed on a semiconductor chip are mounted on a circuit substrate with electrodes formed on, and are melted by heating for bonding.
[0004] The solder bonding method by the conventional flip chip bonding will be explained with reference to FIG. 4.
[0005] First, an electrical wiring 111 is formed of an Al film on a semiconductor substrate 110 with a prescribed device. Next, an electrode 116 is formed of a Ti film 112 , an Ni film 113 and an Au film 114 on an electrical wiring 111 , and a solder bump 118 is formed on the electrode 116 .
[0006] On the other hand, an electrode 130 is formed of a Cr film 122 , a Cu film 124 , an Ni film 126 and an Au film 128 on an alumina substrate 120 with a prescribed circuit. Thus, the circuit substrate 132 with the electrode 130 formed on is formed
[0007] Then, the solder bump 118 on the semiconductor substrate 110 is aligned with the electrode 130 on the circuit substrate 120 , and is heated for the flip chip bonding. Such flip chip bonding makes the connection by means of lead wires unnecessary. The wiring length can be short.
[0008] Conventionally, Pb—Sn (Pb: lead, Sn: tin)-based solder materials have been widely used in the flip chip bonding. However, the Pb contained in Pb—Sn-based solder materials have isotopes, and the isotopes are intermediate products or terminal products of the decay series of U (uranium) and Th (thorium). Uranium (U) and thorium (Th) decay by the emission of He (helium), the solder materials emit α-rays. The α-rays affect the operations of semiconductor devices, often causing the so-called soft errors. In a case that Pb flows into soil, the Pb is solved by acid rain, often affecting environments. From the ecological viewpoint, solder materials containing Pb as a non-main component are required.
[0009] As a solder material which replaces the Pb—Sn-based solder materials, solder materials containing Sn as a main component is noted.
[0010] However, in a case that a solder material containing Sn as a main component is used, because the Ni and Cu in the electrodes 116 , 130 are reactive to the Sn in the solder hump 118 , heat applied by the flip chip bonding produces metal compounds, etc., such as Ni—Sn, Cu—Sn, etc. When the Ni reacts to the Sn, and the Ni film 113 is lost, it is difficult that the bonding between the solder bump 118 , and the electrodes 116 , 130 can be satisfactory because the Ti film 112 , for example, and the solder bump 118 are incompatible with each other. In reliability test, such as a heat-cycle test, etc., the bonding was defective, and conduction, etc. are unsatisfactory. The reliability is poor.
SUMMARY OF THE INVENTION
[0011] An object of the present invention is to provide a solder bonding method, and an electronic device and a process for fabricating the electronic device, which make the bonding satisfactory even by the use of a solder material containing Sn as a main component.
[0012] The above-described object is achieved by a solder bonding method comprising the step of solder bonding a first electrode to a second electrode having a solder bump of mainly Sn on an upper surface thereof, the first electrode and/or the second electrode including a metal layer of an alloy layer containing Ni and P, an alloy layer containing Ni and B, or an alloy layer containing Ni, W and P. The metal layer of an alloy layer containing impurities, such as P, etc. can prevent the Ni of the metal layer from combining with the Sn in the solder bump. Accordingly, good bonded states can be obtained.
[0013] The above-described object is achieved by a solder bonding method comprising the step of solder bonding a first electrode to a second electrode having a solder bump of mainly Sn formed on an upper surface thereof, the first electrode and/or the second electrode including a metal layer of mainly Ni, and the solder bonding step being followed by the step of heat treating the alloy layer. The heat treatment can crystallize the metal layer, whereby the Ni of the metal layer can be prevented from combining with the Sn in the solder bump.
[0014] The above-described object is achieved by an electronic device comprising a first substrate including a first electrode, a second substrate including a second electrode having a solder bump of mainly Sn formed on an upper surface thereof, the first electrode and the second electrode being solder bonded to each other, the first electrode and/or the second electrode including a metal layer of an alloy layer containing Ni and P, an alloy layer containing Ni and B, or an alloy layer containing Ni, W and P. The metal layer of an alloy layer containing impurities, such as P, etc. can prevent the Ni of the metal layer from combining with the Sn in the solder bump. Accordingly, good bonded states can be obtained. Electronic devices having good bonded states can be provided.
[0015] The above-described object is achieved by an electronic device fabrication process comprising the step of solder bonding a first electrode formed on a first substrate to a second electrode which is formed on a second substrate and has a solder bump of mainly Sn formed on an upper surface thereof, the first electrode and/or the second electrode including a metal layer of an alloy layer containing Ni and P, an alloy layer containing Ni and B, or an alloy layer containing Ni, W and P. The metal layer of an alloy layer containing impurities, such as P, etc. can prevent the Ni of the metal layer from combining with the Sn in the solder bump. Accordingly, a process for fabricating electronic devices having good bonded states can be provided.
[0016] The above-described object is achieved by an electronic device fabrication process comprising the step of solder bonding a first electrode formed on a first substrate to a second electrode which is formed on a second substrate and has a solder bump of mainly Sn formed on an upper surface thereof, the first electrode and/or the second electrode including a metal layer of mainly Ni, and the step of heat treating the metal layer being followed by the solder bonding step. The heat treatment can crystallize the metal layer, whereby the Ni of the metal layer can be prevented from combining with the Sn in the solder bump
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a sectional view showing the solder bonding method according to a first embodiment of the present invention.
[0018] [0018]FIG. 2 is a sectional view showing the solder bonding method according to a second embodiment of the present invention.
[0019] [0019]FIG. 3 is a sectional view showing the solder bonding method according to a second embodiment of the present invention.
[0020] [0020]FIG. 4 is a sectional view showing the conventional solder bonding method.
DETAILED DESCRIPTION OF THE INVENTION
A First Embodiment
[0021] The solder bonding method according to a first embodiment of the present invention will be explained with reference to FIG. 1. FIG. 1 is a sectional view for explaining the solder bonding method according to the first embodiment of the present invention.
[0022] First, a semiconductor substrate 10 of a silicon substrate with a prescribed semiconductor device formed on is prepared. Then, a 100 nm-Ti film 12 is formed on the semiconductor substrate 10 by sputtering. The Ti film 12 is patterned into a plane shape of an electrode 16 . The plane shape of the electrode 16 has, e.g., a 70-100 μm-diameter, and a pitch of the electrode 16 with respect to an adjacent one (not shown) is, e.g., 150-210 μm.
[0023] Then, a plated film 14 containing Ni and P (phosphorus) is formed on the Ti film 12 by electroless plating. A thickness of the plated film 14 is, e.g., 6 μm, and a phosphorus content of the plated film 14 may be, e.g., 5-20 wt %. The plated film 14 contains P because the Ni of the plated film 14 is prevented from combining with the Sn in the solder bump. A phosphorus content of the plated film 14 is not essentially 5-20 wt %. It is preferable to set a phosphorus content suitably to obtain a required bonded state.
[0024] A film thickness of the plated film 14 is suitably set so that a satisfactory bonded state can be achieved even when the Ni of the plated film 14 is combined with the Sn in the solder bump 18 by heat applied upon the flip chip bonding to resultantly thin the plated film 14 . Thus, the electrode 16 of the Ti film 12 and the plated film 14 is formed.
[0025] Next, a heat treatment is performed at 400-600° C. for about 0.5-2 hours to crystallize the plated film 14 . The heat treatment is performed for the following reason. That is, the plated film of the Ni film formed simply by electroless plating has amorphous state, and has weak metal combining force and a number of pin holes. Accordingly, when the plated film formed simply by electroless plating is subjected to heat by the flip chip bonding or others, the Ni of the plated film tends to combine with the Sn in the solder bump. A diffusion velocity of the Ni of the plated film 14 formed by electroless plating is higher by 2-3 times a diffusion velocity of an Ni metal plate or a plated film formed by electrolytic plating. As a result, Ni—Sn-based metal compounds are grown by the flip chip bonding in the plated film formed by electroless plating, and the plated film is lost. In the present embodiment, the plated film 14 formed by electroless plating is crystallized by the heat treatment, so that the Ni of the plated film 14 can be prevented from combining with the Sn in the solder bump 18 to thereby produce Ni—Sn-based compounds. Furthermore, as described above, the plated film 14 contains P. Whereby the Ni of the plated film 14 can be furthermore prevented from combining with the Sn of the solder bump 18 . In the present embodiment, the plated film can be formed by electroless plating, which permits the plated film to be formed by simpler process in comparison with electrolytic plating.
[0026] Next, a solder bump 18 is formed of a solder material containing Sn as a main component on the electrode 16 . As a method for forming the solder bump 18 , dimple plating or others, for example, may be used. It is preferable that a Pb concentration of the solder material of the solder bump 18 is, e.g., below 1 ppm. Preferably, an α-ray amount to be emitted from the solder material of the solder bump 18 is, e.g., below 0.01 cph/cm 2 for the prevention of soft errors. Thus, a semiconductor device 19 with the solder bump 18 formed on the electrode 16 of the semiconductor substrate 10 is fabricated.
[0027] On the other hand, a Cr film 22 and a Cu film 24 are formed on an aluminum substrate 20 by sputtering. Then, the Cr film 22 and the Cu film 24 are patterned into a plane shape of an electrode 30 . A diameter of the plane shape of the electrode 30 is, e.g., 70-100 μm, and a pitch of the electrode 30 with respect to an adjacent one (not shown) is, e.g., 150-210 μm.
[0028] Next, a 6 μm-thickness plated film 26 is formed on the Cu film 24 by electroless plating. The plated film 26 may be formed in the same way as the plated film 14 . Then, a 50 nm-thickness Au film 28 is formed by flash plating. The Au film 28 , which is highly reactive to Sn, can contribute to improving a wettability. Thus, the electrode 30 is formed of the Cr film 22 , the Cu film 24 , the plated film 26 and the Au film 28 . Thus, the circuit substrate 32 with the electrode 30 formed on is formed.
[0029] Next, the semiconductor device 19 and the circuit substrate 32 are aligned with each other to be subjected to the flip chip bonding in a nitrogen atmosphere in a reflow furnace. Thus, the semiconductor device 19 is mounted on the circuit substrate 32 , and an electronic device is fabricated.
Results of Reliability Evaluation Test
[0030] Results of a reliability evaluation test made on electronic devices fabricated by using the above-described solder bonding method will be explained with reference to Tables 1-1 to 2-2. Tables 1-1 to 2-2 show results of the reliability evaluation test made on the electronic devices fabricated by using the solder bonding method according to the present embodiment.
[0031] A diameter of the solder bump 18 was 70-100 μm. A pitch of the solder bump with respect to an adjacent one (not shown) was 150-210 μm. Film thicknesses of the plated films 14 , 26 were both 6 μm.
[0032] In the reliability evaluation test, a resistance value was measured immediately after the flip chip bonding, and a heat cycle test (−55° C.-125° C.) was repeated to measure a resistance at every 50 cycle. In Tables 1-1 to 2-2, a residual film thickness means a residual film thickness of the plated film of an Ni-based alloy formed on the circuit substrate 32 . In Controls 1 to 4 , films containing no impurity, such as P, etc., were formed by electroless plating, and the heat treatment was not performed.
TABLE 1-1 P Content in Heat Treatment Heat Treatment Plated Film Temperature Time (wt %) (° C.) (Hours) Example 1 5 400 1 Example 2 5 400 1 Example 3 5 400 1 Example 4 5 400 1 Example 5 15 400 1 Example 6 15 400 1 Example 7 15 400 1 Example 8 15 400 1 Control 1 — None None Control 2 — None None Control 3 — None None Control 4 — None None
[0033] [0033] TABLE 1-2 Content of Residual Elements other Film than Sn in Solder Heat Cycle Bonded Thickness Bump (wt %) (Cycle) State (μm) Example 1 Ag:3.5, Zn:5 Above 300 Good 3 Example 2 Sb:5 Above 300 Good 3 Example 3 Ag:3.5 Above 300 Good 3 Example 4 Ag:3.5, In:5 Above 300 Good 3 Example 5 Ag:3.5, Zn:5 Above 300 Good 4 Example 6 Sb:5 Above 300 Good 4 Example 7 Ag:3.5 Above 300 Good 4 Example 8 Ag:3.5, In:5 Above 300 Good 4 Control 1 Ag:3.5, Zn:5 200 Fair 0-2 Control 2 Sb:5 200 Fair 0-2 Control 3 Ag:3.5 150 Fair 0-2 Control 4 Ag:3.5, In:5 150 Fair 0
[0034] [0034] TABLE 2-1 P Content in Heat Treatment Heat Treatment Plated Film Temperature Time (wt %) (° C.) (Hours) Example 9 5 600 1 Example 10 5 600 1 Example 11 5 600 1 Example 12 5 600 1 Example 13 15 600 1 Example 14 15 600 1 Example 15 15 600 1 Example 16 15 600 1
[0035] [0035] TABLE 2-2 Content of Residual Elements other Film than Sn in Solder Heat Cycle Bonded Thickness Bump (wt %) (Cycle) State (μm) Example 9 Ag:3.5, Zn:5 Above 300 Good 4 Example 10 Sb:5 Above 300 Good 4 Example 11 Ag:3.5 Above 300 Good 4 Example 12 Ag:3.5, In:5 Above 300 Good 4 Example 13 Ag:3.5, Zn:5 Above 300 Good 4 Example 14 Sb:5 Above 300 Good 4 Example 15 Ag:3.5 Above 300 Good 4 Example 16 Ag:3.5, In:5 Above 300 Good 4
[0036] As shown by Controls 1 to 4 in Tables 1-1 and 1-2, the plated film containing no impurity, such as P or others, was formed by electroless plating and was not subjected to the heat treatment, a residual film thickness of the plated film was as thin as about 0-2 μm. Good bonded state could not be maintained. “Fair” indicating a bonded state means “bonded, but the bonded state is not good”.
[0037] In contrast to this, as shown in Examples 1 to 16 in Tables 1-1 to 2-2, the plated films 14 , 26 contained P and were subjected to the heat treatment. Residual film thicknesses of the plated films 14 , 26 was above 3 μm both with a 5 wt % P content and a 15 wt % P content. Good bonded states were maintained.
[0038] As described above, according to the present embodiment, the plated films of Ni films formed by electroless plating are crystallized by the heat treatment, whereby the Ni of the plated films can be prevented from combining with the Sn in the solder bump. The bonded state can be good. In the present embodiment, the plated films are formed by the electroless plating, which makes the step of forming the plated films simple.
[0039] In the present embodiment, the plated film is containing Ni as a main component contain P. Whereby the Ni of the plated films can be prevented from combining with the Ni in the solder bump. The bonded state can be good.
A Second Embodiment
[0040] The solder bonding method according tot a second embodiment of the present invention will be explained with reference to FIG. 2. FIG. 2 is a sectional view explaining the solder bonding method according to the present embodiment. The same members of the present embodiment as those of the solder bonding method according to the first embodiment of FIG. 1 are represented by the same reference numbers not to repeat or to simplify their explanation.
[0041] The solder bonding method according to the present embodiment is characterized mainly in that a plated film 14 a containing Ni and B (boron) is formed on a Ti film 12 , by electroless plating, and a plated film 26 a containing Ni and B on a Cu film 24 by electroless plating.
[0042] The plated films 14 a , 26 a are subjected to the heat treatment as in the first embodiment. Boron contents of the plated films 14 a , 26 a may be, e.g., 5-20 wt %. The plated films 14 a , 26 a contain B, whereby the Ni of the plated films can be prevented from combining with the Sn in a solder pump, as can be prevented by the P in the plated films in the first embodiment. Accordingly, the present embodiment can provide electronic devices having the bonds in good states.
Results of Reliability Evaluation Test
[0043] Then, results of a reliability evaluation test made on electronic devices fabricated by using the above-described solder bonding method. Tables 3-1 to 4-2 show the results of the reliability evaluation test made on the electronic devices fabricated by using the solder bonding method according to the present embodiment.
[0044] As in the first embodiment, a diameter of the solder bump 18 was 70-100 μm. A pitch of the solder bump 18 with respect to an adjacent one was 150-210 μm. Film thicknesses of the plated films 14 a , 26 a were 6 μm as in the first embodiment. The reliability evaluation test was the same as in the first embodiment.
TABLE 3-1 B Content in Heat Treatment Heat Treatment Plated Film Temperature Time (wt %) (° C.) (Hours) Example 17 1 400 1 Example 18 1 400 1 Example 19 1 400 1 Example 20 1 400 1 Example 21 10 400 1 Example 22 10 400 1 Example 23 10 400 1 Example 24 10 400 1
[0045] [0045] TABLE 3-2 Content of Residual Elements other Film than Sn in Solder Heat Cycle Bonded Thickness Bump (wt %) (Cycle) State (μm) Example 17 Ag:3.5, Zn:5 Above 300 Good 4 Example 18 Sb:5 Above 300 Good 4 Example 19 Ag:3.5 Above 300 Good 4 Example 20 Ag:3.5, In:5 Above 300 Good 4 Example 21 Ag:3.5, Zn:5 Above 300 Good 3 Example 22 Sb:5 Above 300 Good 3 Example 23 Ag:3.5 Above 300 Good 3 Example 24 Ag:3.5, In:5 Above 300 Good 3
[0046] [0046] TABLE 4-1 B Content in Heat Treatment Heat Treatment Plated Film Temperature Time (wt %) (° C.) (Hours) Example 25 1 600 1 Example 26 1 600 1 Example 27 1 600 1 Example 28 1 600 1 Example 29 10 600 1 Example 30 10 600 1 Example 31 10 600 1 Example 32 10 600 1
[0047] [0047] TABLE 4-2 Content of Residual Elements other Film than Sn in Solder Heat Cycle Bonded Thickness Bump (wt %) (Cycle) State (μm) Example 25 Ag:3.5, Zn:5 Above 300 Good 4 Example 26 Sb:5 Above 300 Good 4 Example 27 Ag:3.5 Above 300 Good 4 Example 28 Ag:3.5, In:5 Above 300 Good 4 Example 29 Ag:3.5, Zn:5 Above 300 Good 4 Example 30 Sb:5 Above 300 Good 4 Example 31 Ag:3.5 Above 300 Good 4 Example 32 Ag:3.5, In:5 Above 300 Good 4
[0048] As shown by Examples 17 to 32 in Tables 3-1 to 4-2, a residual film thickness of the plated film 26 a was above 3 μm both with a 1 wt % B content and a 10 wt % B content. The bonded states were good.
[0049] As described above, according to the present embodiment, the plated film of Ni film formed by electroless plating are subjected to the heat treatment, and the B contained in such plated films can prevent the Ni of the plated films from combining with the Sn in the solder bump. Electronic devices having the bonds in good states can be provided.
A Third Embodiment
[0050] The solder bonding method according to a third embodiment of the present invention will be explained with reference to FIG. 3. FIG. 3 is a sectional view explaining the solder bonding method according to the present embodiment. The same members of the present embodiment as those of the solder bonding method according to the first or the second embodiment shown in FIG. 1 or 2 are represented by the same reference numbers not to repeat or to simplify their explanation.
[0051] The solder bonding method according to the present embodiment is characterized mainly in that a plated film 14 b containing Ni, W (tungsten) and P is formed on a Ti film 12 by electroless plating, and a plated film 26 b containing Ni and B is formed on a Cu film 24 by electroless plating.
[0052] The plated films 14 b , 26 b are subjected to the heat treatment as in the first embodiment. Tungsten (W) contents the plated films 14 b , 26 b may be, e.g., 5-15 wt %. Phosphorus (P) contents of the plated films 14 b , 26 b may be, e.g., 5-10 wt %. The W and P contained in the plated films 14 b , 26 b can prevent the Ni of the plated films 14 b , 26 b from combining with the Sn in the solder bump. Accordingly, the present embodiment can provide electronic devices having the bonds in good states.
Results of Reliability Evaluation Test
[0053] Next, results of a reliability evaluation test made on electronic devices fabricated by using the above-described solder bonding method will be explained with reference to tables 5-1 to 6-2. Tables 5-1 to 6-2 show the results of the reliability evaluation test made on the electronic devices fabricated by using the solder bonding method according to the present embodiment.
[0054] As in the first embodiment, a diameter of the solder bump was 70-100 μm, and a pitch of the solder bump with respect to an adjacent one was 150-200 μm. Film thicknesses of the plated films 14 b , 26 b were 6 μm as in the first embodiment. The reliability evaluation test was the same as in the first embodiment. A P content was 5 wt %.
TABLE 5-1 W Content in Heat Treatment Heat Treatment Plated Film Temperature Time (wt %) (° C.) (Hours) Example 33 5 400 1 Example 34 5 400 1 Example 35 5 400 1 Example 36 5 400 1 Example 37 10 400 1 Example 38 10 400 1 Example 39 10 400 1 Example 40 10 400 1
[0055] [0055] TABLE 5-2 Content of Residual Elements other Film than Sn in Solder Heat Cycle Bonded Thickness Bump (wt %) (Cycle) State (μm) Example 33 Ag:3.5, Zn:5 Above 300 Good 4 Example 34 Sb:5 Above 300 Good 4 Example 35 Ag:3.5 Above 300 Good 4 Example 36 Ag:3.5, In:5 Above 300 Good 4 Example 37 Ag:3.5, Zn:5 Above 300 Good 3 Example 38 Sb:5 Above 300 Good 3 Example 39 Ag:3.5 Above 300 Good 3 Example 40 Ag:3.5, In:5 Above 300 Good 3
[0056] [0056] TABLE 6-1 W Content in Heat Treatment Heat Treatment Plated Film Temperature Time (wt %) (° C.) (Hours) Example 41 5 600 1 Example 42 5 600 1 Example 43 5 600 1 Example 44 5 600 1 Example 45 10 600 1 Example 46 10 600 1 Example 47 10 600 1 Example 48 10 600 1
[0057] [0057] TABLE 6-2 Content of Elements Residual other than Sn in Film Solder Bump Heat Cycle Bonded Thickness (wt %) (Cycle) State (μm) Example 41 Ag: 3.5, Zn: 5 Above 300 Good 4 Example 42 Sb: 5 Above 300 Good 4 Example 43 Ag: 3.5 Above 300 Good 4 Example 44 Ag: 3.5, In: 5 Above 300 Good 4 Example 45 Ag: 3.5, Zn: 5 Above 300 Good 4 Example 46 Sb: 5 Above 300 Good 4 Example 47 Ag: 3.5 Above 300 Good 4 Example 48 Ag: 3.5, In: 5 Above 300 Good 4
[0058] As shown by Examples 33 to 48 in Tables 5-1 to 6-2, a residual film thickness of the plated films was above 3 μm both with a 5 wt % W content and a 10 wt % W content. The bonded states were good.
[0059] As described above, according to the present embodiment, the plated films of Ni films formed by electroless plating were subjected to the heat treatment, and the plated films contain W and P, whereby the Ni of the plated films can be prevented from combining with the Sn in the solder bump. Accordingly, electronic devices having the bonded states in good states can be fabricated.
Modified Embodiments
[0060] The present invention is not limited to the above-described embodiments and can cover other various modifications.
[0061] For example, a thickness of the plated films is not limited to the above-described thickness and may be suitably set so as to obtain required bonded states.
[0062] Contents of impurities, such as P, B, W, etc. contained in the plated films formed of Ni as a main component are not limited to those of the above-described embodiments and may be suitably set so as to prevent to a required extent, the Ni of the plated films from combining with the Sn in the solder bump.
[0063] In the above-described embodiments, the plated films contain impurities, such as P, etc., but impurities contained in the plated films are not limited to P, etc. The plated films may contain impurities other than P, etc. as long as the impurities can prevent the Ni of the plated films from combining with the Sn in the solder bump.
[0064] In the above-described embodiments, a heat treatment temperature was 400-600° C., and a heat treatment time was 0.5-2 hours. However, they are not limited to them and may be suitably set so that the plated films can have a required crystal state.
[0065] In the above-described embodiments, the solder bump was formed by dimple plating. However, the solder bump is not essentially formed by dimple plating and may be formed by, e.g., using a solder paste, vapor-depositing a solder alloy, or transfer.
[0066] The above-described embodiments exemplify cases that the circuit substrate and the semiconductor device are bonded to each other. The semiconductor device may be any semiconductor device, e.g., LSI or others. The above-described solder bonding method is applicable to fabrication of any electronic device, e.g., fabrication of multi-chip module, etc.
[0067] In the above-described embodiments, alumina substrates are used but are not essential. Any substrate, e.g., resin substrates, such as BT resin substrates, etc., glass epoxy substrates, AlN substrates, etc., may be used.
[0068] In the above-described embodiments, the plated films contain impurities, such as P, etc. However, the plated films may contain no impurity, such as P, etc. as long as the plated films are heat-treated, whereby the Ni of the plated films can be prevented, to a required extent, from combining with the Sn in the solder bump.
[0069] In the above-described embodiment, the plated films are heat-treated, but may not be heat-treated as long as the plated films contain impurities, such as P, etc., whereby the Ni of the plated films can be prevented, to a required extent, form combining with the Sn in the solder bump.
[0070] In the above-described embodiments, the plated films contain impurities, such as P, etc., and are heat-treated. However, the plated films may contain no impurities, such as P, etc. and may not be heat-treated as long as the plated films have sufficient thicknesses, whereby the bonded state can be good.
[0071] In the above-described embodiments, the plated films are formed by electroless plating but may not be essentially formed by electroless plating. The plated films may be formed by another film forming technique, such as electrolytic plating or others. | A solder bonding method comprises the step of solder bonding a first electrode 30 to a second electrode 16 having a solder bump 18 of mainly Sn formed on the upper surface thereof. The first electrode 30 and/or the second electrode 16 includes metal layers 14, 26 formed of an alloy layer containing Ni and P, an alloy layer containing Ni and B, or an alloy layer containing N, W and P. The metal layer of the alloy layer containing impurities, such as P, etc. can prevent the Ni of the metal layer from combining with the Sn in the solder bump. Accordingly, good bonded states can be obtained. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image forming apparatus capable of image formation under optimum image forming conditions in response to the detected image density.
2. Description of the Prior Art
There is already known an apparatus in which an original is illuminated with the light of a determined intensity and is scanned with a photosensor to detect, by the output signals thereof, the light intensities from the background area and image area of said original, whereby the image forming condition such as the exposure or developing bias is appropriately determined according to thus detected information.
In such apparatus, when the maximum output voltage of the photosensor is selected equal to the maximum level of the predetermined voltage range, the minimum output voltage of the photosensor for a usual original is several times smaller than said maximum level. Consequently the maximum value may become unmeasurable if the signal level is so selected to allow sufficiently precise measurement of the minimum value. On the other hand, the measurement of the minimum value may become insufficiently precise if the signal level is so selected to allow precise measurement of the maximum value. Particularly when the original consists of a negative image such as a microfilm, the precision of the automatic exposure adjusting function is often deteriorated since the exposure is generally determined by the maximum output voltage of the photosensor with reference to the minimum voltage thereof.
The appropriate exposure E for a film original is determined in the following manner in relation to the luminance B obtained by logarithmic conversion of the output S of the photosensor receiving the light transmitted by the original. An appropriate exposure En for a negative original is determined by:
En=α.sub.1 B.sub.min +β.sub.1 (B.sub.max -B.sub.min)+γ.sub.1 ( 1)
wherein B min and B max are respectively minimum and maximum luminances obtained by logarithmic conversion of the outputs S min and S max receiving the lights transmitted by the background and image areas of the original, and α 1 , β 1 and γ 1 are constants in which α 1 <0 and β 1 <0. Similarly an appropriate exposure Ep for a positive original is determined by:
Ep=α.sub.2 B.sub.max +β.sub.2 (B.sub.max -B.sub.min)+γ.sub.2 ( 2)
wherein α 2 , β 2 and γ 2 are constants in which α 2 >0 and β 2 >0.
However, linear calculation formulas such as (1) and (2) explained above may reduce the automatically adjustable density range in practice, since the appropriate exposure determined by these formulas may become different from the actually desirable exposure at a high or low image density depending on the characteristics of the photosensitive member, charger or developing bias. Particularly the contrast-dependent second correction term in the foregoing equations (1) and (2) may not be appropriate under certain process conditions and should be non-linearly modified according to whether the image contrast is high or low.
It is therefore considered to adopt non-linear equations for determining the appropriate exposure E by selecting suitable functions f(x) and g(y) for the first and second terms of the foregoing formulas (1) and (2). More specifically the appropriate exposure En Ep are determined by:
En=f(B.sub.min)+g(B.sub.max -B.sub.min)+K.sub.1 ( 3)
for a negative original, wherein K 1 is a constant, and
Ep=f(B.sub.max)+g(B.sub.max -B.sub.min)+K.sub.2 ( 4)
for a positive original, wherein K 2 is a constant. In this manner it is rendered possible to achieve automatic exposure control within the practically realizable range of density and contract in the process.
The above-mentioned formulas (3) and (4) can perform correct exposure control if the light is measured over the entire image area of the original, but the image line is not necessarily positioned in the measureing area if it is locally limited. The probability of presence of image lines within the light measuring area is quite low in certain originals such as patent drawings, so that the calculated exposure fluctuates depending on whether the image lines exist in the light measuring area since the second term of the formula (3) or (4) is a function of the contrast or difference in luminance between the background and image areas of the original. Thus the exact copy density control is not possible as the exposure varies depending on whether the image lines are present in the light measuring area at the detection of the image density. Such situation occurs also at the control of the copy density with other adjusting means.
SUMMARY OF THE INVENTION
In consideration of the foregoing, an object of the present invention is to provide an image forming apparatus capable of appropriate image formation.
Another object of the present invention is to provide an image forming apparatus capable of image density detection with a high precision.
Still another object of the present invention is to provide an image forming apparatus capable of varying the gain of amplifying means according to the maximum and minimum values of the image density.
Still another object of the present invention is to provide an image forming apparatus capable of adjusting the reproduced image density at a high speed.
Still another object of the present invention is to provide an image forming apparatus capable of adjusting the reproduced density by access to memory means storing reproduced density data in response to detected image density.
The foregoing and still other objects of the present invention will become fully apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an electrophotographic copier embodying the present invention;
FIG. 2 is a block diagram of a control circuit therefor;
FIG. 3 is a wave form chart showing the voltage supplied to an illuminating lamp shown in FIGS. 1 and 2;
FIGS. 4-1 and 4-2 are flow chart showing the procedure of exposure control;
FIGS. 5-7 are circuit diagrams showing circuits for detecting the maximum and minimum image densities with two amplifiers; and
FIGS. 8 and 9 are circuit diagrams showing circuits for detecting the maximum and minimum image densities with an amplifier.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now the present invention will be clarified in detail by an embodiment shown in the attached drawings.
FIG. 1 schematically shows an electrophotographic copier embodying the present invention, wherein a microfilm original 1 is illuminated by an illuminating unit composed of an illuminating lamp 2, a spherical mirror 3 and a condenser lens 4, and the light from the original 1 is guided through a projecting lens 5, flat mirrors 6, 7 and a slit 9 of a slit plate 8 and projected onto a photosensitive drum 10. The mirrors 6, 7 are fixed in a mutually perpendicular positions on a support member 11, which integrally moves in a direction A together with the mirrors 6, 7. The mirrors 6, 7 are normally placed in a home position, move in the forward direction in the copying cycle to expose the photosensitive drum 10 to the image of the original 1, and return in the backward motion to the home position after said exposure step. The photosensitive drum 10 is rotated at a constant speed in a direction A indicated by arrow, and the mirrors 6, 7 are moved in synchronization with the rotation of the photosensitive drum 10 at a speed equal to 1/2 of the peripheral speed thereof. Immediately in front of the photosensitive drum 10 there is provided with a slit plate 8 having the aforementioned slit 9.
As explained in the foregoing, the image of the original 1 is split in a slit and focused on the periphery of the photosensitive drum 10 through the slit 9, whereby the periphery of the photosensitive drum 10 is exposed to the entire image of the original 1 by the scanning indicated by arrows A and B. A photosensor 12 is positioned in the vicinity of the slit 9 of the slit plate 8 to receive a part of the projected image reflected by the mirrors 6, 7. The photosensor 12 is used for detecting the image density of the original 1 by sensing the light transmitted by the original 1, thus determining the exposure prior to the image exposure to the photosensitive drum 10. Said detection of the image density with the photosensor 12 is conducted in a preliminary scanning of the original 1 by the mirrors 6, 7 prior to the normal exposure step, and the intensity of the lamp 2 is controlled in response to the light intensity received by the photosensor 12 during said preliminary scanning, thus appropriately regulating the exposure to the photosensitive drum 10 and providing a satisfactory copy of the original.
FIG. 2 is a block diagram of a control circuit for use in the electrophotographic copier shown in FIG. 1, for the purpose of controlling the copy density through exposure control by digital signal processing with a microcomputer. Image density signals obtained by photoelectric conversion in the photosensor 12 are supplied, after amplification in an output amplifying circuit 13, to a maximum sample hold circuit 14 and a minimum sample hold circuit 15. Said sample hold circuits 14, 15 respectively detect the maximum and minimum values of the image density of the original 1, and the maximum luminance information (B max ) and the minimum luminance information (B min ) thus obtained are converted into digital signals in an A/D converter 16 incorporating a multiplexer and are supplied to a central processing unit (CPU) 18 through an I/O port 17.
The sample holding of the maximum and minimum values of said image density signals is conducted at a determined process timing, and the sample signals S 1 , S 2 and reset signals Re 1 , Re 2 are supplied from the CPU 18 to the sample hold circuits 14, 15 through the I/O port 17. The CPU 18 performs data processing as will be explained later in response to the maximum luminance information B max and the minimum luminance information B min , and supplies pulses corresponding to the result of said processing to a phase control circuit 19. A bidirectional transistor (triac) in said phase control circuit 19 is turned on and off repeatedly in response to said pulses, thus performing phase control of the power supply to the illuminating lamp 2. The exposure is controlled in this manner to appropriately regulate the copy density.
Now there will be given an explanation on the aforementioned process in the CPU 18, taking an example of copying from a negative original image.
The appropriate exposure E is determined from the maximum luminance information B max and the minimum luminance information B min supplied to the CPU 18, based on a functional formula involving functions f(x) and g(y) to be explained in the following:
E=f(B.sub.min)+g(B.sub.max -B.sub.min)+K.sub.3 (5)
The functions f(x), g(y) of the maximum and minimum values are stored as a table in a read-only memory (ROM) 20 shown in FIG. 2, wherein f(x) is a function for calculating the reference exposure or the amount of correction in response to the luminance of the background of the original, while g(y) is a function for calculating the amount of correction in response to the difference in luminance between the background area and the image line area of the original, namely the density contrast. The constant K 3 may also be incorporated in the function f(x) or g(y) to obtain K 3 =0, so that the equation (5) is represented solely by the functions f(x) and g(y).
As an example, let us assume that K 3 =0 and that the function f(x) is defined in such a manner that the correction function becomes g(y)=0 at a standard contrast (y=3-4) and at a very low contrast (y=0), and the values of the functions f(x) and g(y) are stored as a table as shown in Tabs. 1 and 2.
TABLE 1______________________________________ x f(x)______________________________________ 5 1 4 2 3 3 2 5 1 7 0 10______________________________________
TABLE 2______________________________________ y g(y)______________________________________ 5 -1 4 0 3 0 2 +1 1 +1 0 0______________________________________
In such case the appropriate exposure E is determined as follows:
Example 1: for B max =4, B min =1:
E=f(1)+g(4--1)=7+0=7
Example 2: for B max =3, B min =2:
E=f(2)+g(3--2)=5+1=6
Example 3: for B max =2, B min =2 (case of no constrast)
E=f(2)+g(2--2)=5+0=5
In the above-mentioned function g(y), a value g(y)=0 is determined by referring to the table in case of y<1, but such table reference can be dispensed with by defining the function g(y)=0 in case of y<y s in which y s is a reference value. The reference value y s may be determined in an arbitrary manner.
The value of the exposure E thus calculated is converted into the number of count from the zero-crossing point of the AC terminal voltage supplied to the illuminating lamp, based on a table shown in Tab. 3:
TABLE 3______________________________________E 12 11 10 9 8 7 6 5 4 3 2 1 0______________________________________n(50) 8 28 39 46 51 55 58 61 64 66 68 68 68 n(60) 8 22 32 37 42 45 48 51 53 54 56 56 56______________________________________
Tab. 3 shows the relationship between the number of count from the aforementioned zero-crossing point in case the illuminating lamp 2 is driven by a commercial AC power supply of 50 Hz or 60 Hz and the exposure obtained by phase control utilizing the triac, and is stored as a table in advance. In Tab. 3 n(50) and n(60) respectively represent the counts at 50 Hz and 60 Hz, and the exposure is limited at a value at E=2. In case the timer performs the counting operation at an interval of 1 μsec., the set time T of the timer for a power supply frequency of 50 Hz is given by:
T=100×n(50) (μsec)
Consequently the time T for the aforementioned example 1, in case of 50 Hz, is given by:
T=100×55=5500 μsec
while that for the aforementioned example 2, in case of 50 Hz, is given by:
T=100×58=5800 μsec.
FIG. 3 shows the terminal voltage wave form of a cycle of the aforementioned illuminating lamp 2. The triac in the phase control circuit 19 is turned off for the set time T of the timer from the zero crossing point a, b or c but is turned on upon expiration of said time T and remains turned on until the next zero-crossing point, thus supplying a current to the illuminating lamp 2 as indicated by the hatched area.
As explained in the foregoing, the copy density can be exactly controlled by the regulation of the exposure by the illuminating lamp 2 in response to the contrast of the image density of the original. In said control, the phase control circuit 19, performing as the regulating means for the copy density, is controlled according to the result of data processing in the CPU 18, conducted by the table of first and second functions f(x), g(y) stored in advance in the ROM 20. FIG. 4-1 shows a flow chart of the procedure for calculating the appropriate exposure.
In the foregoing there has been explained the operation for a negative original, but a similar control is conducted also for a positive original. In such case the first term in the formula (5) is replaced by a function f(B max ), and third and fourth function tables utilized in the data processing in the CPU 18 are stored in the ROM 20 for achieving exact exposure control.
In the foregoing embodiment the function g(y) is so determined that g(y) becomes equal to zero for a standard contrast, but it is also possible to define this function as g(y)=P, wherein P is an arbitrary constant. In such case g(y)=P is reached for an extremely low contrast. On the other hand, if g(y) is so selected to attain g(y)=0 at the standard contrast, there may be employed an equation E=f(x)+K 4 for an extremely low contrast, wherein K 4 is a constant.
More specifically the appropriate exposure E is calculated from the maximum luminance information B max and the minimum luminance information B min supplied to the CPU 18 in such case utilizing functions f(x), g(y) and h(z) as will be explained in the following.
Thus, the appropriate exposure E is calculated, when the difference between the maximum and minimum values of the image density of the original exceeds a determined value (B max -B min ≧determined value), by:
E=f(B.sub.min)+g(B.sub.max -B.sub.min)+K.sub.3 (5)
wherein K 3 is a constant, whereas it is calculated, when said difference is less than a determined value (B max -B min <determined value), by:
E=h(B.sub.min)+K.sub.4 (6)
wherein K 4 is a constant. The functions f(x), g(y) and h(z) of the variables x, y, z responding to the maximum and minimum values are stored, as tables, in the read-only memory 20 shown in FIG. 2, wherein f(x) and h(z) are utilized for calculating the standard exposure or the amount of correction in response to the luminance of the background area of the original, while g(y) is used for calculating the correction in response to the contrast or the difference of the luminances in the background area and image line area of the original. The constants K 3 , K 4 may be incorporated in f(x), h(z) or g(y) to write the equations (5), (6) solely with the function f(x), g(y) and/or h(z).
As an example, let us now assume that K 3 m K 4 =0 and that the function f(x) is defined in such a manner that the correction function becomes g(y)=0 at a standard contrast (y=3-4) while the function h(z) is so defined that the exposure is solely determined by h(z) in case of y<2, i.e. if the contrast is less than a determined value "2", and the values of the functions f(x), g(y) and h(z) are stored as tables as shown in Tabs. 4, 5 and 6:
TABLE 4______________________________________ x f(x)______________________________________ 5 1 4 2 3 3 2 5 1 7 0 10______________________________________
TABLE 5______________________________________ z h(z)______________________________________ 5 2 4 3 3 4 2 6 1 7 0 9______________________________________
TABLE 6______________________________________ y g(y)______________________________________ 5 -1 4 0 3 0 2 +1______________________________________
In this case the appropriate exposure E is calculated as follows:
Example 1: for B max =4 and B min =1:
E=f(1)+g(4-1)=7+0=7
Example 2: for B max =3 and B min =2:
E=h(2)=6.
The appropriate exposure E thus calculated is converted, by the aforementioned table shown in Table 3, into the number of count from the zero-crossing point in the terminal AC voltage supplied to the illuminating lamp 2. The data processing in the CPU 18 is also conducted with the function tables f(x), g(y) and h(z) stored in advance in the ROM 20 used as a memory for storing the amounts of adjustment of the copy density in response to the detected density. FIG. 4-2 shows a flow chart of the procedure for calculating the appropriate exposure.
In the foregoing there has been explained the operation for a negative original, but a similar control is conducted also for a positive original. In such case the first term in the formula (5) or (6) is replaced by a function f(B max ) or h(B max ), and fourth, fifth and sixth function tables utilized in the data processing in the CPU 18 are stored in the ROM 20 for achieving exact exposure control.
In the foregoing embodiment the copy quality or the copy density is automatically controlled by the exposure, but such control can also be achieved by the developing bias or the process speed, and in such case the formula (5) or (6) can be used without change if the function f(x), g(y) or h(z), or the values of the tables stored in the ROM 20, are suitable changed.
Besides the exposure control can be achieved, in addition to the phase control of the illuminating lamp explained above, also by the control of the terminal voltage of or the current in the lamp, and moreover control with a diaphragm or a filter is likewise possible.
As explained in the foregoing, the use of memory means for storing in advance the amounts of adjustment of the copy density in response to the maximum and minimum values of the detected image density and the adjustment of copy density by making access to said memory means in response to the detected values enable easy and accurate adjustment of the copy density even when the density of image line in the original image cannot be detected in copying a film original, thus practically expanding the range of density adjustment and allowing high-speed control based on the already stored amounts of adjustment.
In case of controlling the image forming conditions such as exposure in response to the maximum and minimum values of the image density, it is naturally essential to detect said maximum and minimum values with a high precision.
FIG. 5 shows a control circuit capable of measuring both the maximum and minimum values of the output voltage from the photosensor by suitably varying the gains of two amplifiers in the measurements of said maximum and minimum values.
The light transmitted or reflected by an original is scanned by a photosensor PD (corresponding to the photosensor 12 in FIG. 1) to convert said light into a current I, which is in turn converted into a voltage by a feedback circuit composed of an operational amplifier OP1 and a resistor R1. A condenser C1 is connected parallel to the resistor R1 to intercept the unnecessary high frequency components and to prevent oscillation.
The voltage obtained by conversion in the operational amplifier OP1 is supplied to operational amplifiers OP2 and OP3. A resistor R2 and a condenser C2, and a resistor R3 and a condenser C3 respectively connected to the input terminals of said operational amplifiers OP2, OP3 constitute integrating filters. Also a variable feedback resistor VR2 and a resistor R, and a variable feedback resistor VR3 and a resistor R are respectively connected to the inverted input ports of said operational amplifiers OP2, OP3. In the above-explained structure, the operational amplifier OP2 amplifies the output voltage of the operational amplifier OP1 with a gain of 1+VR2/R. On the other hand the operational amplifier OP3 amplifies the output voltage of the operational amplifier OP1 with a gain of 1+VR3/R.
The output signals of the operational amplifiers OP2, OP3 are supplied, respectively as a maximum level output signal and a minimum level output signal, to an analog-to-digital converter AD, of which digital output signals are in turn supplied to a central processing unit CPU for ordinary image processing whose details will be omitted.
In case a negative image is used for measurement, the variable resistor VR3 is adjusted in such a manner that the output of the operational amplifier OP3 comes close to the reference voltage for the analog-to-digital coverter AD for a negative image with a lowest background density in the normally acceptable range, and the variable resistor VR2 is adjusted in such a manner that the output of the operational amplifier OP2 comes close to the reference voltage of the analog-to-digital converter AD for a negative image with a lowest image line density in the normally acceptable range regardless of the contrast thereof.
Such adjustments allow to achieve light measurement with a high precision, fully utilizing the resolving power of the analog-to-digital converter AD for both of the image line area and the background area of the negative original.
On the other hand, in case a positive image is measured, the variable resistor VR2 is adjusted in such a manner that the output of the operational amplifier OP2 comes close to the reference voltage of the analog-to-digital converter AD for an original with a lowest background density in the normally acceptable range, and the variable resistor VR3 is adjusted in such a manner that the output of the operational amplifier OP3 comes close to the reference voltage of the analog-to-digital amplifier OP3 for an original with a lowest image line density in the normally acceptable range regardless of the contrast thereof.
The analog-to-digital converter AD is provided therein with a multiplexer which alternately introduces the output voltage MAX from the operational amplifier OP2 and the output voltage MIN from the operational amplifier OP3 to the analog-to-digital converter AD in the course of the light measurement in response to signals from the central processing unit CPU. The duty ratio of the output signals MAX/MIN need not be equal to 50%, and the central processing unit CPU can easily modify, by appropriate softwares, the duty ratio for example to emphasize the image line area which is generally more difficult to pick up (i.e. to increase the proportion of the output voltage MAX in case of a negative image), or to vary said ratio according to the scanning position.
As explained in the foregoing, the voltages MAX, MIN introduced into the analog-to-digital converter AD are supplied to the central processing unit CPU after conversion into digital signals. In this step the output voltages MAX and MIN are respectively compared in succession with the maximum and minimum values, so that the data finally remaining at the end of the light measurement represent the data of the image line area and the background area on the negative image. Such data representing the image line area and the background area are used in the known process to regulate the exposure, developing bias etc., thus controlling the image forming conditions to obtain an appropriate image.
If the difference of the gains of the operational amplifiers OP2 and OP3 is already known in the circuit shown in FIG. 5, it is possible, as shown in FIG. 6, to regulate the feedback of the operational amplifier OP1 with a variable resistor VR1 and resistors r1, r2, to replace the resistors R with resistors r3, r4 and to replace the variable resistors VR2, VR3 with fixed resistors r5, r6. In such case the variable resistor VR1 is provided for regulating the gain of the entire circuit in order to compensate the eventual fluctuations in the components such as the photosensor PD.
In the foregoing two embodiments the output voltages MAX and MIN are introduced into the central processing unit CPU on time-sharing basis by means of the multiplexer, but such structures may deteriorate the accuracy of the data because of the limited number of samples in case the converting speed of the analog-to-digital converter AD is low. In such case there may employed sample-hold circuits as shown in FIG. 7. In such case, as already explained before, the light received by the photosensor PD is converted into a voltage by means of a current-voltage converting circuit 21 incorporating an operational amplifier OP1 and supplied then to amplifying circuits 22, 23 of respective gains N, M and incorporating operational amplifiers OP2, OP3. In the present embodiment, the N- and M-times amplified voltages are respectively supplied to sample hold circuits SH1, SH2.
The gains N and M are determined by the density range of the original image in the same manner as explained before.
As already known, the sample hold circuits SH1, SH2 receive reset signals RS1, RS2 and sampling signals S1, S2 from the output ports of the central processing unit CPU.
The sample hold circuit SH1 holds the maximum peak while the sample hold circuit SH2 holds the minimum peak.
The voltages thus held are supplied, as explained in the foregoing, to the analog-to-digital converter AD incorporating a multiplexer in alternate switching. Said switching may be conducted once for each sampling.
It is also possible to repeat the sampling operation several times for each position, and to average the maximum values and minimum values for each position.
In such case it is furthermore possible to make a correction for the shading phenomenon of the lens by taking a weighted average of the sampled data for each position, thus further improving the accuracy.
Furthermore the accuracy of measurement can be improved both for the maximum and minimum values by employing an amplifier and selecting the gain thereof suitably for the maximum measurement and for the minimum measurement. FIG. 8 shows a circuit structure for such embodiment. The light transmitted or reflected by an original is scanned with a photosensor PD to convert said light into a current I, which is in turn converted into a voltage by a feedback circuit composed of an operational amplifier together with an analog switch AS1 and a variable resistor VR1 or with an analog switch AS2 and a variable resistor VR2.
The analog switches AS1, AS2 can be composed of field-effect transistors with insulated gates, and signals MAXS and MINS from the central processing unit CPU render either one of the analog switches AS1, AS2 conductive. For example, when the analog switch AS1 is turned on while the analog switch AS2 is turned off, the amplifier OP provides an output voltage -I×VR1 in which I represents the photocurrent of the photosensor PD and the resistance in the analog switch AS1 is neglected.
On the other hand, in case the analog switch AS1 is turned off while the analog switch AS2 is turned on, the amplifier OP provides an output voltage -I×VR2.
The central processing unit CPU receives the signals in succession from the analog-to-digital converter AD, and selects the reference for comparison for the maximum or minimum value in synchronization with the switching of the analog switches AS1, AS2.
Thus, in case a negative image is measured, the variable resistor VR4 is regulated in such a manner that the output of the operational amplifier OP comes close to the reference voltage of the analog-to-digital converter AD for a negative image with a lowest background density within the practically acceptable range, and the variable resistor VR3 is regulated in such a manner that the output of the operational amplifier OP comes close to the reference voltage of the analog-to-digital converter AD for a negative image with a lowest image line density within the normally acceptable range, regardless of the contrast. In this manner light measurement can be achieved with a high accuracy, fully exploiting the resolving power of the analog-to-digital converter AD for both the image line area and the background area of the negative image.
On the other hand, in case a positive image is measured, the variable resistor VR3 is regulated in such a manner that the output of the operational amplifier OP comes close to the reference voltage of the analog-to-digital converter AD for an original image with a lowest background density within the normally acceptable range, and the variable resistor VR4 is regulated in such a manner that the output of the operational amplifier OP comes close to the reference voltage of the analog-to-digital converter AD for an original image of a lowest image line density within the normally accepted range, regardless of the contrast.
Switching signals MAXS and MINS from the central processing unit CPU activate the analog switches AS1, AS2 alternately to regulate the gain of the operational amplifier OP for the maximum signal MAX and the minimum signal MIN in alternate manner, whereby the operational amplifier OP supplies the analog-to-digital converter AD with output signals representing the maximum and minimum values of the output voltage of the photosensor PD in time-sharing basis. The duty ratio of said switching signals MAXS and MINS need not be equal to 50%, and the central processing unit CPU can easily modify, by appropriate softwares, the duty ratio for example to emphasize the image line area which is generally more difficult to pick up (i.e. to increase the proportion of the output voltage MAX in case of a negative image), or to vary said ratio according to the scanning position.
As explained in the foregoing, the voltage supplied to the analog-to-digital converter AD is supplied to the central processing unit CPU after conversion into a digital signal. In the course of the light measurement said signal is compared, in the operational amplifier OP, with the maximum value or with the minimum value respectively when said amplifier OP has a gain corresponding to the maximum or minimum value, and data finally remaining at the end of the light measurement step represent measured data corresponding to the image line area and the background area of the negative image. Such data representing the image line area and the background area are used in the known process to regulate the exposure, developing bias etc. thus obtaining an appropriate image.
If the difference of the gains for the maximum and minimum values in the operational amplifier OP is already known, it is possible, as shown in FIG. 6, to replace the variable resistors VR3, VR4 with fixed resistors R4, R5, to variably regulate the amount of feedback from the operational amplifier OP whereby the eventual fluctuation for example in the photosensor PD can be compensated by the variable resistor VR5. In such case an analog switch AS3 is serially connected to the resistor R4 but the resistor R5 is not provided with any analog switch. Thus, for the signal MIN, the analog switch AS3 is turned off to obtain an output voltage -I×R5 from the operational amplifier OP in response to the photocurrent I of the photosensor PD, and, for the signal MAX, the analog switch AS3 is turned on to obtain an output voltage -I×R4/R5 from the operational amplifier OP. The present embodiment is characterized by a simpler structure and easier adjustment, since there is employed only one variable resistor VR5 and the central processing unit CPU is required to generate only one switching signal KS to the analog switch AS3.
As explained in the foregoing, the gain of the amplifier is adjusted to the levels suitable for the measurements of the maximum and minimum signals of the photosensor. Thus, for a negative original such as a photographic film, the background density provides the reference minimum output of the photosensor, but it is rendered possible to avoid a situation where the use of a high measuring level deteriorates the accuracy of minimum measurement or the use of a low measuring level hinders the measurement of the maximum output. In this manner the maximum and minimum values can both be measured with a satisfactory accuracy.
In the foregoing embodiment the image density of the original is detected by measuring the light from the original, but it is also possible to detect the image density by forming an electrostatic latent image or a developed image corresponding to the original on a photosensitive member and measuring the surface potential or the developed image density. | There is disclosed an image forming apparatus capable of image formation under optimum image forming conditions in response to the detected image density. The image forming apparatus has image forming unit for forming an image corresponding to an original on a recording material, detector for detecting the image density of the original, and controller for controlling the operable condition of said image forming unit to regulate the copy density in response to the image density detected by said detector said controller includes memory storing control data for the operable condition of said image forming unit in response to the detected image density, and is adapted to make an access to said memory in response to the detection signal of said detector and to control said operable condition according to control data obtained by said access. | 6 |
The present application claims priority from U.S. Provisional Patent Application Ser. No. 60/756,781 filed Jan. 6, 2006. This document is to be expressly incorporated herein in its entirety by this specific reference thereto.
The present invention generally relates to sealing devices which require added sealing performance and as such particularly applies to severe fluid sealing applications such as, for example, a sealing system or structure for a wash-pipe rotary swivel joint used in oil drilling rig top drives.
The present invention is particularly applicable for rotary sealing systems for sealing drilling mud on land or sea-based drilling platforms. The conditions in this operation include a combination of extremely high pressure, up to 7,500 psi, high-speed up to 2000 fpm and high temperature to 350° Fahrenheit or higher.
Drilling pipe diameters are generally from 3 to 5 inches and as a result of high pressure×velocity (PV) conditions, the life of the sealing system is relatively short and unpredictable.
The present invention includes a sealing structure which provides predictability in seal service life which, in turn, prevents costly unplanned downtime and longer sealing system life by useful factors.
SUMMARY OF THE PREFERRED EMBODIMENTS OF THE INVENTION
A rotary fluid-sealing structure using speed reduction stages in accordance with the present invention generally includes a rotatable lower member, a fixed upper member, and an intermediate rotatable member disposed between the lower and upper members.
A first sealing system is disposed between the lower member and the intermediate member and a second sealing system is disposed between the intermediate member and the upper member.
Means, coupling the lower member and the intermediate member, is provided for causing the intermediate member to have a rotational speed lower than a rotational speed of the lower member in order to reduce speed differential across each of the sealing systems.
In accordance with aspects of the present invention, a plurality of intermediate rotatable members may be sequentially disposed between the lower member and the upper member. Thus, sealing systems disposed between adjacent lower intermediate and upper members are provided with lower or reduced speed differentials there across.
In other aspects of the present invention, a fluid-sealing structure may include a spline driven rotatable lower wash pipe, a fixed upper wash pipe, and an intermediate rotatable wash pipe concentrically disposed with the lower wash pipe and having one end thereof disposed over an end of the lower wash pipe and another end thereof abutting a face of the upper wash pipe.
In yet other aspects of the present invention, a rotary fluid-sealing system is disposed between the lower wash pipe and the intermediate wash pipe and a pressure sealing system is disposed between the intermediate wash pipe and the upper wash pipe.
The pressure sealing systems for the reduced-speed stages could use either of several types of fluid seals including an elastrometric V-type packing or an energized lip-seal of a polymeric type plastic material, etc. For this example, the figure shows a pressure seal-system innovation. At each pressure-seal location is a seal system consisting of two pressure-seals separated by a grease-pack. This configuration provides a means of isolating the harsh sealing challenges of both the abrasive media and the high differential pressure.
In certain preferred embodiments, a sun driving gear is disposed on an outer circumference of the lower wash pipe along with a fixed ring gear and a plurality of planetary spur gears, coupled to the intermediate wash pipe, are disposed between the lower wash pipe driving gear and the ring gear in order to cause the intermediate wash pipe to have a rotational speed lower than a rotational speed of the lower wash pipe to reduce speed differentials across each of the sealing systems. Preferably, a rotational speed experienced by each of the sealing systems is half the rotational speed of the lower wash pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention may be more clearly understood by the following detailed description when considered in conjunction with the appended drawings of which:
FIG. 1 is a cross sectional view of a rotary fluid-sealing structure using space-reductions stages in accordance with the present invention generally showing a lower member, and intermediate member, and an upper member along with two sealing systems and a sun-driving gear, ring gear with planetary spur gears disposed therebetween;
FIG. 2 is a cross sectional view taken along the line 2 - 2 of FIG. 1 showing the planetary gear system; and
FIG. 3 is a view taken along the line 3 of FIG. 2 illustrating an individual planetary gear engaging the sun-driving gear and the ring gear.
DETAILED DESCRIPTION
With reference to FIG. 1 , a rotary fluid-sealing structure 10 provided in accordance with aspects of the present invention is shown, which includes a rotatable lower member, or wash pipe, 12 which is driven by a shaft spline 14 for a lower drive collar (not shown) along with a fixed upper member, or wash pipe 20 , with an intermediate rotatable member, or wash pipe 24 , disposed between the lower wash pipe 12 and upper wash pipe 20 as will be hereinafter described in greater detail. The fluid-sealing structure 10 may be useable with a land or sea-based drilling platform comprising drivers, such as motors and pumps, a rotating drill string, a hoisting structure, and means for circulating drilling fluid.
A first pressure sealing system 28 is disposed between the lower member, or wash pipe, 12 and the intermediate member, or wash pipe, 24 . The first sealing system 28 , is a media-isolation sealing system and is configured to isolate two harsh conditions of a hard to seal media, i.e. drilling mud that is both abrasive and non-lubricating and a high-pressure differential. The components of the sealing system 28 , namely a floating seal 30 , a rear seal 32 and a grease pack, or lubricating fluid, 34 , are preferably selected to withstand adverse conditions. In operation, the media isolation system functions as follows:
The media pushes on the floating barrier lip seal 30 , which is typically a U-cup lip seal that can be spring and media pressure energized. Behind the floating seal 30 is a lubricating fluid 34 , usually grease, that transfers pressure to the rear seal 32 and provides lubrication for the sealing system 28 to increase surface life. The floating seal 30 then floats a small distance to maintain the pressure on the grease pack, or lubricating fluid, 34 .
A second sealing system 38 is disposed between the intermediate wash pipe 24 and a face 40 of the upper wash pipe 20 and includes a floating seal 44 , a rear seal 46 , and a grease pack, or lubricating fluid, 48 disposed there between. The second sealing system 38 , is a media-isolation sealing system similar to the sealing system 28 described above. The two seal system may be known as pressure seals in the relevant art.
It should be appreciated that while the wash pipe drive system, or structure, 10 is shown with one intermediate wash pipe member 24 , an arrangement with multiple identical or similar intermediate wash pipes may be incorporated to further reduce PV values on the seal systems to provide a longer service life, only two seal systems 28 , 38 being shown. As further discussed below, a respective epicyclic gearing or planetary gearing system would further reduce the rotational velocity of each successive intermediate wash pipe to thereby reduce the PV values and therefore increase seal performance and seal life.
With reference also to FIG. 2 , a sun-driving gear 52 is disposed on a circumference 54 of the lower wash pipe 12 along with a fixed ring gear 58 and a plurality of planetary spur gears 60 provide a means, coupling the lower wash pipe 12 and the intermediate member pipe 24 , for causing the intermediate wash pipe 24 to have a lower rotational speed than a rotational speed of the lower wash pipe in order to reduce speed differentiation across each of the sealing systems 28 , 38 .
It should be appreciated that while a geared system is provided for coupling the lower wash pipe 12 and the intermediate wash pipe 24 for exemplary purposes, the drive system could incorporate any of several drive mechanisms or means (not shown) such as chains, belts, other mechanical drive systems, an electric motor system, a hydraulic motor system or pneumatic motor system. All of these couplings for reducing the speed between the lower wash pipe 12 and intermediate wash pipe 24 are to be considered within the scope of the invention.
In accordance with the present invention, the intermediate wash pipe 24 rotates at a reduced speed, perhaps 50 percent, relative to the lower wash pipe rotation and thus the two sealing systems 28 , 38 will experience lower speed differential there across, which provides for reduced PV values and therefore an increase in seal service life.
In operation, the sun-drive gear 52 meshes with the planetary spur gear 60 , which in turn meshes with the fixed ring gear 58 to obtain a speed reduction that is determined by the gear ratios. The spur gear 60 may be coupled with the intermediate wash pipe 24 by pins 64 .
More particularly, the intermediate wash pipe 24 may be supported at an upper end 66 by a bushing 68 and a plurality of spring energized lip seals 72 , 74 , 76 Lubricating oil is provided in a cavity 78 for lubricating the drive gear 52 , ring gear 58 , and plurality of planetary gears 60 .
The sealing system 28 bears against a retaining ring 82 which provides a fixture for supporting a bushing 84 for a lower portion 88 of the intermediate wash pipe 24 . Similarly, a retaining ring 92 supports a bushing 68 , and retaining ring 119 supports a bushing 94 .
The structure 10 is assembled with a wash pipe top nut 96 screwed to threads 100 on the fixed upper wash pipe 20 along with bolts 102 , 104 , 106 , 108 , 110 . Relief ports 114 , 116 are provided to divert any media leakage, which eventually migrates past the pressure seals, away from any critical components such as the centering bushings 68 , 84 and the planetary gear 60 . Spring energized low friction lip seals 72 , 74 , 118 are placed, as shown, to confine any leakage from the sealing system to the relief ports 114 , 116 .
Although there has been hereinabove described a specific rotary fluid-sealing structure using speed-reduction stages in accordance with the present invention for the purpose of illustrating the manner in which the invention may be used to advantage, it should be appreciated that the invention is not limited thereto. That is, the present invention may suitably comprise, consist of, or consist essentially of the recited elements. Further, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein. Accordingly, any and all modifications, variations or equivalent arrangements which may occur to those skilled in the art, should be considered to be within the scope of the present invention as defined in the appended claims. As examples, grease ports may be incorporated to replenish the grease packs, each sealing system may include multiple seals having multiple grease packs positioned there between to gradually reduce the seal back pressure for the subsequent seal stages, and using split-housings where applicable for ease of maintenance and repairs, just to name a few. | The present invention provides for a rotary fluid-sealing structure for a harsh environment which reduces the PV pressure (×velocity) that a sealing system may be exposed through the use of a rotary speed reducing planetary gear system. The system may have multiple stages with the amount of velocity reduction produced by the system being determined by the number of stages and the planetary gear ratios. Several alternatives are presented for the sealing under extreme conditions such as found in the interface between a wash-pipe and a rotary drilling string in a drilling rig. | 4 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/147,888, filed Jun. 8, 2005, which claims priority to U.S. Provisional Patent Application Ser. No. 60/577,860, filed Jun. 8, 2004, the entire content of each of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to AC magnetic tracking systems and, in particular, to detecting and establishing phase coherency between magnetic signal sources and sensors.
BACKGROUND OF THE INVENTION
[0003] Position and orientation tracking systems (“trackers”) are well known in the art. For example, U.S. Pat. Nos. 4,287,809 and 4,394,831 to Egli et al.; U.S. Pat. No. 4,737,794 to Jones; U.S. Pat. No. 4,314,251 to Raab; and U.S. Pat. No. 5,453,686 to Anderson, are directed to AC electromagnetic trackers. U.S. Pat. No. 5,645,077 to Foxin discloses an inertial system, and combination systems consisting of two different trackers, such as optical and magnetic, are described in U.S. Pat. No. 5,831,260 to Hansen and U.S. Pat. No. 6,288,785 B1 to Frantz et al. Other pertinent references include U.S. Pat. No. 5,752,513 to Acker et al. and U.S. Pat. No. 5,640,170 to Anderson.
[0004] In the classical AC magnetic tracking system there typically is a single, static source of the three-axis fields which can be detected by multiple sensors which are free to move about a nearby volume ( FIG. 1 ). Past magnetic systems wishing to cover more distance have created a larger source and driven it at high energy levels and then often even enlarged on that. This approach (see FIG. 2 ) always has proved difficult since the magnetic near field drops off as the third order of range from the source. That is, the signal is proportional to 1/r 3 .
[0005] Another factor is the error signal caused by magnetic signals creating responses that distort data because of eddy currents induced in nearby conductive materials. Although there is controversy over whether distortion is less or greater for pulsed DC or for AC magnetic trackers, in general there is very little difference if the objective is to obtain updates of tracking data very rapidly where stretching of the pulsed DC cycle to allow transients to decay prior to data collection is not allowed.
[0006] Although the desired direct magnetic signal and the eddy current distortion signal in theory maintain a constant ratio with energy level, there is a nonlinear phenomenon which alters this constant ratio. When operating at or above the signal level where the nonlinearity occurs, proportionality holds. Consequently, increasing source drive in order to increase operating range creates no benefit over most of the volume because distortion continues as a serious problem. Hence, a large magnetic field source is quite limited in extending operating range. Reversal of the source and sensor roles here offers an alternative for covering a larger volume.
[0007] If the source drive level is kept low such that the effects of secondary fields from eddy currents tends to fall at or below the noise floor of the sensing circuitry, that is the source-sensor coupling range is kept short, distortion is rarely a significant problem. In short, the nonlinearity of the noise floor acts as a natural “filter” against the weaker eddy current fields, which must cover much more distance to where the eddy currents are generated and onward to the sensor than does the direct signal. Therefore, if we were to distribute multiple sensors along the periphery of a volume that exceeds the normal source-sensor operating range, then a small, low power source acting as a “sensor” offers the opportunity to track an object over a large volume (see FIG. 3 ) without eddy current distortion being a derogatory factor.
[0008] Of course, operation of several static sensors in order to track a source pseudo-“sensor” raises the issue of maintaining several movement reference points in the volume. That is, there can be one at each sensor. The track of position and orientation (P&O) reported out to the host computer must be referenced to a common point. This point could be one of the sensors or some arbitrary point known by the system. Fortunately, referencing movement back to a common point is a relatively simply geometry problem with somewhat more complex bookkeeping of the various known sensor data points and the computation of track data. The benefits that make this worthwhile are avoidance of raising eddy current distortion and still maintaining strong signals throughout a large volume.
[0009] What makes this tracking over a larger area difficult is the incoherency of signal frequencies between a remote wireless source and the tracking sensor(s). Tracking of both regimes of sensors from a source and sources from one or more sensors ( FIG. 4 ) has been done for many years as long as they are connected to a single set of electronics. However, existing systems do not provide the freedom to move through a 3D volume with or without being wired.
[0010] Initial landmark AC tracker literature made no distinction between whether the source or the sensors were static or moving. It simply states that the position and orientation (P&O) reported was the P&O relative to each other. In some later disclosures the concept of making the source(s) move and leaving the sensor(s) static was given innovative stature nevertheless. However, the systems cited remained tethered through cabling and greatly simplified the engineering problem of signal detection, synchronization and tracking.
[0011] The advent of microcircuits improved battery longevity and more sensitive receiving circuitry as well as providing significantly more cost effective processing. This has made possible wireless field sources which can generate detectable signals of sufficient strength for tracking and do so for at least an hour before battery re-charging. The consequence of this situation is that small 3-axis field sources now offer a way to achieve wireless P&O tracking without the need of radio links if on-the-fly signal detection and synchronization can be provided for small wireless field sources.
[0012] Several previous patents deal with tracking the movement of passive sensors relative to a stationary source of AC magnetic fields. U.S. Pat. No. 4,054,881 to Raab is one example, Tracking of remote sources with sensors is one subject of U.S. Pat. No. 6,188,355 to Gilboa. Gilboa also discusses the source being wireless under several constraints for achieving synchronization between the source signals and the sensors. In one embodiment there is a requirement to switch the wireless source and the tracking sensors back and forth between transmit and receive in order to obtain synchronization between them. In another embodiment there is a requirement that the three frequencies generated, one for each leg of the transmitting coil, be harmonically related. In yet another embodiment reception of a threshold triggering event at the wireless source in order to start all transmitted signals in unison is explained. These constraints, plus a requirement to perform calibrations at over 32 position and 32 orientation settings, leads to significant complexity, considering that phase adjustments are subject to drift over time.
SUMMARY OF THE INVENTION
[0013] In an AC magnetic tracker this invention broadly enables one or more multi-axis field sources, each operating at a different frequency, or frequency set, to be detected and tracked in three-dimensional space, even when wireless or otherwise not physically connected to the tracking system. Multiple sources can be tracked simultaneously as they each operate with their own unique detectable set of parameters.
[0014] According to a preferred method, three transmitted frequencies are computed at a receiver having three receiver coils, resulting in nine complex numbers, each with real and imaginary components. The phase of each frequency is rotated to remove its imaginary component and apply the correct sign to its real component. The frequencies are summed by restricting the complex values to two quadrants to avoid cancellation, resulting in eight possible phase combinations. The four phase combinations that lead to phase-adjusted matrices with a negative determinant are eliminated, as are three of the remaining four possible combinations that lead to phase-adjusted matrices which are rotated 180 degrees in azimuth, elevation, or roll. The position and orientation (P&O) of the receiver is then computed using the remaining phase-adjusted matrix.
[0015] The step of eliminating three of the four combinations is preferably based upon a procedure invoked during system initialization. For example, the method may further include the steps of orientating the transmitter and receiver to a known condition with wide tolerances; computing the P&O for the remaining four possible phase-adjusted matrices; and using the matrix that with the P&O solution having the best match to the correct transmitter phases. The transmitter and receiver are preferably oriented at ±90 degrees.
[0016] The method may further include the step of updating the identification of the remaining matrix between P&O solutions to compensate for phase drift. The nine complex numbers may be arranged as a matrix, with rows being indicative of receiver coil and column being indicative of frequency. The remaining phase-adjusted matrix may be determined by controlling the manufacturing process such that all magnetic sources have the same physical parameters.
[0017] The invention not only provides the ability to uniquely identify one or more sources by their frequencies, but also to synchronize with these frequencies in order to measure signals that then allow tracking the position and orientation (P&O) of the source(s). Further, these sources need not be present at the time of system start-up but can come and go while being detected, discriminated and tracked.
[0018] A source may be tracked if it is wireless and battery-operated or powered by another system due to the ability to synchronize and achieve coherency. Also, due to the reciprocity between ‘sources’ and ‘sensors’ as discussed above, inverse operation is also possible; that is, where it is desirable to synchronize one or more sensors with a source having a known phase.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a block diagram of a typical AC magnetic tracking system;
[0020] FIG. 2 is a block diagram showing how past magnetic systems wishing to cover more distance have created a larger source and driven it at high energy levels;
[0021] FIG. 3 shows how, if one were to distribute multiple sensors along the periphery of a volume that exceeds the normal source-sensor operating range, then a small, low power source acting as a “sensor” offers the opportunity to track an object over a large volume;
[0022] FIG. 4 is directed to the reciprocity of the tracking relationship; and
[0023] FIG. 5 depicts a wireless source(s) whose signals are detected by a true sensor connected to an electronics unit.
DETAILED DESCRIPTION OF THE INVENTION
[0024] If one desires a remote “sensor” to track, it really does not matter whether the source or sensor is tracked because the P&O calculation is the relative position and orientation between source and sensor. If adequate sensitivity and low noise performance can be achieved with the sensor and a means can be found to determine the source frequency/frequency set and become synchronized with this external source of orthogonal fields, then the source can be remotely disposed as a “pseudo-sensor.” Furthermore, once this is accomplished and there is no constraint placed on the source signals except that they create signals from a frequency population consistent with the system, there can be sources both wireless and wired being tracked as pseudo-sensors. Applicable wireless configurations are disclosed in U.S. patent application Ser. No. 11/147,977, the entire content of which is incorporated herein by reference.
[0025] The reciprocity of the tracking relationship is shown in FIG. 4 , where two “sensors” ( 1 ) are being detected by a single true sensor ( 2 ) and processed by tracker electronics ( 3 ) for output to a host computer. Furthermore, we could have a wireless source(s) ( FIG. 5 ) as the “sensor” ( 1 ), whose signals are detected by a true sensor ( 2 ) connected to the electronics unit ( 3 ).
[0026] The first issue to be resolved when a field source enters the region where tracking is to occur is to determine the operating frequency of the source signal(s). If that source is hardwired into the system and also driven by the electronics unit, the frequency is known. If it is wireless or being driven by other electronics its frequency must be determined. This can be accomplished by using the sensor coils as a probe for detecting energy in the environment. The software resident in the tracker DSP can be made to perform a Fourier analysis of the signals read in to identify if frequency/frequencies in the design set for the system are detected. Only a small portion of the spectrum needs to be analyzed since the candidate operating frequency range always will be known.
[0027] The frequency range typically is from a few thousand Hertz to no more than 40 kHz, which does not require a great deal of time to analyze. Digital filtering with the DSP can then be set at the frequencies detected in order to extract the various geometric components of signal coupling from each source coil to each sensor coil. Further, since the set of frequencies existing in the overall system design would always be known, the spectrum scanning can be made very rapid with little concern for aliasing the frequency since only an approximate value is required. The known design frequency nearest the indicated frequency always can be concluded from the indication extracted.
[0028] It is important that the signal detection circuitry and algorithm remain efficient because it must run essentially continuously in the background so that the tracker is always able to acquire a source entering the area of a sensor and release a source exiting such an area in real-time. Of course there is the possibility of interfering signals or noise that could lead to a false conclusion so that adequate signal-to-noise margin must be set into the spectrum analysis algorithm as well.
[0029] The next problem is to effect synchronism with the source signal(s) in order to optimize data collection. One way of doing this is explained as follows. A typical tracking device generates and samples magnetic fields using data converters whose sampling rate is derived from a single clock source. This is commonly referred to as coherent sampling. One significant advantage of this is that the frequency being detected is exactly the same as the one being generated, and the phase relationship between the current flowing through the magnetic field source and the voltage across the magnetic field sensor is constant and can be easily measured. This is important because the phase relationship is used when computing the transfer function between the sensor voltage and source current, one of the steps in computing position and orientation. It is also the only obstacle to overcome in a non-coherent system once the transfer function is properly computed the subsequent steps are identical to a coherent system.
[0030] To understand how a non-coherent system makes up for not knowing the phase relationship, it is helpful to review in detail how a coherent system operates. As previously stated, the requirement is to compute the transfer function between the sensor and source. The tracker DSP measures signals from the source and sensor using a Fourier transform which produces a complex result for each time-series input. This produces two signal matrices V and I where V is a 3×3 sensor voltage matrix and I is a 3×3 source current measurement. Depending on the signal conditioning circuitry, it also may be necessary to adjust the magnitude and phase of either or both results to compensate for fixed delays in the electronics. The result from the source measurement is then multiplied by the matrix
[ jω x 0 0 0 jω y 0 0 0 jω z ]
to produce the time derivative of the sinusoidal waveforms (j indicating imaginary part or imaginary number √−1; ω=2πf). At this point the phase differences between the same columns of both matrices are 0 or π. To compute the transfer function between source and sensor, the sensor matrix V is multiplied by the inverse of the source matrix dI/dt, all operations using complex numbers. The resulting matrix will contain zero (or as close as the system accuracy yields) imaginary components. The signal magnitudes will be in the real component, along with the proper sign. The real components are then used in the subsequent calculations.
[0031] In a system where the tracker DSP can only measure the sensor signal (one example of a non-coherent system) the transfer function must be computed where the source current is somehow indirectly determined. The magnitude of the source current can be a certain value either guaranteed by design or determined during the calibration procedure of the source and then loaded into the sensor electronic memory but the correct source phase is still unknown.
[0032] The determination of the correct source current phase involves a novel ‘process of elimination’ to resolve phase ambiguity. Position and orientation (P&O) computation begins with computing the 3 transmitted frequencies as received by each of the 3 receiver coils. This is typically done by a Fourier analysis of several hundred points of time-domain data. For convenience, the resulting 9 elements are arranged in a 3×3 matrix of complex numbers, each row representing one of the receiver coils and each column the transmitted frequency.
V = [ v 11 v 12 v 13 v 21 v 22 v 23 v 31 v 32 v 33 ]
Rotating the phase of each column by the phase of the corresponding transmitter current effectively zeroes out the imaginary component and applies the correct sign to the real component, Rotating the phase is the process of adjusting each element of the signal matrix above with the corresponding source phase. With the exception of the 0 or π ambiguity, the phase of the source is equal to the phase of the sensor divided by j. Each column of the above matrix corresponds to one of the three individual source phases. One element of each column could be used to resolve the phase ambiguity, but it is best to sum all three elements of the matrix column, as in a weighted-average filter, since signal to noise ratio (SNR) limitations can adversely affect computations. Because the elements may have different signs for positive and negative received signals, it is necessary to restrict the complex values to 2 quadrants to avoid canceling out as they are summed. This is allowable since there is already a 180 degree uncertainty. Which 2 quadrants the data is constrained to depend on the relative magnitude of the real and imaginary portions. Failure to observe this precaution will result in erroneous results as the phase is close to a multiple of pi/2 and system noise is greater than the sine or cosine of the phase angle. The 2-quadrant summations of each column of the receiver voltage matrix are computed as follows, where i is the row number and j is the column number.
ϕ j ′ = ∑ i = 1 3 sign ( Re ( v ij ) ) × v ij
ϕ j ″ = ∑ i = 1 3 sign ( Im ( v ij ) ) × v ij
[0033] The real component of φ′ j is compared to the imaginary component of φ″ j . The summation with the largest term is normalized to unity magnitude and used as the trial phase φ″ j . The following pseudo-code demonstrates this.
if
Re (φ′ j )> Im (φ″ j )
then
φ″ j =φ′ j /|φ′ j |
else
φ″ j =φ″ j /|φ″ j |
[0034] Given the 180 degree uncertainty of each trial phase, eight combinations are possible, but only one gives the right P&O solution. Four of the possibilities can be eliminated right away because they will produce a phase-adjusted matrix with a negative determinant, which is invalid. Of the remaining four, the three incorrect combinations manifest themselves with P&O solutions that have incorrect signs in the x, y, or z measurements or are rotated 180 degrees in either azimuth, or elevation, or roll. A procedure invoked by the user during system startup resolves the ambiguities. With the receiver to transmitter orientation set to a known condition with very wide tolerances (i.e. ±90 degrees), the tracker computes P&O for all four phase-adjusted matrices. The orientation solution that matches the known condition closest used the adjusted matrix with the 3 correct transmitter phases φ 1 , φ 2 and φ 3 .
[0035] After the initial determination of transmitter phases, they must be continuously updated due to the fact that the phase relationship drifts over time due to the inexactness of time bases of the two systems. To address this problem, for each P&O solution, the trial phases are computed as above. The same uncertainty exists as before, but it can be resolved by using the phase which is more similar to the previous solution's phase. Therefore, no restrictions on movement are needed after initial determination of correct phase.
[0036] One consequence of operating wirelessly is that there will be a natural tendency to extend the range of operation between transmitter and receiver. To overcome the weak signals that come with extended range, it is possible to add more transmitters or receivers, whichever type of device remains wired to the electronics unit. For example, if a transmitter is wireless and tracked, several receivers can be distributed about a larger volume. If all receivers are sampled simultaneously, the trial phase summations can run through all receiver signals.
[0037] To complete the position and orientation calculation the magnetic moment of the source is determine as follows.
M = [ m x ϕ 0 0 0 0 m y ϕ 1 0 0 0 m z ϕ 2 ] ,
where m is the current times the effective area of each source winding. Matrix S, normalized signal matrix, is computed from actual data collected by the tracker DSP as follows.
S=V•M −1
Once this normalized signal matrix is created, the teachings of U.S. Pat. No. 4,737,794, incorporated herein by reference, can be used to complete the position and orientation calculation.
[0038] In order to track another pseudo-sensor source that may enter the environment of a sensor, the same Fourier analysis to determine frequency is done and same process for determining the phase relationship. When one of these “sensors” moves onward to where another true sensor detects it, the frequency may unavoidably be detected again, but the phase relationship just discovered can be passed along internally from the first sensor. Operation continues in this way as movement passes through the sensors and as the detectable number of pseudo-sensor sources comes into range. The P&O of the pseudo-sensors is computed based on the sensor geometry and the reference point established. The true sensors must be positioned at known P&O from the single reference point in order to do this. Computation of pseudo-sensor P&O can be performed either in the tracker electronics unit or in the host computer.
[0039] One additional event occurs when the number of true sensors on a tracking unit is exhausted but additional movement range is desired. Then an additional tracker system with known P&O of its sensors can be added and tied back to the same host computer. The second tracker system simply goes through the same frequency detection process and synchronization as the first system to perform tracking of the pseudo-sensor(s).
[0040] A final point for wireless pseudo-sensor sources concerns their characterization matrix. This set of data normally is retrieved at power up from a PROM incorporated in a tracker source or sensor. It is impossible in this case for a wireless source to provide such a characterization PROM, so such data sets must be pre-loaded into the Tracker Electronics Unit (TEU) memory and be retrieved and used whenever the frequency of a particular wireless source is detected. For this reason the best performance will be obtained if a set of wireless pseudo-sensor sources is always associated with the TEU, or TEUs, servicing a given 3D volume.
[0041] In summary, we have disclosed a system for detecting non-coherent magnetic signal sources and achieving and maintaining phase synchronization with them without placing any special start-up or harmonic relationships on the source. Further, we have devised a means for extending a string of sensors over a large area to be used successively as the source moves through the sequence of sensors to track low power three-axis field sources without causing distortion via induced eddy currents because of the low level signals involved. The tracker electronics scans for a family of three frequencies per source out of a pre-arranged set intended for the system, computes synchronization, applies characterization data to the signals and computes position and orientation results for output to a host computer. Because of the independent manner in which the tracker determines frequency and then achieves and maintains synchronization, pseudo-sensor sources can achieve operation over even larger spaces than a single tracker can accommodate by concatenating additional tracker systems with their pre-spaced sensors and connecting to the same host computer. Note that a source also can be tracked if it is powered by another system as opposed to being driven by a battery due to the ability to synchronize and achieve coherency. Also, due to the reciprocity between ‘sources’ and ‘sensors’ as discussed above, inverse operation is also possible; that is, where it is desirable to synchronize one or more sensors with a source having a known phase. | In an AC magnetic tracker one or more multi-axis field sources, each operating at a different frequency, or frequency set, are detected and tracked in three-dimensional space, even when wireless or otherwise not physically connected to the tracking system. Multiple sources can be tracked simultaneously as they each operate with their own unique detectable set of parameters. The invention not only provides the ability to uniquely identify one or more sources by their frequencies, but also to synchronize with these frequencies in order to measure signals that then allow tracking the position and orientation (P&O) of the source(s). Further, these sources need not be present at the time of system start-up but can come and go while being detected, discriminated and tracked. It also should be noted that application of such systems in multiples with more sensors not synchronized to a source or sources also could be employed to give the reverse appearance of a known source phase and incoherency with the sensors. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of prior U.S. provisional application Ser. No. 60/645,451 filed on Jan. 20, 2005.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to devices for transporting pipe. More particularly, the invention relates to a device for transporting drill pipe wherein the device is stackable and capable of being used in several modes of transportation.
[0006] 2. Description of Related Art
[0007] A large volume of drilling pipe is used in oilfield drilling operations. As wells are drilled to ever greater depths, the number of sections of pipe required is continually increasing. The pipe is typically shipped loose and held together with slings. The modes of transportation for drill pipe are many, especially when the final destination is an offshore drilling rig. Starting from a pipe yard, the pipe will often be transported by both truck and boat before reaching the rig.
[0008] It is crucial that the drill pipe be kept stable and secure when it is transported. If the pipe load shifts on either a workboat or a truck the results can include an overturned trailer or a sunken vessel which could cause injury to workers, destruction of equipment and delayed delivery times. Many man-hours are expended in transporting individual drill pipe sections from one mode of transportation to another. The offloading of pipe from the boat to the rig is inherently dangerous, especially when the seas are rough. It would be a valuable savings in man-hours and a marked safety achievement if multiple sections of drill pipe could be moved in a systematic, uniform, and safe manner. Although utilizing the pipe basket will result in an increase in freight expenditures, the overall cost savings associated with utilizing the pipe basket will far outweigh the additional freight expenditure due to the pipe basket's safety advantages.
[0009] It is an object of the present invention to provide a modular pipe basket which is capable of holding multiple pipe sections.
[0010] It is another object of the present invention to provide a basket which can be stacked on another basket.
[0011] It is another object of the present invention to protect the ends of the pipe from damage.
[0012] It is another object of the invention to provide a basket which securely holds the pipe sections within the basket while maintaining the center of gravity at approximately the midpoint of the basket.
[0013] It is another object of the invention to provide a basket which has a balanced four point sling pickup system to enable stable lifting of the pipe basket with a crane or other like lifting means.
[0014] It is another object of the invention to provide a basket that will enable lifting of the pipe basket with a forklift or other like lifting means.
[0015] It is another object of the invention to provide a basket which has open side access to enable loading or unloading of pipe sections from the basket with either a forklift, crane or other lifting means.
[0016] It is another object of the invention to provide a basket that is compatible with truck and boat transportation and which can be moved between these two modes of transportation with relative ease.
[0017] It is another object of the invention to provide a basket which can include at least one container or bin for pipe thread protectors.
BRIEF SUMMARY OF THE INVENTION
[0018] The present invention is a modular pipe basket. The basket includes at least two stanchions, a rectangular base, and two end caps. In a preferred embodiment, the base has longitudinal members and cross members. In a particularly preferred embodiment, the device will include at least one bin, and the bin will include an integrated end cap.
[0019] The modular pipe basket of the present invention has several advantages over the prior art systems. One advantage of the present invention is that the baskets are stackable.
[0020] Another advantage of the present invention is that the basket can accommodate different size pipes.
[0021] Another advantage of the present invention is that the basket will allow for centering of the drill pipe sections so that the center of gravity will be located at the midpoint of the basket.
[0022] Another advantage of the present invention is that the basket can accommodate various components associated with the drill pipe sections such as pipe end caps and wood strips which will be stored in the bin located at one or both ends of the pipe basket.
[0023] Still another advantage of the present invention is that the end cap of the basket will provide a backstop for potential load shifts of the pipe sections.
[0024] These and other objects, advantages, and features of this invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a side view of the preferred embodiment of the invention.
[0026] FIG. 2 is a top view of the preferred embodiment of the invention.
[0027] FIG. 3 is a fragmentary side view of one of the bins with the bin top in the open position.
[0028] FIG. 4 is an end view of the invention depicting the ladder system.
[0029] FIG. 5A is a fragmentary side view of a portion of the invention depicting the preferred embodiment of the stanchion system design with load securing means.
[0030] FIG. 5B is a reverse fragmentary side view of a portion of the invention depicting the preferred embodiment of the stanchion system design with strap receiver.
[0031] FIG. 6 is a side view of the invention depicting one pipe basket stacked on top of another.
DETAILED DESCRIPTION OF THE INVENTION
[0032] As shown in FIG. 1-2 , modular pipe basket 100 includes base 101 , stanchions 102 , and end caps 103 . Base 101 has two ends and is rectangular. Base 101 includes longitudinal members 104 , cross members 105 , and support members 106 . Cross members 105 are welded to longitudinal members 104 and are substantially perpendicular to longitudinal members 104 . In a preferred embodiment, support members 106 bridge between longitudinal members 104 and cross members 105 diagonally (i.e. at angles which are not right angles) so as to provide the maximum strength and rigidity to base 101 .
[0033] In the embodiment depicted in FIG. 2 , base 101 includes only two longitudinal members 104 , but those skilled in the art may wish to include two or more longitudinal members 104 . Similarly, while the figures show the use of five pairs of cross members 105 (three pairs in the midsection and one pair at each cap), those skilled in the art may wish to employ a different number of cross members 105 so long as cross members will support the pipe held in basket 100 . For weight savings, longitudinal members 104 , cross members 105 , and support members 106 are rigid round or square tubing or rigid beams which are joined together either by welding or other fastening means. Those skilled in the art could construct base 101 in other configurations, such as using a solid sheet of steel.
[0034] In a preferred embodiment, basket 100 will include at least two (one on each side) stanchions 102 . Stanchions 102 project upwards from longitudinal members 104 wherein stanchion 102 is in a plane that is substantially perpendicular to said base. Stanchion 102 can be made of square or round tubing; beam material; or other equivalent structure. For maximum strength each connection between stanchion 102 and longitudinal member 104 is reinforced with stanchion support 107 . Stanchion supports 107 are cut in a roughly triangular shape and then welded to stanchion 102 and longitudinal member 104 . It would be obvious to one skilled in the art to use another method of bracing stanchion 102 such as using a metal beam or other like structure. In another preferred embodiment, footings 109 are placed at the bottom of the base 101 in spaced pairs so as to create recesses 108 between each pair of footings 109 . Recess 108 formed by pair of footings 109 allow top of each stanchion 102 on bottom pipe basket 100 to fit into recess 108 when stacking basket 100 . Footing 109 may or may not extend across the entire width of the base. Footing 109 will also elevate basket 100 from ground level so as to provide a space underneath base 101 for forklift forks to slide under basket 100 for lifting of basket 100 . It would be obvious to one skilled in the art to use a means for receiving forklift forks without footing 109 by creating at least one aperture in the side of base 101 for receiving forklift forks.
[0035] Basket 100 will also include two end caps 103 . Each end cap 103 provides a means to stop and prevent pipe from sliding out of either end of basket 100 . For example, if basket 100 were being carried on a typical flatbed truck trailer and the truck had to make a sudden stop, end cap 103 would prevent the pipe from sliding forward and endangering the truck driver. In addition, the end cap will have ability to prevent damage to the ends of the pipes when transporting and storing the pipe in pipe basket 100 . End cap 103 should be constructed of steel plate, corrugated metal, expanded metal, or any material or design that will perform the desired function of arresting the sliding movement of the drill pipe.
[0036] In a particularly preferred embodiment, basket 100 will include at least one bin 110 which will have integrated therein an end cap 103 to stop the pipe from sliding as shown in FIG. 3 . Bin supports 123 can be used to add strength and rigidity to the connection between bin 110 and longitudinal members 104 . Alternatively, in the absence of bin 110 , the bin supports 123 can be joined directly to the end cap 103 to add strength and rigidity to end cap 103 . Additionally, bin 110 will provide storage space on pipe basket 100 and shall comprise end wall 114 , two side walls 112 , a front wall 113 and a bottom 111 . Preferably, the end cap 103 will serve as end wall 114 for the bin, but those skilled in the art may wish to introduce end cap 103 independently from bin 110 . Furthermore, those skilled in the art may wish to locate end cap 103 between bin 110 and pipe loading area 126 . Typically, drill pipe is already threaded and thread protectors will be on the threaded sections of the drill pipe when the pipe is shipped. Although the bins can be used for various items, it is contemplated by the inventors that bin 110 will provide a convenient container for storage of the thread protectors and wood strips. Having bin 110 on basket 100 provides a way for the pipe purchaser to return the thread protectors, along with the basket, to the pipe seller.
[0037] Bin 110 will include bin bottom 111 , which can be made of steel grate or expanded metal so as not to collect water. Bin 110 will also include side walls 112 , front wall 113 , and end wall 114 . Bin 110 may also include lid 115 . For added strength, bin 110 can be made by integrating beams into side walls 112 , front wall 113 , end wall 114 , or bin bottom 111 . In addition, any of the bin walls can be reinforced by ridge which can be created by bending the plate steel used to fabricate the walls. Bin 110 can also include lid 115 . In a preferred embodiment, at least one bin wall shall be constructed of corrugated metal so as to provide increased strength and reduction of weight of pipe basket 100 . To provide maximum strength to bin 110 and basket 100 ; side walls 112 , front wall 113 , and end wall 114 can be made from one piece of sheet steel which is bent at right angles to form bin 110 . Also, square or round tubing or beam material can also be used to add support to bin 110 by providing a rigid frame for bin 110 .
[0038] To assist personnel in accessing the top of basket 100 and the inside of bin 110 , bin 110 can also include an integrated ladder 117 as shown in FIG. 4 . The ladder 117 would preferably be recessed into the end cap 103 so as not to protrude from the pipe basket 100 . In addition, the ladder can be installed on each end cap 103 provided that the ladder 117 is incorporated on alternate sides from the ladder on the opposing end. This will allow ladder 117 on bottom basket to always line up with ladder 117 on the top basket in the event the baskets are stacked on top of each other. In addition, ladder hand support 124 can be installed to provide a hand grip for personnel climbing ladder 117 .
[0039] As shown in FIG. 1 , one or more load securing points 118 can be placed along pipe basket 100 . Preferably, load securing point 118 would be located within stanchion support 107 as shown in FIGS. 5A and 5B . More preferably, load securing point 118 would be provided in at least four points along the base 101 ; two along each alternate side of the pipe basket 100 . At least one load securing means 119 can be placed on one side of pipe basket 101 at load securing point 118 wherein load securing means would preferably be a ratcheting apparatus or equivalent fastening means as shown in FIG. 5A . Although load securing means 119 is shown in an upright position in FIGS. 1, 5A and 6 , a slight modification to the load securing point 118 can be made so that the load securing means 119 can be inverted thereby positioning the load securing means 119 upside down within load securing point 118 . At least one strap receiver 127 will be placed on the opposite side from load securing means 119 to provide a connection for strap 125 as shown in FIG. 5B . The strap receiver 127 can be a hook, grapple, clasp, catch, or other equivalent securing means. Strap 125 will be used to hold the drill pipe securely in place during transport wherein such strap 125 can comprise of a cloth, metal or polymer strap, chain, cable or other like tie down means. In the stacked configuration shown in FIG. 6 , one or more of the straps from the bottom basket 100 may be wrapped around the longitudinal members 104 or any part of the top basket 100 so as to secure the two baskets together during transport or storage.
[0040] To assist in safely lifting the pipe basket 100 with the use of a crane or other like lifting means, it would be preferable to use sling lifting brackets 121 which can be incorporated into the pipe basket 100 as shown in FIGS. 5A and 5B . Sling lifting brackets 121 are rigid members that preferably project diagonally (i.e. at angles which are not right angles) from longitudinal members 104 and are located at four different points along the pipe basket 100 . However, the sling lifting brackets 121 can also project perpendicular or parallel from longitudinal members 104 . Also shown in FIGS. 5A and 5B , sling lifting bracket 121 contains pad eye 119 which is an aperture placed in sling lifting bracket 121 so as to allow a connection point for the lifting slings of a crane or other like lifting device. Ideally, pad eyes are drilled, not cut, so as to provide superior strength for pad eyes 119 which are used as lift points. It would be obvious to one skilled in the art that pad eye 119 can also be a separate device that is joined to pipe basket 100 . To lift basket 100 , one may connect a sling to pad eye 119 . The sling lifting brackets 121 are added to provide additional lifting support. It will be obvious to those skilled in the art that pad eyes could be placed at several points on basket 100 including but not limited to stanchion 102 , stanchion support 107 and base 101 . In addition, stanchion support 107 could serve as sling lifting bracket 121 .
[0041] In a preferred embodiment, the material for all the components of the pipe basket 100 will be galvanized carbon steel to help reduce corrosion of pipe basket 100 . In another preferred embodiment, longitudinal member 104 would be made of 10 inch thick beams to allow for adequate support of pipe basket 100 .
[0042] By way of example only, pipe basket 100 could have a total length of 38 feet with a usable interior space that can accommodate pipe of up to 34 feet in length. Basket 100 can be made with a width of approximately four feet and a height of about 54 inches. With these dimensions, two baskets 100 can be placed side by side on a conventional truck trailer.
[0043] In operation, basket 100 is loaded with drill pipe. Once basket 100 is loaded with the desired quantity of pipe, strap 125 can be tightened over the pipe using strap load securing points 118 . As shown in FIG. 6 , a first pipe basket 100 can be stacked on top of a second pipe basket 100 . The two baskets can be secured together using the straps 125 and load securing means 119 or equivalent securing means. As the pipe loaded therein is used, any thread protectors on the pipe and wood stripping used to space the pipes can be placed in bin 110 .
[0044] There are, of course, other alternate embodiments which are obvious from the foregoing descriptions of the invention, which are intended to be included within the scope of the invention, as defined by the following claims. | A modular pipe basket for transporting pipe is disclosed. The modular pipe basket will comprise a rectangular base, two or more stanchions and one or more end caps. In another embodiment, the modular pipe basket will incorporate a storage compartment or bin for storing miscellaneous piping accessories. In addition, the modular pipe basket may be equipped with a four point sling pickup system for lifting the basket with a crane along with the means for lifting the basket with a forklift. | 1 |
TECHNICAL FIELD
[0001] This invention relates to air handling equipment. Specifically, it relates to thermal isolation of chambers that house heating, ventilation and air conditioning components.
BACKGROUND ART
[0002] The delivery of a cool, dry air stream is necessary for a variety of applications ranging from industrial processes (e.g. plastics, food processing), to comfort control of large indoor spaces, to clean room environment control. Air handling chambers are designed to house the appurtenances necessary for the treatment of such air flow streams. The chambers are designed to accommodate a variety of components, depending on the application (e.g. cooling coils, desiccant wheels, and filtration systems).
[0003] The temperature within an operating air handling chamber is often substantially below the temperature surrounding the chamber. Such chambers are often deployed in high humidity environments. For example, outdoor or roof mounted chambers are routinely exposed to high temperature, high humidity ambient conditions associated with summer time operation. Indoor units are often installed within a high humidity environment associated with the process that requires air handling.
[0004] Conventional air handling chambers utilize a modular panel design. The walls of the chamber are constructed from pre-formed panels that mate with each other along jointed seams. The panels typically have a hard (often metallic) shell that is filled with a thermal insulation material. Some modular panel designs feature edges that are enclosed with the shell material, so that the mating edges of abutting panels have a stiff interface suitable for the insertion of a sealing material. The shell, typically constructed from a higher thermal conductivity material than the insulation material within, thermally bridges the thickness of the panel, creating a zone of lower temperature on the shell exterior along the seam of the joint. Condensation can form and accumulate when the temperature of these zones fall below the dew point temperature of the surrounding air.
[0005] Other designs leave the insulation exposed on the panel edges, the insulating material of one panel being formed to mate directly with the insulation of an adjoining panel. Such designs are more difficult to seal with interstitial materials at the joints and are prone to leakage of the cooler interior air because insulation materials tend to be of lower density and are less resistant to wear. Leakage through the joints effectively cools the outer surfaces of the panels near the seams, which also leads to the formation and accumulation of condensation on the exterior shell.
[0006] Conventional air handling chambers also utilize a base design that is prone to the formation of external condensation. Some chambers house heavy components, such as high capacity compressors or large banks of air-to-fluid heat exchangers. For the sake of rigidity, standard base structures form a thermal bridge between the chamber interior and the exterior of the base.
[0007] The food processing industry is particularly sensitive to condensation or “sweating” on the exterior of air handling equipment. Accumulation of condensation leads to the formation of droplets that can fall into food products or otherwise contaminate sanitized areas. Even outdoor units can cause contamination of food processing areas. For example, a roof-mounted unit typically has ductwork that extends from the bottom of the chamber and into the building through the roof. Condensation that forms on the exterior of the walls and base of the chamber can flow downward, attach to exterior of the ducting and make its way into the food processing area, thereby posing a contamination risk. The Food and Drug Administration has recognized the health risks associated with condensation in food processing facilities, and has promulgated rules and guidelines regarding condensation on air handling enclosures. See, e.g., 9 CFR Part 416, “Sanitation Requirements for Official Meat and Poultry Establishments, Final Rule,” 2000.
[0008] Heat flux through a solid medium, expressed in Watts per square meter, is directly proportional to the thermal conductivity of the medium (hereinafter referred to as k) and inversely proportional to the thermal path length (hereinafter referred to as L). That is, heat flux is proportional to the ratio k/L. In the case of a planar wall such as utilized in a thermal isolation chamber, the thermal path length L is dominated by the thickness of the insulation between the inner and outer wall assembly. A thicker wall enables the use of a higher conductivity material, whereas a thin wall requires the use of a lower conductivity material to maintain the exterior temperatures above the dew point temperature.
[0009] Generally, the thermal conductivity of so-called “thermal insulation” or “thermal insulative” materials can be of any magnitude, provided the available thermal path length L is long enough (i.e. the wall is thick enough) to maintain the exterior temperatures above the dew point temperature.
[0010] There exists a need for an air handling chamber design that minimizes or avoids the formation of condensation on exterior surfaces, yet is readily adapted to the construction of chambers of various sizes.
SUMMARY OF THE INVENTION
[0011] The air handling chamber in accordance with the present invention in large measure solves the problems outline above. The wall, ceiling and base structures of the air chamber hereof thermally isolate the external surfaces and the base from the chamber interior, thus preventing the formation of exterior condensation. Inherent advantages of the design also include improved wall strength, enhanced thermal efficiency, less leakage into or out of the controlled gas stream, and improved suppression of the noise generated by the components within the chamber. Moreover, the method of construction allows the designer to specify a chamber of any size and walls of any thickness without compromising the thermal and flow containment integrity of the unit.
[0012] The side walls of certain embodiments of the invention have a continuous outer wall and a continuous inner wall with no structural element bridging the two walls. That is, if the inner wall and outer wall are each made of metal, there is no need for a metallic bridge to exist between the two structures. A gap separates the two walls and is filled with an insulation material to thermally isolate the interior of the chamber from the exterior wall. Likewise, the top of the chamber has a continuous internal ceiling and a continuous external roof, with no direct contact therebetween. The roof and ceiling are separated by a gap that may be filled with a rigid insulation board that is self supporting and provides additional strength to the structure.
[0013] For larger embodiments, each interior or exterior surface may be constructed by joining segments of sheet material together to form a continuous surface. In certain embodiments of the invention, flanges are formed on the abutting edges of the segments. The segments are then joined at the flanges by crimping, welding, fusing, riveting, capping or by other joining techniques available to the artisan. The joined flanges create a rib that protrudes from one surface of the joined segments. The rib may be oriented to extend into, but not all the way across, the gap, to provide essentially continuous surfaces on the interior and exterior of the chamber. The ribs also serve to stiffen the structure.
[0014] With many joining techniques, seams will be formed at each junction between adjacent sheets. The seams on the outer wall may be offset or “staggered” with respect to the seams on the inner wall. A staggered arrangement lengthens the leak path between seams through the insulation, providing a better seal than with standard modular constructions. Also, for embodiments implementing flanged abutments that reside between the interior and exterior walls, the staggered arrangement provides a longer thermal path between the flange and the opposing wall than an arrangement where the flanges are directly opposite each other.
[0015] Accordingly, the various configurations of the present invention implement a structural scheme that combines the advantages of both increased thermal resistance and increased leak resistance through the sidewall assembly.
[0016] In another embodiment of the invention, the base assembly features an internal base structure and an external base structure. The internal base structure is mounted within the external base structure, with a thermally resistant interstitial material disposed between the two structures. The interior shell (interior wall and ceiling) is supported on the internal base structure, and the exterior shell (exterior wall and roof) is supported on the external base structure. The base structures are characterized by large interfaces in contact with the interstitial material to distribute the weight of the chamber and appurtenances within over a large area. The distributed load allows the use of non-metallic or non-structural material as the interstitial material, thereby increasing the thermal resistance between the internal and external base frames. Also, any appendages or penetrations that pass through the base assembly, side walls or roof (e.g. drain pan fixtures, electrical conduits, etc.) are also thermally broken between the interior surface and the exterior surface by bifurcating the appendage or penetration into an interior and an exterior segment, and interposing a low conductivity coupling therebetween.
[0017] The spatial and structural constraints of the subject thermal isolation chambers provide for the use of insulation materials having a thermal conductivity of 1 Watt per meter per Kelvin or less. Such insulators have a thermal conductivity that is substantially lower (an order of magnitude or more) than the metals commonly used in construction of the chamber walls. The thermal isolation provided by the structure of the air chamber is greatly improved over conventional chambers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of an air chamber in accordance with the present invention.
[0019] FIG. 2 is a partially exploded view of the air chamber base assembly.
[0020] FIG. 3 is a perspective view of the base assembly depicted in FIG. 2 .
[0021] FIG. 4 is a sectional end view of the base assembly.
[0022] FIG. 5 is a sectional view taken along line 5 - 5 of FIG. 3 .
[0023] FIG. 6 is a fragmentary sectional side view of the base assembly.
[0024] FIG. 7 is a fragmentary plan view of the sidewall assembly of the air chamber.
[0025] FIG. 7A is an enlarged view taken at 7 A of FIG. 7 .
[0026] FIG. 7B is an enlarged view taken at 7 B of FIG. 7 .
[0027] FIG. 8 is a sectional, elevation view of the air chamber.
[0028] FIG. 8A is an enlarged view taken at 8 A of FIG. 8 .
[0029] FIG. 8B is an enlarged view taken at 8 B of FIG. 8 .
[0030] FIG. 9 is a fragmentary, perspective view of a portion of a sidewall assembly, without insulation, but depicting the installation of insulation.
[0031] FIG. 10 is similar to FIG. 9 , but depicting insulation partially installed in the sidewall.
[0032] FIG. 11 is similar to FIG. 10 , but with insulation installation completed.
[0033] FIG. 12 is a perspective view of an air chamber in accordance with the invention, having an extended chamber.
[0034] FIG. 13 is a sectional, elevation view of the air chamber of FIG. 12 .
[0035] FIG. 14 is a plan view of a sidewall assembly of the air chamber depicted in FIG. 12 .
[0036] FIG. 15 is a sectional view of an electrical feed through assembly taken at 15 of FIG. 8 .
[0037] FIG. 16 is a sectional view of plumbing feed through assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Referring to the drawings, a thermally broken chamber 10 includes a base assembly 15 and an upper assembly 20 . Referring to FIGS. 2 through 4 , the base assembly 15 includes an exterior base 25 and an interior base 30 . The exterior base 25 is generally rectangular and has an exterior frame 35 having side members 40 , 45 and end members 50 , 55 . The exterior frame 35 defines an interior perimeter 60 , and outer perimeter 62 and a lower or grounding plane 65 . The exterior base 25 also includes a number of cross members 70 that extend between the side members 40 and 45 of the base frame 35 . The cross members 70 each have an upper surface 75 and a lower surface 80 . The lower surfaces 80 of the cross members 70 may be arranged flush with the lower plane 65 , as illustrated in FIGS. 2 and 6 .
[0039] The interior perimeter 60 of the exterior frame 35 has an upper portion 85 extending above the upper surfaces 75 of the cross members 70 , best portrayed in FIG. 4 . The upper portion 85 of the interior perimeter 60 and the upper surfaces 75 of the cross members 70 are lined with structural thermal insulation materials 90 and 92 , respectively.
[0040] Referring again to FIG. 2 , the lined surfaces of the exterior base 25 define a caging 95 that houses interior base 30 . The interior base 30 includes an interior frame 100 having side members 105 , 110 and end members 115 , 120 . The interior frame 100 has a top face 102 and defines an exterior perimeter 125 and an upper plane 130 . The interior base 30 has a number of cross members 135 that extend between the side members 105 and 110 of the interior frame 100 . Referring to FIG. 5 , the cross members 135 are positioned within the interior frame 100 to align with the cross members 70 of the exterior base 25 longitudinally when the interior base 30 is placed within the caging 95 of the exterior base 25 . Each of the cross members 135 of the interior base 30 are dimensioned so that an upper surface 140 is flush with the upper plane 130 and a lower surface 145 contacts the structural thermal insulation material 92 that lines the upper surfaces 75 of the cross members 70 of the exterior base 25 when the interior base 30 is placed within the caging 95 of the exterior base 25 . The interior base also includes a floor plate 150 that generally covers the cross members 135 and interior frame 100 . An air passage 155 or other access port may be provided through the floor plate 150 , as required by the particular application.
[0041] By the arrangement described above, there is no direct contact between the exterior base 25 and the interior base 30 . Rather, the structural thermal insulation materials 90 and 92 are interstitial between the structural interfaces of the exterior base 25 and the interior base 30 . Where the interior base 30 and exterior base 25 are metallic, there is no metal that bridges the two structures, resulting in enhanced thermal isolation between the interior and exterior of the chamber 10 .
[0042] Referring to FIG. 6 , the base assembly 15 also includes a thermal insulation material 160 deposited between and within the cross members 70 and 135 of the exterior base 25 and interior base 30 , respectively. The base assembly 15 may be inverted for this operation, so that the grounding plane 65 of the base assembly 15 is on top, as depicted in FIG. 6 . Inverting the base assembly 15 entails capturing the interior base 30 within the exterior base 25 so that the base assembly 15 remains assembled during the inverting operation. Excess thermal insulation 160 that extends above the grounding plane is then removed flush with grounding plane 65 . A cladding sheet (not depicted) may be affixed to the base assembly 15 at the grounding plane 65 to protect the underside of the base assembly 15 .
[0043] Preferably, the thermal insulation material 160 is a multi-component polyurethane foam, such as HANDI-FOAM® Quick-Cure manufactured by Fomo Products, Inc. of Norton, Ohio. Foam insulation of this type can be injected into voids and comers in the base assembly 15 , thereby providing uniform thermal insulation between the cross members 70 and 135 .
[0044] For most applications, the structural thermal insulation material 90 that lines the upper portion 85 of the interior perimeter 60 of the exterior frame 35 is subject to less contact pressure than the structural thermal insulation material 92 that lines the upper surfaces 75 of the cross members 70 . Accordingly, a material of lower density (and therefore typically lower thermal conductivity) may be used for the structural thermal insulation material 90 than for the structural load-bearing thermal insulation material 92 .
[0045] Functionally, the use of numerous cross members 70 and 135 , or the use of cross-members 70 and 135 having larger contact surfaces 75 and 145 , respectively, allows the weight of the interior base 30 and any structure or appurtenances mounted thereon to be spread over a large contact area 165 . For a given weight load, a larger contact area 165 will distribute the weight, reducing the contact pressure exerted on the interstitial structural thermal insulation material 92 . A lower contact pressure typically allows the use of a lower density structural thermal insulation material 92 , which in turn will generally decreases the thermal conduction between the exterior base 25 and the interior base 30 . Accordingly, depending on the contact pressures of a particular application, a variety of materials may be used for the structural thermal insulation material 92 , ranging from higher density structural plastics to moderate density rubber or silicone matting to lower density thermal insulation boards.
[0046] Furthermore, the use of a lower density structural thermal insulation material 90 will result in less heat conduction through the interior perimeter 60 . Likewise, the thermal insulation material 160 reduces the thermal conduction between the floor plate 150 of the interior base 30 and the lower plane 65 of the base assembly 15 . The reduced thermal conduction provided by the thermal break scheme of the base assembly 15 results in higher operating temperatures on the exterior surfaces of exterior base 25 . As a result, there is less chance of forming or accumulating condensation on the exterior surfaces of the base assembly 15 .
[0047] An alternative configuration for the thermal isolation between the interior base 30 and the exterior base 25 is also presented in FIG. 6 . The upper surfaces 75 of the exterior cross members 70 may be only partially lined with a number of structural thermal insulation segments 93 . Intermediate areas 94 between the structural thermal insulation segments 93 may be left exposed (as depicted) or fitted with a low density thermal insulation (not depicted). If the intermediate areas 94 are left exposed, air may serve as an insulator between the aligned cross members 70 and 135 , or the void may be filled with thermal insulation 160 during the buildup of the base assembly 15 (see FIG. 6 and accompanying text).
[0048] Functionally, the structural thermal insulation segments 93 suspend the cross members 135 of the interior base 30 above the upper surfaces 75 of the exterior cross members 70 , thereby preventing direct contact between the interior base 25 and the exterior base 30 . The thermal conductivity through intermediate areas 94 are inhibited either by air, the thermal insulation 160 , or a low density thermal insulation, and the functional utility of the unit may be enhanced over the configuration of FIG. 2 . Again, where the interior base 30 and the exterior base 25 are of metallic construction, there is no metal-to-metal contact between the structures, resulting in greater thermal isolation between the interior and exterior of the chamber 10 .
[0049] Returning to FIG. 1 , the upper assembly 20 of the thermally broken chamber 10 includes a sidewall assembly 170 and a cap assembly 175 . Referring to FIGS. 7, 7A and 7 B, an embodiment of the sidewall assembly 170 is depicted having an interior wall 180 , an exterior wall 190 , and an opening 201 . The interior and exterior walls 180 and 190 are separated by a gap 202 that may be of constant dimension. The gap 202 defines a center line 203 equidistant between the interior wall 180 and the exterior wall 190 . The interior wall 180 is a continuous structure that does not bridge to the exterior wall 190 . The interior wall 180 may be constructed of a series of interior wall panels, as illustrated in FIG. 7 by numerical references 181 through 188 . Each of the interior wall panels 181 - 188 have an inward surface 204 that faces toward the interior of the sidewall assembly 170 and an outward surface 205 that faces the gap 202 .
[0050] The embodiment depicted in FIGS. 7, 7A and 7 B has interior wall panels 181 - 188 with flanged edges 210 , each flanged edge 210 having a rib portion 215 projecting perpendicular to the outward surface 205 , and a free end portion 220 that depends from the rib portion 215 in a direction parallel to the outward surface 205 . Adjacent interior wall panels 181 - 188 are joined by connecting the abutting rib portions 215 to each other, forming a seam 217 between the adjoined wall panels. A filler material 218 may be interstitially placed between the abutting rib portions 215 . The version of the invention illustrated in FIG. 7 depicts the free end portions 220 extending over the outward surface 205 , so that the abutting flanged edges 210 form a T-shaped cross-section 222 . The configuration depicted in FIG. 7 represents the flanged edges 210 oriented within the gap 202 , thereby providing a relatively smooth interior surface for interior wall 180 .
[0051] While the invention is not limited to locating the flanges 210 within the gap 202 , there are certain applications where such an arrangement provides advantages. For example, a orienting the flanges 210 within the gap 202 provides a smooth flow boundary for air flowing through the chamber, thus reducing frictional and turbulent head losses. Also, a smooth interior wall inhibits the growth of bacterial and is more readily cleaned-an important consideration for units servicing the food industry.
[0052] The opening 201 is defined by a split frame 223 having an inner portion 224 and an outer portion 226 . The two portions 224 and 226 are separated by a thermal break 228 , such as an o-ring or bellows made of a compliant material such as neoprene or silicone. The opening may be used as a doorway for chamber access, or as an airway for connecting ductwork. When the opening 201 is used as a doorway, a split door 229 may be mounted to form a closure. The door is of a construction similar to the split frame 223 ; specifically, it has an inner portion 230 and an outer portion 231 separated by a thermal break 232 .
[0053] The function of the split frame 223 and split door 229 configurations is to reduce the thermal conduction between the interior of the thermally broken chamber 10 and the ambient surroundings. The thermal isolation provided by the thermal breaks 228 and 232 enable the exterior surfaces near the opening 201 to operate at a higher temperature, thereby inhibiting the formation and accumulation of condensation on the exterior of the thermally broken chamber 10 .
[0054] Referring to FIG. 8 , the interior wall 180 is dimensioned and positioned so that it is entirely supported by the interior frame 100 . A bottom flange 207 is formed on the bottom of each interior wall panel 181 - 188 . The bottom flange 207 is fastened or otherwise connected to the top face 102 of the interior frame 100 .
[0055] Once the interior wall 180 is constructed and mounted onto the interior frame 100 , the exterior wall 190 is built around the interior wall 180 . The exterior wall 190 is also continuous, and may be constructed from a series of exterior wall panels 191 - 196 and corner panels 197 - 200 . Each of the exterior wall and corner panels 191 - 200 have an inward surface 233 that faces toward the gap 202 and an outward surface 234 . In the embodiment depicted in FIG. 7 , the exterior wall and corner panels 191 - 200 have at least one flanged edge 235 , each having a rib portion 240 that projects perpendicular to the inward surface 233 and a free end portion 245 that depends from the rib portion 240 in a direction parallel to the inward surface 233 .
[0056] Adjacent flanged edges (e.g. between wall panels 193 and 194 ) are joined by connecting the abutting rib portions 240 to each other, forming a seam 242 between the adjoined panels. A filler material 244 such as caulk or gasket material may be interstitially located between the abutting rib portions 240 . The version of the invention depicted in FIG. 7A illustrates the free end portions 245 of abutting flanged edges 235 extending in the same direction, thereby forming an L- shaped cross-section . The FIG. 7 depiction portrays the joining of a flangeless edge portion 250 on exterior wall panel 193 to exterior corner panel 198 . The flangeless edge portion 250 is connected to a portion of the outward surface 234 of the corner panel 198 . Flangeless panel edges may be joined to flanged panel edges at any junction on the exterior or interior panels. The seam formed by the union of the flangeless edge portion 250 and the corner panel 198 may be filled with an appropriate sealer (not depicted).
[0057] The exterior wall 190 is dimensioned and positioned so that it is entirely supported by the exterior frame 35 . In the configuration depicted in FIG. 8 , the exterior wall 190 is mounted to the exterior frame 35 through the outer perimeter 62 . By this construction, a bottom surface 255 terminating the gap 202 is formed by the top faces 58 and 102 of the exterior frame 35 and interior frame 100 , respectively.
[0058] The method of joining abutted flanged edges 210 or 235 , or for joining the flangeless edges 250 to adjacent panels, as well as the method for mounting the sidewall assembly 170 to the base assembly 15 , may be by fusing, welding, crimping, fasteners, or by any other means available to an artisan. In addition to providing a workable means for connecting adjacent panels, the flanged edges 210 and 235 provide strength and buckling resistance to the sidewall assembly 170 .
[0059] The configuration of the invention illustrated in FIG. 7 limns the flanged edges 210 and 235 of the interior wall panels 181 - 188 and exterior wall panels 191 - 200 protruding into the gap 202 . While this arrangement may be preferred in many applications, the flanges may also be oriented to protrude away from the gap 202 .
[0060] Referring to FIGS. 9 through 11 , the gap 202 is filled with an insulation material 260 . Neoprene spacers 265 may be used to maintain proper spacing between the interior wall 180 and the exterior wall 190 . While any appropriate insulation may be used, a preferred insulation material is a multi-component “slow rise” polyurethane foam 261 , such as HANDI-FOAM® SR, manufactured by Fomo Products, Inc. of Norton, Ohio. The slow rise polyurethane 261 is gunned into the gap 202 , as portrayed in FIG. 9 , and onto the bottom surface 255 of the gap 202 . The slow rise polyurethane 261 slowly expands to fill the gap 202 and overflow the top edges of the sidewall assembly 170 , as depicted in FIG. 10 . After the slow rise polyurethane 261 is cured, the excess overflow is shaved flush with the top edges if the sidewall assembly 170 .
[0061] The embodiment of FIG. 7 also illustrates some flanged edges 210 of the interior wall 180 in a “staggered” arrangement with respect to the flanged edges 235 of the exterior wall 190 . That is, the flanged edges 235 of the exterior wall 190 are sometimes located approximately mid-way between the flanged edges 210 of the interior wall 180 .
[0062] The filler materials 218 and 244 help prevent leakage through the sidewall assembly 170 and the attendant transpiration cooling of the exterior seams 242 . The “staggered” relationship between interior flanged edges 210 and exterior flanged edges 235 serves at least two functions. First, if the interior and exterior flanged edges 210 and 235 are aligned directly opposite each other, there is a relatively short conduction path through the thermal insulation material 260 between the respective free ends 220 and 245 . By staggering the interior and exterior flanged edges 210 and 235 , the thickness of the insulation material 260 between a given free end 220 or 245 and the opposing exterior or interior wall 190 or 180 is increased, resulting a higher operating temperatures for the exterior wall 190 , thereby reducing the chance of condensation formation and accumulation.
[0063] Second, the staggered arrangement functions to increase the path length between any leaks that may occur between the corresponding interior seams 217 and exterior seams 242 . The increased path length through the insulation material 260 reduces leakage through the sidewall assembly 170 . Also, it is preferred, but not necessary, that the insulation material 160 be of a closed-cell form to further inhibit leakage through the side wall assembly 170 .
[0064] The T-shaped and L-shaped cross-sections 222 and 237 also cooperate to enhance leakage resistance through the sidewall assembly 170 . Air leaking through a T-shaped cross-section 222 will initially enter the insulation material 260 in the gap 202 at an angle that is perpendicular to the center line 203 of the gap 202 . On the other hand, air leaking through an L-shaped cross-section 237 will initially enter the gap 202 in a direction that is parallel to the center line 203 . The orthogonal relationship between the entry vectors forces the air to travel a tortuous path, further increasing the leak path resistance. The various means of increasing the leak path resistance combine to reduce the leakage of air through the sidewall assembly 170 and to decrease the attendant transpiration cooling of the exterior wall 190 near the exterior seams 242 . This allows the exterior wall to operate at a higher temperature, thereby reducing the chance of forming and accumulating condensation.
[0065] A cross-sectional view of the cap assembly 175 is also illustrated in FIG. 8 . The cap assembly 175 includes a ceiling 270 and a roof assembly 275 that define a cap interior 285 . The cap interior is filled with thermal a insulation material 290 . The ceiling 270 may be formed by joining individual ceiling panels 295 and 296 , or as one continuous sheet (not depicted). As in the formation of the interior and exterior walls 180 and 190 , the ceiling panels 295 and 296 may be formed with flanged edges 300 appropriate for the formation of T-shaped cross-sections 305 or L-shaped cross-sections (not depicted), as previously discussed. The flanged edges may protrude into the cap interior 285 as limned in FIG. 8 , or protrude downward from the ceiling 270 (not illustrated).
[0066] While the thermal insulation material 290 may be of any appropriate type, a preferred form is rigid insulation board 291 . Rigid insulation board 291 is structurally self-supporting (meaning that it can span a significant distance without external support) and lends structural support to the roof assembly 275 . Also, the insulation scheme for the cap assembly 175 may involve a combination of different insulation materials, such as a loose fill insulation between flanged edges 300 of the ceiling panels 295 and 296 , capped with rigid insulation board 291 that rests on the flanged edges 300 .
[0067] The ceiling 270 has an edge portion 310 that extends over the interior wall 180 . The weight of the ceiling 270 and the portion of the weight of the insulation material 290 that is supported by the ceiling 270 is thereby transferred to the interior base 30 through the interior sidewall 180 . In some instances, the self-supporting nature of rigid insulation board 291 allows its weight to be shifted to the roof assembly 275 or directly to the exterior wall 190 .
[0068] The roof assembly 275 includes a top portion 276 , an outer portion 280 and a channel frame 355 . The top portion 276 may be formed by joining individual roof panels 315 - 318 , or may be constructed from one continuous sheet (not portrayed). As in the formation of the interior and exterior walls 180 and 190 , the roof panels 315 - 318 may be formed with flanged edges 320 . The flanged edges 320 may protrude into the cap interior 285 (not depicted), or protrude upward from the top portion 276 of the roof assembly 275 , as detailed in FIG. 8 .
[0069] While T-shaped and L-shaped cross-sections may be formed between the roof panels 315 - 318 , an alternative is a J-shaped cross-section 325 as detailed in FIG. 8 . Like the L-shaped cross section, the J-shaped cross-section includes rib portions 330 and 331 and free end portions 335 and 336 that depend from the rib portions 330 and 331 in the same direction, and a filler material 338 disposed between rib portions 330 and 331 . However, the uppermost free end portion 336 of the J-shaped cross section 325 also has a cap edge portion 340 that extends downward from the uppermost free end portion 336 . The cap edge portion 340 provides an effective shield against inclement elements such as rain, industrial sprays and the like from entering the seam formed by the junction of the flanged edges 320 .
[0070] The outer perimeter portion 280 of the roof assembly 275 depends from an edge portion 345 of the top portion 276 . The outer perimeter may have a skirt portion 350 at the lower extremity. A channel frame 355 is attached to the top portion 276 inside the outer perimeter portion 280 in the FIG. 8 embodiment of the invention. A spacer 360 is placed between the channel frame 355 and the outer perimeter portion 280 , creating a gap 365 therebetween. The spacer 360 may be formed from a gasket or caulk material. The spacer 360 is seated on a protruding upper edge 270 of the exterior wall 190 , the upper edge 270 extending into the gap 365 .
[0071] The skirt portion 350 serves to guide placement of the roof assembly 275 onto the exterior wall 190 , and also serves as a drip lip that directs water shedding from the roof assembly 275 away from the unit. The weight of the roof assembly 275 , as well as any thermal insulation material 290 , 291 supported by these elements, is transferred to the exterior base 25 through the exterior wall 190 . When the spacer 360 is formed from a gasket or caulk material, it provides a seal between the exterior wall 190 and the roof assembly 275 .
[0072] The cap assembly 175 is assembled on the sidewall assembly 170 in the FIG. 8 configuration. The ceiling 270 is placed over the interior wall 180 so that the edge portion 310 of the ceiling 270 extends over the top edge of the interior wall and is attached thereto. The thermal insulation material 290 is then placed over the ceiling 270 , followed by the placement of a layer of the rigid insulation board 291 over the thermal insulation material 290 . The roof assembly 275 is guided over the protruding upper edge 370 of the exterior wall 190 to encapsulate the thermal insulation 290 , 291 .
[0073] Effectively, the construction of FIG. 8 provides an interior shell 372 mounted on the interior base 15 and an exterior shell 374 mounted on the exterior base 25 , with thermal insulation 260 isolating the two structures. The interior shell 372 includes the interior wall 180 and the ceiling 270 . The exterior shell 374 includes the exterior wall 190 and the roof assembly 275 . There is no direct contact between the interior shell 372 and the exterior shell 374 . Accordingly, where metals are used in the fabrication of the interior shell 372 and exterior shell 374 , there is no metal-to-metal contact between the two shells.
[0074] Referring to FIGS. 12 through 14 , another version of the invention is presented. Sometimes, it is necessary to divide or split a thermally broken chamber 375 into one or more sections (e.g. to ship the unit or move it into a confined space). Accordingly, the thermally broken chamber 375 is divided into a first section 380 and a second section 385 . The first section 380 and the second section 385 each have open ends 382 and 386 that define planes 390 and 395 , respectively. A pair of shipping split channels 396 are located at the open end of each section 380 and 385 . The base assembly 15 , sidewall assembly 170 and cap assembly 175 of each section 380 and 385 are configured to have continuous flanged faces 400 and 405 that are flush with planes 390 and 395 , respectively. A sealing material 420 such as a gasket, caulk line or o-ring is placed between the flanged faces 400 and 405 before joining the two sections 380 and 385 . An upward extending flange 410 is formed on the top portion 276 of the roof assembly 275 at the interface of the continuous flanged faces 400 and 405 . A flange cap 425 is mounted over upward extending flange 410 . Sidewall seams (not depicted) that are formed at the interface of the two sections 380 and 385 are covered with strips 415 that may be fastened or bonded to the adjoining exterior walls 190 . A sealant such as a gasket or calking (not depicted) may be sandwiched between the strips 415 and the sidewall seams.
[0075] In operation, the sealing material 420 seals the interface upon joining the two sections. The shipping split channels 396 provide support for the open ends during shipment and movement, and are used to draw the two sections 380 and 385 together once the chamber 375 is in place. The flange cap 425 and strips 415 prevent incendiary elements such as rain or industrial sprays from seeping into the unit.
[0076] Referring to FIG. 15 , an electrical feed through 430 abiding with the concept of the invention is depicted. The electrical feed through 430 includes an electrical conduit 434 joined to a thermal insulative coupling 436 having electrical or signal cabling 438 passing therethrough. The thermal insulative coupling 436 and the electrical conduit 343 may be threadably engaged using thread sizes that are standard in the electrical industry. The thermal insulative coupling 434 is fabricated from a material having a thermal conductivity that is lower than standard electrical conduit, such as PVC pipe or some other polymer or fluoropolymer. The electrical conduit 434 penetrates and is connected to the exterior wall 190 of the sidewall assembly 170 , but does not bridge all the way across the gap 202 . Rather, the thermal insulative coupling 436 bridges between interior wall 180 and the electrical conduit 434 . The region within and/or near the thermal insulative coupling 436 is filled with a thermally insulating sealant 440 such as silicone or epoxy.
[0077] Functionally, the electrical feed through 430 thermally isolates the interior wall 180 from the exterior wall 190 by interposition of the thermal insulative coupling 436 , which inhibits axial heat conduction through the electrical feed through 430 . The thermally insulating sealant 440 , in addition to maintaining the pressure integrity of the chamber, prevents cool air from inside the chamber from reaching the electrical conduit 434 , thereby cooling it from the inside. The thermally insulating sealant also inhibits radial conduction from the interior wall 180 to the electrical or signal cabling 438 , which tend to be high thermal conductors. All of these factors combine to inhibit the cooling of the external wall 190 and the electrical conduit 434 , and the attendant formation of condensation thereon. The use of standard threaded couplings on the thermal insulative coupling 436 enables the use of standard electrical conduit during field installation.
[0078] Referring to FIG. 16 , a plumbing feed through 432 is illustrated. The particular embodiment of the plumbing feed through 432 is tailored to service a drain pan 442 , and is conceptually similar to the electrical feed through 430 . Specifically, the plumbing feed through 432 includes a drain pipe 444 that passes through the exterior frame 35 and is in fluid communication with the drain pan 442 through a thermal insulative coupling 446 , the coupling 446 penetrating the interior frame 100 . Alternatively, the drain pipe 444 may be replaced with a plug (not depicted) that blocks the thermal insulative coupling 446 , the plug being preferably of a low thermal conductivity.
[0079] The effect of the plumbing feed through 432 is the same as for the electrical feed through 430 —namely, the interposition of the thermal insulative coupling 446 reduces conduction between interior frame 100 and the exterior frame 35 , thus allowing the base assembly 15 to operate at a higher temperature and reduce the chance of condensation formation. Of course, the thermal insulative coupling 446 cannot be filled with a permanent sealant, lest the plumbing feed through not serve its intended purpose of draining the chamber. However, the effect of chamber air cooling the drain pipe 444 may be mitigated by the presence of water that fills the drain pipe 444 and thermal insulative coupling 446 . The drain pipe 444 may be sealed off downstream (e.g. with a valve) and drained only periodically, so that over most of the operational life of the chamber there is no air circulating into the drain pipe 444 . The water within the drain pipe 444 and thermal insulative coupling 446 will be stagnant, and tend to equilibrate with the local temperature of the surroundings. Hence the mitigation of the cooling effect of an open drain pipe 444 . The aforementioned plug in the thermal insulative coupling 446 would produce the same effect.
[0080] The preceding discussions assume that the air streams being handled by the various embodiments of the invention are at a temperature less than the temperature of the ambient surroundings. Also, some reference is made to certain structural components being metallic. Such examples are not to be considered limiting, as the invention may have utility in a wide range of air and fluid handling situations, and thermally conductive structural components are not limited to metals. Furthermore, the invention may be embodied in other specific and unmentioned forms without departing from the spirit or essential attributes thereof, and it is therefore asserted that the foregoing embodiments are in all respects illustrative and not restrictive. | An air chamber for the housing of air handling components including an interior shell surrounded by an exterior shell, the shells being separated by materials of relatively low thermal conductivity. The interior shell is peripherally mounted on an interior base. The interior base is disposed within an exterior base that supports the exterior shell. A structural thermal insulation material is disposed interstitially between the interior and exterior bases and the interior base and interior shell are thermally isolated from the exterior base and exterior shell. | 5 |
[0001] This is a continuation-in-part of U.S. patent application Ser. No. 10/797,410, filed Mar. 10, 2004, which is currently pending, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a method of manufacturing a decorative fencing system, and, more particularly, to a method of manufacturing a decorative fencing system that includes multiple components and may be arranged in a potentially unlimited number of combinations and permutations, to be used as a small or low fence, or a decorative accent fence for an outdoor yard or walk, or a combination thereof.
[0004] 2. Description of the Related Art
[0005] The art fails to specifically address either the problem or the solution reached by the applicant. Decorative fencing systems have long been known in the industry, as has the use of sectional fence structures to create various configurations for fencing systems. Some examples of such fencing systems are shown in references that date back to the mid to late 1800s.
[0006] A common shortcoming in the related art is inflexibility. In many systems, the fence can be assembled by the user in only a single configuration. In other systems, while more than one configuration is possible, it is complicated and time consuming for the user, after assembling the fence in one configuration, to disassemble it and reassemble it in another configuration.
[0007] There has long been a need for a decorative fencing system, which can be easily and quickly assembled in one configuration, easily and quickly disassembled, then easily and quickly reassembled in any one of a nearly limitless variety of different configurations.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a method of manufacturing a decorative fencing system having several components that may easily and quickly be arranged in one of a nearly limitless number of configurations or combinations, easily and quickly disassembled, and easily and quickly reassembled in another one of the nearly limitless number of configurations or combinations.
[0009] The present invention provides a method of manufacturing such a decorative fencing system that may be used as a small or low fence, or a decorative accent fence for an outdoor yard or walk, or even a combination thereof.
[0010] The present invention further provides a method of manufacturing such a decorative fencing system that allows a user to purchase and use only those elements necessary to create the design or shape of his or her choosing.
[0011] The present invention further provides a method of manufacturing such a decorative fencing system that may be either permanently or temporarily affixed to the ground.
[0012] The present invention further provides a method of manufacturing such a decorative fencing system which includes all the elements necessary to create a standard fence, including base units, gates and end units.
[0013] The present invention further provides a method of manufacturing such a decorative fencing system which may include a variety of interchangeable, structural, functional, and decorative elements.
[0014] The present invention further provides a method of manufacturing such a decorative fencing system in which the individual components are manufactured from a variety of materials or be provided with a variety of finishes.
[0015] The present invention, as broadly disclosed herein, comprises a method of manufacturing a decorative fencing system, designed to be used as a small fence or decorative accent fence for an outdoor yard, or a combination thereof. The fencing system is manufactured to include several different components that may be joined in various combinations so as to create a limitless number of different configurations or arrangements. The components include base units, decorative end units and gate units, each of which may be removably and interchangeably attached to the other components in any combination thereof. Each of these components are removably and interchangeably attached to post sections which are inserted through post rings or post hinges on the individual components to thereby allow for each component to be rotated to the desired position relative to the post section. The post sections can be removably and interchangeably secured to the ground by means of stakes that are first driven into the ground.
[0016] In one embodiment, the post sections are removably and interchangeably insertable into respective sleeves in the stakes, to thereby provide support and stability for the fencing system. The fence components are removably and interchangeably attachable to selected post sections to create a desired fence configuration.
[0017] In another embodiment, the post sections are manufactured to be friction-fit to the stakes, the stakes driven into the ground, and the fence components are then removably and interchangeably attached to selected post sections, in order to create a desired fence configuration.
[0018] In still another embodiment, a lower portion of the posts are manufactured to be hollow, and the stakes are configured with a protruding extension. The hollow lower portions of the posts are removably and interchangeably insertable over a respective protruding portion of selected stakes, and the fence components are removably attachable to selected post sections to interchangeably create a desired fence configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The objects and advantages of the present invention will be apparent from the detailed explanation of the preferred embodiments of the invention in connection with the accompanying drawings, wherein:
[0020] FIG. 1 is a front elevational view of a portion of the decorative fencing system of the present invention showing various components thereof.
[0021] FIG. 1A is a top view of a post ring attached to a structural fencing portion in FIG. 1 .
[0022] FIG. 2 is an exploded side view of one embodiment of a post and stake of the present invention, wherein a diameter of a removable post is smaller than an internal diameter of a stake sleeve.
[0023] FIG. 2A is an exploded side view of another embodiment of a post and stake of the present invention, where an internal diameter of a removable post is substantially identical to an internal diameter of a stake sleeve.
[0024] FIG. 3 is an exploded side view of one embodiment of a post and stake of the present invention, wherein an internal diameter of a removable post is larger than a diameter of a post receiving extension on the stake.
[0025] FIG. 4 is a front elevational view of a fence base unit.
[0026] FIG. 5 is a front elevational view of a fence end unit.
[0027] FIG. 5A is a front elevational view of another embodiment of a fence end unit.
[0028] FIG. 6 is a front elevational view of fence gate units.
[0029] FIG. 7 is a front view of a decorative fence system in accordance with the invention.
[0030] FIG. 8 is a top perspective view depicting different arrangements of the decorative fence system of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring to the drawings and, in particular, to FIGS. 1, 1A , and 2 , the decorative fencing system of the present invention, referred to generally by reference numeral 10 , is illustrated. The fencing system 10 comprises separate structural components 12 including a base unit 14 , a gate unit 16 , and an end unit 18 , which are arranged and combined with each other so as to create a potentially limitless number of configurations for the decorative fencing system 10 .
[0032] The fence structural components 12 are manufactured to be attached to each other by means of one or more posts 20 to which the fence structural components 12 may be removably and interchangeably attached. In the preferred embodiment, the means for attaching the fence structural components 12 comprises post rings 22 , depicted in FIGS. 1 and 1 A, which are disposed on either end of the base units 14 or on one end of the end units 18 , shown in FIG. 5 , or by post hinges 24 , which are disposed on the outside edges of the gate units 16 shown in FIG. 6 . The post rings 22 are annular elements having an inner diameter slightly larger than the diameter or width of the posts 20 such that post 20 may be slidably inserted within the post rings 22 to thereby engage either the base unit 14 or end unit 18 . As broadly embodied herein, the inner diameter of the post rings 22 is approximately 21 mm and the diameter of the posts 20 is approximately 19.76 mm. Similarly the post hinges 24 , include annular elements similar to the post rings 22 coupled with a hinge 26 , that allows the individual gate elements 28 of the gate unit 16 to swing open and shut. In the preferred embodiment, the gate elements 16 comprise a pair of complementary doors that may be operated independently or concurrently, although other designs are possible so as to fit with the design and theme of the decorative fencing system 10 .
[0033] As illustrated in FIGS. 1 and 4 - 6 , each of the structural components 12 includes two post rings 22 or post hinges 24 at each end at which the component 12 may be attached to the post 20 . For example, the base unit 14 includes two post rings 22 on either side thereof, the gate unit 16 includes two post hinges 24 on the outside edge of each gate element 28 , and the end unit 18 includes two post rings 22 on one side thereof. In the preferred embodiment, the post rings 22 or post hinges 24 are attachable to a substantially vertical element 30 so that the post rings 22 or post hinges 24 are in alignment when receiving the posts 20 . Alternate embodiments are possible in which either the post rings 22 or post hinges 24 are attachable to horizontal components or other elements provided, however, that the post rings 22 or post hinges 24 are in alignment. Furthermore, while in the preferred embodiment only two post rings 22 or post hinges 24 are disposed along each vertical element 30 , more may be provided so as to further strengthen and secure the attachment of the structural components 12 to the posts 20 .
[0034] It should also be appreciated that while in the preferred embodiment, the post rings 22 and post hinges 24 are disposed at the top and the bottom of the vertical elements 30 , as shown in FIGS. 1 and 4 - 6 , they may be positioned at various heights along the length of the vertical elements 30 as may be desired. For example, as illustrated in FIGS. 1 and 4 - 6 , the height of the upper post ring 32 on the base unit 14 is higher than that of the upper post ring 22 on the end unit 18 , which, in turn, is higher than upper post hinge 24 on the gate unit 16 . This configuration facilitates the combination of two or more structural components 12 since the post rings 22 or post hinges 24 will not necessarily interfere with each other. It should also be appreciated that, in the preferred embodiment, contact should be avoided between the post hinges 24 and the post rings 22 so as to prevent interference with the operation of the hinges. Toward that end, it may be preferred to mount the lower post hinges 24 of the gate unit 16 as broadly depicted in FIG. 6 , above the lower post rings 22 of either the base unit 14 or the end unit 18 .
[0035] The decorative fencing system 10 is secured to the ground by means of one or more stakes 40 . The stakes 40 are designed to be driven into the ground and receive the posts 20 to thereby support the structural components 12 in place. In the preferred embodiment, the stakes 40 are manufactured to be wedge shaped or to include a plurality of fins so as to facilitate their insertion into the ground, although a variety of alternative designs are possible. Preferably, the stakes 40 are pointed at one end, so that the stakes can be forcibly driven into the ground. However, if the user prefers to dig a hole for the stakes 40 , this can be done, and these elements could be of practically any shape or size, provided they could receive and retain the posts 20 .
[0036] In one preferred embodiment, as broadly depicted in FIG. 2 , the stakes 40 receive and retain the posts 20 by means of a stake sleeve 42 , essentially a cylindrical recess or cavity within the body of the stake 40 having an internal diameter slightly larger than the diameter or width of the post 20 such that the post 20 will be received within and retained by the stake sleeve 42 only by means of frictional contact therebetween. The posts 20 preferably are manufactured to be removably held only by friction, so that they are removable from each stake sleeve 42 and insertable into another stake sleeve 42 , as desired. They are not welded or otherwise permanently affixed in place. As broadly embodied herein, in this embodiment the preferred internal diameter of the stake sleeves 42 is approximately 22 cm-22.5 cm, and the preferred external diameter is approximately 26.5-28 cm. There is some clearance between the post 20 and the internal surface of the stake sleeve 42 . In this embodiment, post 20 can be removed from stake 40 , leaving stake 40 in the ground, and reinserted into another stake 40 driven into the ground at a different selected location.
[0037] Alternatively, in another preferred embodiment, as broadly depicted in FIG. 2A , the posts are made larger, so that the diameter of the posts 20 are substantially identical to an internal diameter of the stake sleeve 42 . In this embodiment, the posts 20 are permanently friction-fit into the stake sleeves 42 . In this embodiment, removal of post 20 from the ground for movement to another selected location, also requires removal of the stake 40 from the ground.
[0038] In another preferred embodiment, as depicted broadly in FIG. 3 , stake 40 is manufactured with an extending solid post-receiving portion 44 , and the post 20 has a hollow portion 48 at its lower distal end, with a diameter larger than the diameter of the post receiving portion 44 . In this embodiment, each selected post hollow portion 48 fits over each selected post-receiving portion 44 , and the posts 20 are supported thereby. In this embodiment, like the embodiment of FIG. 2 , post 20 can be removed from stake 40 , without removing stake 40 from the ground, and moved to another stake 40 , which is driven into the ground at a different location.
[0039] Ideally, the stake sleeve 42 or post-receiving portion 44 should be of sufficient length so as to securely receive the post 20 , and the length of the portion of the stake 40 that is inserted into the ground, or the length of post hollow portion 48 that sits on top of post-receiving portion 44 should be sufficient to prevent the post 20 from toppling over when the decorative fencing system 10 is assembled. In a preferred embodiment, the length of the portion of the stake 40 that is inserted into the ground, or that sits on top of post-receiving portion 44 is approximately 10 cm, although longer stakes 40 may function just as well, and shorter ones may also serve effectively, provided the weight of the structural components and posts 20 are not too great, and the ground itself is firm enough to retain the stake 40 therein. Also in the preferred embodiment, the stake sleeve 42 should extend above the ground level by a sufficient height to allow the desired clearance between the bottom of the structural components 12 and the ground. As broadly embodied herein, a preferred height of the stake sleeves 42 is approximately 15-20 cm, with a height above the ground of approximately 5 cm-8 cm. This is most significant for the gate unit 16 , since the gate elements must clear any uneven ground in order to allow the gate elements to open and close properly. Furthermore, the combined weight of the post 20 and any structural components 12 attached thereto serve to force the post 20 within the stake sleeve 42 and prevent the post from sliding out prematurely.
[0040] The end units 18 , broadly depicted in FIGS. 5 and 5 A, serve to provide decorative termination points for the decorative fencing system 10 , and as such, include a decorative termination point 44 on the side opposite the vertical element 30 or the side to which the post rings 22 are attached. Rather than use a separate post 20 to anchor the termination point 44 to the ground, a separate stake pin 50 can be provided at the termination point 44 . The stake pin 50 extends below ground level when the end unit 18 is attached, thereby securing the end of the end unit 18 to the ground. As illustrated in FIGS. 5 and 5 A, in preferred embodiments the stake pin 50 can be thin to facilitate its insertion into the ground. It also is of approximately the same length as the stake 40 , although a shorter stake pin 50 would work just as effectively.
[0041] In the preferred embodiment of the method of manufacturing fencing system 10 , the components of fencing system 10 are manufactured from tubular steel, and both square and round stock. A powder coat finish may be provided on some or all of the elements. For example, a separate color or finish or a different material, such as bronze colored cast iron, may be used for decorative accents 48 such as finials 51 or decorative ball caps 52 .
[0042] Preferably, jigs are set up and all of the component pieces are cut from tubular steel, wire rod, and flat stock, i.e., the stakes 40 , the posts 20 , structural components 12 , post rings 22 , post hinges 24 , and so on.
[0043] Curved pieces are then formed at appropriate locations in the end structural components 12 , and some structural components 12 are shaped into end units 18 or gate units 16 .
[0044] The post rings 22 are cut, and stamped into their final shape.
[0045] Holding the components in jigs, decorative finials 50 may be welded into ends of the posts 20 or vertical pieces of structural components 12 , and hinges 24 are welded into place on gate units 16 . Rings 22 are also welded into appropriate locations on structural components 12 .
[0046] The components are prepared for powder coating either through insertion into a metal pellet sand blast chamber or through the use of an acid wash sequence that ends with drying to eliminate water in the crevices prior to coating.
[0047] Individual pieces are then powder coated.
[0048] Alternative manufacturing methods, or minor variations on the above method, are also contemplated, including manufacturing individual components out of solid iron or steel pieces, then welding and then finishing by powder coating or painting. The components may be produced as individual cast iron pieces and finished with various paint techniques to create different appearances.
[0049] It should be appreciated that the design of the individual structural components shown in the drawings represent one possible design for the decorative fencing system 10 of the present invention. A variety of different designs and decorative accents 48 are contemplated, such as a Victorian design or a more modern design. The only limitation is that the design of the system 10 is embodied by the structural components 12 and tied together by the posts 20 , post rings 22 and post hinges 24 , and that the structural components 12 and posts 20 are removable and interchangeable so that a wide variety of fence configurations can be assembled, as explained below.
[0050] The process of assembling the fencing system 10 is designed to be simple and easy to alter. In the preferred embodiment, a stake 40 is driven into the ground, and the individual structural components 12 are held into place above the stake 40 . A post 20 is inserted through the post rings 22 and/or post hinges 24 , are then removably inserted into the stake sleeve 42 of the stake 40 , or in another embodiment friction-fit into the stake sleeve. The process is repeated as necessary until the desired configuration is achieved, allowing for a potentially infinite number of combinations and angles between the structural components. Some examples of these variations are illustrated in FIGS. 7 and 8 . Since each of the structural components 12 may be purchased separately, the decorative fencing system 10 may be as large or as small as the user.
[0051] Having thus described the invention with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications can be made therein without departing from the spirit and scope of the present invention as defined by the appended claims. | A method of manufacturing a decorative fencing system for use as a small fence or decorative accent fence for a yard or garden. The fencing system comprises several different structural components that may be joined in various combinations so as to create a nearly limitless number of different configurations or arrangements. The components include base units, decorative end units and gate units, each of which may be attached to the other components in any combination thereof. Each of these components are attached to post sections which are removably and interchangeably inserted through post rings or post hinges or welded onto the individual components to thereby allow for each component to be rotated to the desired position relative to the post section. The post sections are removably and interchangeably secured to the ground by means of stakes that are driven into the ground and the post section is then inserted into a sleeve in the stake, or alternately onto a post-receiving extension on the stake to thereby provide support and stability for the fencing system, with the post section being held by the stake, either removably or permanently. | 4 |
[0001] This application includes material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosure, as it appears in the Patent and Trademark Office files or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
[0002] The present invention relates in general to storage units, and in particular to a modular storage system having a series of panels connected at varying angles for subdividing irregular storage spaces.
BACKGROUND OF THE INVENTION
[0003] Modular systems for building storage units and shelves come in a variety of shapes and sizes. These systems are often built or assembled with a series of panels forming the sides, top and bottom, the panels being attached using connectors. Typically, these panels and connectors are designed specifically to enable connection between adjacent panels at right angles which form the walls of the storage units. While these systems are well designed for conventional spaces, they often fail to efficiently use space where walls may be non-parallel or have irregular contours. Moreover, these conventional units are limited to certain established configurations which may not suit an area's particular needs. Thus conventional storage units often do not adequately make use of all of the space available to them.
[0004] Another drawback of conventional storage units is that the connectors are often rigid and typically have complex structure. These complex connectors may be difficult to assemble and also do not allow for flexible connections between panels or for easy assembly and disassembly of the storage units. Conventional connectors also often require attachment through the supporting walls which can affect the storage unit's structural integrity. Moreover, these complex connectors can also result in increased manufacturing cost of the storage system.
[0005] Thus it would be desirable to provide a modular wall system which will allow for connections of panels at varying angles to maximize storage efficiency. Additionally, it would be desirable to provide a system which allows for flexible connections which are easily assembled and disassembled. Ideally, with this improved storage system, panels may be connected with a variety of different connectors and assembled in many different configurations for use in more than one area.
OBJECTS AND SUMMARY OF THE INVENTION
[0006] In accordance with the general object of the present invention, a modular system for assembling a storage unit is provided which allows for positioning of storage units which fit in spaces which may have irregular contours or in corners which may not form a right angle.
[0007] It is another object of the present invention to provide a modular wall system which has flexible, easy to use connectors.
[0008] It is still a further object of the present invention to provide a modular storage system which can be connected with a variety of different types of connectors.
[0009] The modular storage system of the present invention includes a plurality of panels each of which has a top surface, a bottom surface and side edges. The top surfaces of the panels have a plurality of panel recesses. The system further includes connectors which include two elongated end portions each having a recess along the length thereof and joined together by a flexible linkage. Preferably, each of the panels includes at least one side recess along one of the side edges. Advantageously, the panel recesses extend parallel to one another between two opposite side edges. In a preferred embodiment, each panel has a first set of panel recesses which run parallel to each other and a second set of panel recesses which extend parallel to one another and at an angle, preferably 90 degrees, with respect to the first set of recesses. The system also includes connecting links which connect the panels to the connectors. These connecting links have a first end which is received in the panel recesses and a second end which is received in the connector recesses. Preferably, the ends of the connecting links are joined by a shaft which allows rotation and flexion of the connector relative to the panel. The shaft may, for example, include a ball and socket joint.
[0010] In accordance with another aspect of the present invention, a modular system for assembling a storage unit is provided. The unit includes a plurality of panels each having a top surface, a bottom surface and side edges. The top surfaces include a plurality of panel recesses. The plurality of panels are joined to each other by connecting links. The links have a first end receivable in the recesses of a first panel, a second end receivable in the recesses of a second panel and a flexible shaft connecting the two ends. In an advantageous embodiment, the flexible shaft may be in the form of a ball and socket joint.
[0011] In accordance with still another aspect of the present invention, a modular system for building a storage unit is provided. The unit includes a plurality of panels, each of the panels having a top surface, a bottom surface and side edges. The panels include a plurality of parallel spaced cylindrical shaped recesses which open in the top surface and in the side edges. Additionally, the unit includes connectors for connecting the panels. The connectors include at least two parallel elongated portions connected by a flexible linkage along their lengths, each of the portions having a cylindrical-shaped recess therein extending along its length. The unit also includes connecting links for connecting the panels to the connectors. The connecting links include first and second cylindrical shaped portions connected by a flexible shaft. The first portion o: the connecting link is receivable in one of the panel recesses and the second portion is receivable in one of the connector recesses.
[0012] Further features and advantages of the present invention will be set forth in or apparent from, the detailed description of preferred embodiments thereof which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of preferred embodiments as illustrated in the accompanying drawings, in which reference characters refer to the same parts throughout the various views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating principles of the invention.
[0014] [0014]FIG. 1 is a front perspective view illustrating a modular storage unit constructed in accordance with the invention in use in a location having non-perpendicular walls;
[0015] [0015]FIG. 1A is a perspective view showing the detail of the interconnection of the panel members by stop links.
[0016] [0016]FIG. 2A is a top view of a panel member;
[0017] [0017]FIG. 2B is a side view of the panel member in FIG. 2A;
[0018] [0018]FIG. 3A is a side view of a connecting link;
[0019] [0019]FIG. 3B is a top view of the connecting link in FIG. 3A;
[0020] [0020]FIG. 3C is a side view of a stop link which further includes a ball and socket joint;
[0021] [0021]FIG. 4A is a planar view of a flat connector;
[0022] [0022]FIG. 4B is an edge view of the connector in FIG. 4A;
[0023] [0023]FIG. 4C is a planar view of an angled connector;
[0024] [0024]FIG. 4D is an edge view of the connector in FIG. 4C;
[0025] [0025]FIG. 4E is a planar view of a connector for direct connection of panels at right angles;
[0026] [0026]FIG. 4F is an edge view of the connector in FIG. 4E;
[0027] [0027]FIG. 5A is a planar view of a top link; and
[0028] [0028]FIG. 5B is an edge view of the top link in FIG. 5A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0030] [0030]FIG. 1 shows the modular system of the invention assembled as a storage unit 10 in the interior of a structure, such as a sailboat, wherein the walls are curved and are not at 90 degrees with respect to one another. The storage unit 10 includes a first panel 12 which includes a series of recesses 16 . A second panel 22 is joined to the first panel 12 by two connecting links 24 , 24 ′ and a connector 26 . Specifically, the first panel 12 is joined to connecting link 24 at recess 16 ′ and is joined to one elongated portion 27 of connector 26 . The connector 26 is joined to the second panel 22 via connecting link 24 ′ at recess 16 ′ and joined to the second elongated portion 27 ′ of connector 26 . The advantage of using two connecting links 24 , 24 ′ and a connector 26 to join adjacent panels 12 , 22 is that it allows the storage unit 10 to be assembled in a variety of configurations including those in which the panels are connected at non-right angles as shown in FIG. 1. For purposes of clarity in illustrating the invention, only two connecting links 24 , 24 ′ are shown in FIG. 1. However, it will be understood that in a typical application more than two connecting links will be required to secure the panels 12 and 22 . A third panel 23 forms the base of the storage unit and is connected to panels 12 , 22 via connectors 29 , 31 , respectively. A number of different connections and units may be formed using the panels, connectors and connecting links. The connecting links 24 , 24 ′ may have one or more edges which have ridges or other means for providing friction to prevent slippage of the panels once they are assembled together. If one surface of the links are provided with ridges and other surfaces are not, the panels may thereby be made to slide together in one direction easily during assembly of the panels, but not to slide in a reverse direction so as to prevent slippage of the assembled panels.
[0031] [0031]FIG. 1A is a perspective view showing the detail of the interconnection of the panel members by connectors 26 and connecting links 32 . In the embodiment shown, stop links are used as connecting links 32 . Such stop links may be used, e.g., where sliding of the panels is not desired. While FIG. 1A shows stop links connecting the panels only at portions of the panels where the recesses cross, it will be understood by those skilled in the art that connecting links may be used at any point along the recesses without departing from the spirit and scope of the invention.
[0032] The panels may be of any shape or size, and may be constructed from any suitable material. Standard shapes and sizes may be provided and may be cut and combined to provide a storage system that fits any particular irregularly-shaped space. Typically, the panels are rectangular such as panels 12 , 22 , but may be triangular or have one or more curved edges. The panels may be constructed from any material which is pliable enough to fit into a space between walls which are not positioned at 90 degrees with respect to each other, but rigid enough to hold the objects for which the storage unit is being used.
[0033] Turning now to FIGS. 2 A-B, the structure of the panels is described in greater detail with reference to panel 12 . Panel 12 includes a top surface 14 and a bottom surface 18 . The panel 12 includes a first set of recesses 16 . A second set of recesses 20 , on the opposite side of panel 12 from recesses 16 , intersect and are positioned at an angle with respect to the first set of recesses 16 . The recesses 16 , 20 may be positioned at various intervals along the top surface 14 and/or bottom surface 18 . Preferably, however, the first set of recesses 16 run parallel to one another and extend from one edge 19 to an opposite edge 21 and the second set of recesses 20 run parallel to each other from another panel edge 23 to an opposite edge 25 such that they are at an angle of 90 degrees with respect to the first set of recesses 16 . This configuration of the recesses 16 , 20 allows for multiple choices in deciding how to connect adjoining panels. Additionally, the configuration of the recesses 16 , 20 allows for connection of multiple panels at varying angles. Preferably, panel 12 includes at least one recess 17 in one or more of the side edges 19 , 21 , 23 , 25 . The recesses 16 , 17 , 20 may have any shape suitable for receiving the connecting links, although they are typically cylindrical with an opening for receiving the connecting links as discussed in connection with FIGS. 3 A-C below.
[0034] FIGS. 3 A-C show a connecting link 24 which allows for connection of adjacent panels. Each connecting link 24 includes two end portions 42 . The end portions 42 are preferably of a shape which corresponds to the shape of the recesses and are sized to fit snugly within the recesses. In the embodiment shown in FIGS. 3 A-B, the end portions 42 are connected by a shaft 44 which is preferably flexible to allow for connection of adjacent panels at varying angles. Alternatively, as shown in FIG. 3C, end portions 42 may be connected by a ball and socket joint 46 providing for rotation and flexion. Connecting links 24 may further include a protrusion 54 , also shown in FIG. 3C, extending outwardly from one or both end portions 42 . The protrusion 54 is designed to fit within the recesses at points 15 where the recesses intersect to prevent slippage in any direction within the recesses 16 , 20 . Recesses 16 and 20 are preferably of equal dimension and positioned within the mid portion of panel 12 such that, at their point of intersection, a through aperture is created. A protrusion 54 is positioned within the recesses to prevent slippage. This allows for the assembly of heavier load bearing storage units.
[0035] The connectors 26 , 60 shown in FIGS. 4 A-F include two elongated end portions 29 , 39 , 61 connected by a hinge 34 , 40 , 64 along the lengths thereof to allow flexion. In the embodiments, shown in FIGS. 4 A-D, the connectors 26 include recesses 28 , 38 and are of a shape suitable for allowing end portions 42 of the connecting links 24 to snap firmly into them, thus providing a tight bond between panels. If the connectors are fabricated of a flexible material, a single connector type may be used and may be flexed to form either the connector shown at 26 or the connector shown at 26 . In an alternative embodiment, shown in FIGS. 4 E-F, wherein adjacent panels are connected at right angles or any angle that the connectors can flex to, connectors 60 may be formed with protrusions 62 which snap directly into parallel, appropriately spaced panel recesses, thereby eliminating the need for connecting links 24 and increasing the rigidity of the connection between panels. While FIGS. 4 a and 4 b show an embodiment wherein adjacent panels are connected in a planar configuration, and FIGS. 4 c and 4 d show an embodiment wherein adjacent panels are connected at right angles to one another, it will be understood that adjacent panels may be connected at various angles without departing from the spirit and scope of the invention.
[0036] The hinge 34 , 40 , 64 can be constructed to allow for varying degrees of flexion. In the FIGS. 4 A-B and 4 E-F embodiments, hinges 34 , 64 are constructed so that adjacent panels may be rotated such that they assume an angle with respect to one another ranging from 60 to 240. FIGS. 4 C-D illustrates connector 26 in the 90-degree orientation. This allows for connection of adjacent panels at a number of different angles.
[0037] The storage unit 10 preferably further includes top links 30 . The top links 30 finish the exposed edges and also provide rigidity to the unit 10 . Top links 30 , shown in FIGS. 5 A-B may be included to finish the panels by closing the recesses, most typically the side edge recesses 17 . Top links 30 also provide added rigidity to the storage unit. The top links 30 are designed to snap into the recesses. The top links 30 include one connection portion 56 and one finished side 58 . Thus, the top link 30 is connected by snapping the connection portion 56 firmly into a recess, thus providing added rigidity. The finished side 58 then provides a smooth edge to the finished unit 10 and may also be decorative.
[0038] While the invention has been particularly shown and described with reference to a preferred embodiment 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 spirit and scope of the invention. | A modular system for assembling a storage unit is provided which includes a plurality of panels and different connectors. The system allows for subdividing spaces which may feature walls, floors, ceilings, etc. at varying angles or in areas having irregular contours. Additionally, the connectors are simple recesses and protrusions which allow for easy assembly and disassembly of the storage unit. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS AND PATENTS
This application is related as a continuation-in-part of commonly owned application Ser. No. 08/514,382, now U.S. Pat. No. 6,042,009, filed Aug. 11, 1995, entitled “POCKET INTERFACE UNIT (PIU) FOR A SMART-DISKETTE”, which is a continuation-in-part of commonly owned application Ser. No. 08/170,166, filed Apr. 19, 1994, now U.S. Pat. No. 5,584,043 (Burkart and Eisele), the subject matter of which are hereby incorporated by reference.
This application is also related to the following commonly owned applications and patents:
application Ser. No. 09/184,350, filed Nov. 2, 1998, still pending, entitled “HOME POINT-OF-SALE (POS) TERMINAL”;
application Ser. No. 09/092,003, now U.S. Pat. No. 5,988,512, filed Jun. 5, 1998, entitled “SMART DATA STORAGE DEVICE”; which is a continuation-in-part of application Ser. No. 08/420,796, still pending;
application Ser. No. 09/086,677, filed May 29, 1998, still pending, entitled “SMART-CARD AND MEMORY MODULE ADAPTER”;
application Ser. No. 09/013,036 filed Jan. 26, 1998, still pending entitled “ADAPTER”, hereby incorporated by reference;
application Ser. No. 08/420,796 filed Apr. 12, 1995, still pending entitled “SMART DATA STORAGE DEVICE” which is a continuation of Ser. No. 07/947,570 (abandoned), which is a continuation of Ser. No. 07/448,093, now U.S. Pat. No. 5,159,182, hereby incorporated by reference;
U.S. Pat. No. 5,471,038 entitled “SMART-DISKETTE READ/WRITE DEVICE HAVING FIXED HEAD”;
application Ser. No. 08/479,747 filed Jun. 7, 1995, still pending, entitled “COMMUNICATION INTERFACE ELEMENT RECEIVABLE INTO A MEDIA DRIVE” which is a continuation of Ser. No. 07/712,897, now U.S. Pat. No. 5,457,590, hereby incorporated by reference; and
application Ser. No. 08/867,496, now U.S. Pat. No. 6,089,459, filed Jun. 2, 1997, entitled “SMART-DISKETTE DEVICE” (allowed) hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of The Invention
The present invention relates generally to the field of computer devices, and in particular, to an adapter element in the shape of a diskette for insertion into a floppy disk drive, which is designed to receive a plurality of memory modules or cards therein.
2. Background Information
There is known a so-called “smart-diskette,” which is a device having the external shape of, for example, a standard 3½ inch diskette, and which contains therein, instead of and/or in addition to a magnetic medium (disk), interface and processing circuitry for providing particular functionality to the device. The known smart-diskette circuitry includes an interface for transferring data between other components provided on the device and/or inserted into the device, and a magnetic head of a standard floppy disk drive into which the device can be inserted. In various forms, the smart-diskette device may include a microprocessor for controlling the device and performing various tasks, such as data encryption. On-board memory may be provided as well in the form of, for example, RAM (random access memory), ROM (read only memory), EEPROM (electronically erasable/programmable read only memory), and/or Flash memory, for storing programs and data. The device circuitry may be provided in the form of discrete components or an application specific integrated circuit (ASIC).
U.S. Pat. No. 5,159,182, and copending application Ser. No. 08/420,796 still pending, disclose embodiments of a smart-diskette insertable element with magnetic interface, processor, power supply and optional display and keypad, designed to be inserted into a standard 3½ inch floppy disk drive of a host computer, i.e., electronic data processing (EDP) equipment, such as a desk-top personal computer (PC) or notebook computer, for example.
An exemplary embodiment of the smart-diskette insertable element disclosed in the above-mentioned patent and application, has a processor with some built-in program/data memory, additional memory for storing data and/or programs, and an interface designed to facilitate the exchange of data between the device and a floppy disk drive read/write head. A driver and coil of the interface convert signals from the processor into the required magnetic form and provide them to the read/write head of a floppy disk drive, and likewise convert signals received from the floppy disk drive read/write head into the required form for use by the processor.
A significant advantage of the smart-diskette insertable element is that, by virtue of its insertability into the standard, ubiquitous, floppy disk drive, and interfaceability therewith, it is possible to carry-out a variety of operations with the processor and/or memory on the element. These include but are not limited to encryption and decryption of data and/or verification of user identity. Such operations are accomplished without requiring any specially designed interface or plug-in boards which might be suitable only for use with a limited number of computer systems. Another advantageous feature of the smart-diskette insertable element is its ability to store additional data and/or programs in on-board and/or add-on memory connected with the on-board processor. This considerably increases the potential areas of application for the element.
The smart-diskette element disclosed in the above patent and application, may be equipped with a battery power source supplying power to the electronic components within the element, and/or a generator/alternator, with associated regulator circuitry, driven by the rotation of a floppy disk drive spindle.
As mentioned, the interface of the smart-diskette insertable element is designed to allow data to be exchanged with the read/write head of a floppy disk drive, and one way this can be achieved is by locating an electromagnetic component on the element, e.g., one or more coils, to be in the vicinity of the read/write head of the floppy disk drive when the element is inserted into the drive, and which generates magnetic field information equivalent to that generated by a magnetic disk of a standard floppy diskette. In this way, the interface simulates a magnetic floppy diskette. This property of the interface allows data to be transferred under control of the on-board processor to the EDP, e.g., data which enables user identification to be verified, thereby providing security to the EDP equipment, or any of a number of other operations, as would be recognized by one skilled in the art. As processor capabilities expand and memory devices with increasing capacity become smaller, the smart-diskette takes on the potential for more and more useful applications.
Related U.S. Pat. No. 5,471,038 discloses a read/write unit with a read/write head and optional electrical contacts, but without the standard disk driving and head moving parts, for use in a desk-top PC or notebook computer to communicate with a smart-diskette. By eliminating the drive motor and moving read/write heads, a significant amount of energy which would otherwise expended by the use of such moving parts is conserved.
Further, such a read/write unit, since it eliminates bulky drive and head motors, can be made more compact than a standard floppy disk drive, thereby reducing the overall size and weight requirements for the computer in which it is installed.
Related copending application Ser. No. 08/514,382 discloses a pocket interface unit (PIU) for use with a smart-diskette. Pocket calculators and diary devices are known and gaining acceptance with busy executives, for example. However, such devices have numerous limitations and disadvantages. For example, although such devices can interface with a desk-top computer to download application programs and/or data, for example, or to upload data entered on the pocket device to the desk-top computer, to do so currently requires inconvenient cabling, and/or a special interface unit, e.g., PCMCIA, with associated costs. Some devices use infra-red beams to communicate between the device and the PC, but these are subject to atmospheric and distance limitations, or may be subject to errors due to dust or dirt on a lens, for example.
In addition, such pocket devices are generally limited to a single special application, such as a phone directory, or a golf-handicap calculator, and do not generally provide the range of capabilities of a notebook computer, for example. Pocket-sized pagers and cellular telephones are also known. However, these respective devices do not generally have the capability of functioning as anything except a pager or telephone, that is, they are generally devices which are dedicated to a single function. Therefore, the fully-equipped, fully-functional executive may be burdened by having to carry around a variety of separate devices, which further disadvantageously cannot readily interface with one another.
The PIU, disclosed in the copending application, for use with a smart-diskette, overcomes these and other problems, as well as providing other advantages over the prior art.
Related U.S. Pat. No. 5,584,043 discloses a smart-diskette adapted to receive at least one memory and/or processor card, such as an ATM, patient information, or bank debit card, FlashPROM card, or the like. For example, FIG. 5 a of the patent illustrates an embodiment adapted for receiving at least one mini-chip card. This disclosed device could be used with the recently developed MMC (MultiMediaCard made by Siemens/SanDisk), or the SSFDC also called a SmartMediaCard (SMC, made by Toshiba).
The so-called MultiMediaCards (MMCs) provide small, transportable audio/video media storage in the form of a card substrate carrying a memory, and an optional processor in some cases, which can be inserted into a number of different media recording/playback devices specifically adapted to receive the MMCs. The MMC memory currently can store, for example, about 8 megabytes of digitized video and/or audio signals. Typically, contacts on the MMC are be used to connect and transfer the digitized video/audio to a media recorder or playback device.
However, if it was desired to load such data onto an MMC from a personal computer or vice versa, until the advent of the smart-diskette embodiment disclosed in the above mentioned patent, which is adapted to receive at least one memory card, such as an MMC, a special add-on device would have been required.
A variety of so-called Flash memory devices (FlashPROMs) have also become known and are more and more widely used, for example, in digital cameras. The above-mentioned MMCs may use Flash memory or any other type of non-volatile memory. However, presently, FlashPROMs typically have a capacity of only about 8 megabytes each, which may limit their usefulness under some circumstances, e.g., for application when more storage capacity is required.
As mentioned, to make full use of the MMCs as proposed, until now, a user would need an entirely new recording/playback device designed with a port for interconnecting with the MMCs to make use of them in their home. In other words, the existing conventional user playback/recording equipment does not generally interface with the newly developed MMCs.
Therefore, a need existed for an adapter device which could permit use of the new MMCs with the existing conventional electronic equipment, such as home/auto recording/playback equipment. Related copending application Ser. No. 09/013,036, still pending meets this need and discloses an adapter for use in adapting a conventional cassette tape playback/recording device with a plurality of Flash memory devices, MMCs, or the like, which store digitized audio, for example. The adapter provides a way of adapting one or more MMCs to conventional recording playback devices, such as a conventional audio or video cassette player. The adapter inserted into a conventional tape device interfaces the tape device with one or more removable storage circuits (e.g., MMCs) which store digital audio and/or video data. By accommodating a number of MMCs at once, a user can advantageously record and/or playback an extended audio or visual work with the adapter.
Of course, MMCs, Flash-memory devices, and the like, can be put to other uses besides storing audio and/or video/image data for use in a home or automobile system. They can be used to store any type of digital data imaginable. However, the inventive adapter disclosed in the copending application is in the form of a tape cassette, i.e., audio, video, or digital (e.g., DAT). While digital tape drives are available as relatively expensive add-on devices for personal computers, these tape drives are not as ubiquitous as the floppy disk drive which are provided with practically every personal computer as a standard feature.
In view of the above background information, to take further advantage of some of the possibilities of MMCs, Flash-memory devices, and the like, and to overcome problems in the art, the inventors have invented the improved adapter described in detail below.
SUMMARY OF THE INVENTION
It is, therefore, a principle object of this invention to provide an improved smart-diskette adapter, in particular, a SmartMultiAdapter (a trademark of SmartDiskette GmbH, Idstein, Germany, all rights reserved) which provides advantages over the prior art and solves the problems in the prior art.
It is, therefore, a further principle object of this invention to provide a method and apparatus for adapting a plurality of memory modules (e.g., MMCs) to a commonly used personal computer storage and retrieval device, such as a conventional 3½ inch floppy disk drive. The term memory modules as used herein refers to modules having at least memory, and perhaps an optional processor in some cases.
It is another object of the invention to provide a method and apparatus that solves the above mentioned problems so that the purchase of additional costly recording/playback equipment to use such memory modules, e.g., MMCs, with a personal computer, or the like, is unnecessary.
According to an aspect of the invention, up to 5 MMCs can be inserted at once into respective sockets on an adapter according to the invention. Two modules are insertable at the left edge of the adapter, two at the right of the adapter, and one at the rear (outer) edge of the adapter. The adapter with one or more memory modules is insertable into a floppy disk drive front edge (inner edge) first.
According to another aspect of the invention, the adapter provides for playback of music and/or image data, for example, from one or more memory modules, via the floppy disk drive of a personal computer.
According to another aspect of the invention, music and/or image data, for example, can be recorded on one or more memory modules via the personal computer floppy disk drive.
These and other objects of the present invention are accomplished by the method and apparatus disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the invention will become apparent from the following detailed description taken with the drawings in which:
FIG. 1 a is a schematic illustration of an exemplary embodiment of the invention for use with MMC modules;
FIG. 1 b is an illustration of an MMC module to be used with the adapter of FIG. 1 a;
FIG. 2 a is a schematic illustration of an exemplary embodiment of the invention for use with SSFDC/SMC modules; and
FIG. 2 b is an illustration of an SSFDC/SMC module to be used with the adapter of FIG. 2 a.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will now be described in more detail by example with reference to the embodiments shown in the Figures. It should be kept in mind that the following described embodiments are only presented by way of example and should not be construed as limiting the inventive concept to any particular physical configuration.
FIG. 1 a shows an exemplary embodiment of the invention, generally indicated as 1 A. In particular, an insertable frame 15 A, in the shape and size of a floppy diskette housing, houses one or more batteries 2 , magnetic interface (e.g., a coil) 3 which is in or adjacent to slot 4 , and a driver/converter (A/D-D/A) 5 . The magnetic interface 3 at slot 4 is arranged to magnetically couple with the read/write head of a floppy disk drive (not shown) when the adapter is inserted therein, to permit the exchange of data therewith. The driver/converter 5 converts digital data signals from the processor 6 into an analog signal form typically used by floppy disk drives (MFM) and drives the magnetic interface 3 therewith. The driver/converter 5 likewise converts analog signals picked-up by the magnetic interface 3 from the read/write head into digital form for use by the processor 6 . The processor 6 is coupled to on-board memory 7 , which may contain programs and/or data and provides storage which can be used by the processor 6 in carrying out its operations. The processor 6 could be a Motorola 6805, or the like, for example. The one or more batteries 2 provide power to the adapter components. A spindle recess 9 is provided on the frame 15 A which accommodates a floppy disk drive spindle when the adapter 1 A is inserted in a drive. An optional generator or alternator and associated regulator circuitry 14 (shown in FIG. 2 a ) could be provided on-board which would be driven by the floppy disk drive spindle in use to provide a recharging of the one or more batteries 2 .
A number of recesses 23 A-E are provided in the frame 15 A, and contacts 19 A are disposed therein for providing connection between the processor 6 and a respective memory module inserted therein. FIG. 1 b shows a memory module 16 A which has corresponding contacts thereon. Although four contacts are shown for illustration purposes, this number may vary depending on the memory module and adapter. Three contacts would probably be sufficient to provide power, ground and signal in the most rudimentary case. However, some contacts to provide address lines, control lines, and the like, are possible. The contacts are illustrated in a line, however other configurations are possible. In short, the number, configuration and function of the contacts is dependent on the type of memory module used, and the invention is not limited to any particular number or configuration or function.
Lines from the contacts 19 A in each of the recesses 23 A-E are routed to the processor 6 . As one skilled in the art would realize, depending on the memory modules used, data may output from the memory modules in serial or parallel form, and this could be by separate dedicated data and/or address and/or control lines, or a shared bus structure. The lines from the contacts could be multiplexed by the addition of a multiplexer, for example. Such details are within the scope of knowledge of those skilled in the art, and as such, need not be described here in detail. The invention is not intended to be limited to any particular memory module or data communication protocol.
The user removable memory modules 16 A may comprise only memory, e.g., Flash-memory, and connectors, i.e., there may be no significant processor power on the module 16 A itself. As known in the art, some types of memory modules may contain a rudimentary state machine logic for handling addressing of memory cells therein, for example, while others may have on-board more significant processing capabilities, for handling addressing, refreshing, etc.
Further, the removable memory modules 16 A could be, for example, the type that are typically used in digital cameras. Since the insertable frame 15 A is designed to fit into a personal computer (PC) floppy disk drive, e.g., a 3½ inch floppy disk drive, pictures taken with a digital camera and stored on a removable memory module 16 A could thus be transferred to a personal computer for editing and the like. The picture data so transferred may appear to the computer user as standard a JPEG (compressed) picture format file, for example, on a standard floppy diskette. The user can access the pictures from the removable memory module 16 A using the standard disk operations of the operating system of the PC. The user can, for example, read or write to the memory, get a directory of the pictures on the memory device, copy, delete, and view with a standard PC picture viewer, etc., just as if using a standard floppy diskette. An individual insertable memory module currently may store on the order of 2 to 16 megabytes. However, with the adapter 1 A, which accommodates up to 5 modules, has an overall storage capacity which is multiplied by 5. This is advantageous for storing relatively long audio and/or visual passages, for example.
Processor 6 could be programmed to perform compression and decompression of data so that memory is used more efficiently. Encryption and decryption of private and/or sensitive data is an option as well. Where transmitting data over public telephone lines may pose a security risk, the adapter 1 A could be useful to encrypt and store such data in memory modules 16 A which can then be transported in a relatively small package to a remote site for decryption through another adapter 1 A. The data can be password protected through interaction between the on-board processor 6 in the adapter 1 A and a personal computer.
As mentioned, besides pictures, audio and multimedia data can be conveniently transferred to and from a PC using this adapter 1 A with memory modules 16 A. Further, the memory modules 16 A could be used to provide a backup of important hard disk data, or to transfer data from one PC to another, as would be apparent to one skilled in the art.
The adapter 1 A could be used to store to memory modules 16 A data, including audio and/or visual information, obtained from the Internet by a personal computer, for example.
Phone numbers and names stored on a personal computer address book could be transferred to the memory modules 16 A with the adapter 1 A, and then used in a cellular phone, or other telephone communication device, adapted to receive memory modules 16 A. Virtually any sort of data stored in a personal computer could be transferred to memory modules 16 A with the adapter 1 A, and conveniently transferred to another device.
Since an adapter 1 A with 5 modules 16 A therein may hold over 40 megabytes of data uncompressed, such an arrangement may be used to conveniently transport personal data files, i.e., spreadsheets, word-processor documents, database files, and the like, thus eliminating the need of carrying an expensive and fragile laptop computer having a hard disk drive storing such data thereon. One or more such adapters 1 A with modules 16 A could be conveniently and safely carried and then used in another personal computer at a remote destination. Since the data is stored in non-volatile memory, it is more safely carried through airport metal detectors and the like, than ordinary floppy disks which can be accidentally erased by such machines. Further, they are not subject to scratching like conventional compact disks, for example.
As mentioned above, digital images can be stored in the memory modules 16 A, either from a PC or from a digital camera device, such as Intel's 971 PC camera or the Polaroid PDC 300, for example. When placed in an adapter 1 A, such images can be transferred to another PC anywhere in the world over the Internet.
Under the control of an application program, when used the first time, a unique number can be assigned to each memory module 16 A and stored therein. The application program further keeps track of what files are stored on which module 16 A and this information can be stored on the respective module 16 A as an index or directory. The index/directory can later be read by another application program so that the desired data can be accessed. This can all be handled according to standard disk operating system (DOS) parameters and formats, or can be handled in a non-standard as an additional way to prevent unauthorized access to the data.
FIG. 2 a shows just one of many possible alternate embodiments, in particular, an embodiment designed for use with 2 SSFDCs 16 B (i.e., SmartMediaCards—SMCs), which have a larger external size and use different interconnecting contacts 19 B. In this illustrated embodiment, only two recesses 23 F-G are provided due to space constraints.
(Note that although it may appear so from the schematic drawing of FIG. 2 a, the modules 16 B would not actually extend into the space of spindle recess 9 , at least not to a point where they interfered with a floppy disk drive spindle.)
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | An adapter which can be plugged into a floppy disk drive of a computer can receive a plurality of user insertable and removable memory modules therein and provide access to the memory modules by the computer for reading and/or writing thereto. The adapter has a frame having an exterior form designed to be insertable into a floppy drive and accommodate the plurality of modules. The frame houses interface circuitry for facilitating the transferring of data between the adapter and a read/write head of a floppy disk drive. The adapter provides a plurality of recesses with contacts for coupling with corresponding contacts of memory modules when inserted therein, providing a path for transferring data to and from the modules. The frame may also accommodate a battery and/or a generator/alternator and associated regulator circuitry 14 (see FIG. 2 a ) for supplying current to the adapter circuitry and the memory modules. | 6 |
FIELD OF THE INVENTION
This invention relates to a jig for assembling a track chain that is universally employed in construction equipment and the like.
BACKGROUND OF THE INVENTION
A track chain to be assembled using the jig according to this invention is partly denoted at 4 in FIG. 1 and FIG. 2. FIG. 3 depicts the joint portion of the track chain 4. A pair of preceding links 1' and a pair of following links 1 are joined together by a track joint 5 by fitting a bushing 3 on a track pin 2, whereby a desired length of track chain 4 can be assembled.
In FIG. 1 and FIG. 2 there is shown a track press 6 as the means employed in the abovementioned assembly. The way of assembling by using this track press 6 will be schematically explained hereinafter.
FIG. 1 shows the state of track press 6 before it is started into operation, wherein the forward (upper in the drawing) portion of the track chain 4 has already been joined together with links 1' by means of a track joint 5'. Hereat, a track joint 5 is carried by a rearward (lower in the drawing) jaw 7', a pair of following links 1 are attached to a pair of pin adapters 9 and a pair of bushing adapters 10 as shown with chain lines in FIG. 1 and with a partly enlarged section in FIG. 4, said links 1 are urged from the right and left sides and advanced toward the track joints 5 and 5' so as to be jointed as shown FIG. 2 and FIG. 5, and then respective adapters are retreated again to the position as shown in FIG. 1.
Particulars of respective adapters 9 and 10 are given in FIG. 4 and FIG. 5. As can be seen therefrom, adapters 9 and 10 include respectively outer cylinders 15 and 16 which have fixed, to their bottom surfaces, threaded rods 13 and 14 screwed in threaded holes 11 and 12 provided in a tool bar 8 referred to afterwards, and open in the direction opposite to said bottom surfaces. In the bores of the hollow outer cylinders 15 and 16 there are slidably fitted inner cylinders 17 and 18 respectively, and said inner cylinders 17 and 18 are always biased by springs 19 and 20 so as to protrude outwards, the springs 19 and 20 resiliently engaging the interior surfaces of the rear walls of the outer cylinders and the inner cylinders. Reference numerals 21 and 22 denote stopper screws that are screwed in transverse threaded holes in the peripheral walls of outer cylinders 15 and 16. The fore ends of said screws are fitted in grooves or slits 23 and 24 formed axially in the outer periphery of inner cylinders 17 and 18 to prevent the inner cylinders 17 and 18 from protruding all the way out of the outer cylinders 15 and 16 so that the sliding of the inner cylinders 17, 18 is limited between forwardmost and rearwardmost positions.
According to the size of the construction equipment to which the track chain 4 is attached, the track pin and link used therein will vary in length, and as a matter of course the distance between the track joints and the distance between respective links will also vary. In the case like this, it will be necessary for the above mentioned assembling device to change the positions of jaws 7 and 7', exchange adapters 9 and 10, further change the distance between adapters 9 and 10, and still further change the moving strokes of said adapters.
In order to change the distance between adapters 9 and 10 in the above mentioned assembling device, this applicant has improved said tool bar previously. The thus improved tool bar 8 is shown in FIG. 6A and FIG. 6B. FIGS. 6A and 6B show the surface and the back of tool bar 8 respectively. This tool bar 8 is provided at the central part with a long hole 27 for attaching the tool bar 8 to a base bed 25 of the track press 6 by means of a bolt 26. Reference numerals 28 and 29 denote small holes in which locating pins (not shown) between the tool bar 8 and the bed 25 are fitted. Threaded holes 11 and 12 are plural in number respectively and take the form of blank threaded holes arranged symmetrically with a long hole 27 as the center. The back surface is provided with plural blank threaded holes 11' and 12' which are located in positions different from those of the threaded holes 11 and 12 provided in the surface but serve for the same purposes.
Changing of the position between adapters 9 and 10 by means of the tool bar 8 of this type is effected in a manner of screwing the threaded rods 13 and 14 of the adapters 9 and 10 in the desired threaded holes 11 and 12. If the predetermined object is not still achieved, the tool bar 8 will be turned over, attached to the base bed 25 and screwed in the desired threaded holes 11' and 12'.
However, the above mentioned device is defective in that since the end opening (openings) of outer cylinder 15 and/or 16 presses on the side end faces of links 1 and 1' at every assembling operation during a long period of usage, the end face of the end opening is crushed, its inner peripheral flange is deformed so as to expand inwards, and thus the inner cylinders 17 and 18 are pressed in the inside of outer cylinders 15 and 16, whereby it becomes impossible for the inner cylinders to move for protruding from the end openings of the outer cylinders.
It is generally said that at the time of assembling (FIG. 2 and FIG. 5), by regulating the insertion distances of inner cylinders 17 and 18 against outer cylinders 15 and 16 to l and L (FIG. 5), the length l (FIG. 3) of the protrudent portion of the track pin 2 from links 1 and 1' can be held constant. However, the above mentioned device is further defective in that it is impossible to compensate the changed insertion distance as outer cylinders and/or inner cylinders wear due to usage and consequently it becomes impossible to hold the length l of the protrudent portion of the pin 2 constant, and that in order to remedy this undersirable state it is necessary to exchange adapters 9 and 10 each time and the assembling operation is retarded due to this exchanging operation.
The above mentioned device is still further defective in that, considering the distances of the opening end surfaces of outer cylinders 15 and 16 from the fitting surface of the tool bar 8, as said opening end surfaces wear due to usage, said distances are shortened so as to result in various disadvantages. Especially, when the degree of wear is unbalanced between those opening end surfaces, due to a long period of usage, links 1 and 1', which support the portion extending from the outer cylinder 16 to the outer cylinder 15, incline gradually so that it becomes impossible to attach the links 1 and 1' at right angles relative to the pin 2 and bushing 3, and in order to remedy this undesirable state it is necessary to exchange adapters 9 and 10 each time, and the assembling operation is retarded due to this exchanging operation. This phenomenon can be observed when re-assembling using the links 1 and 1' after they have been used to some extent. The reason is that when links 1 and 1' are used, they wear markedly at the side end surfaces of the portions supported by the adapter 9 (which are exposed always during use and so liable to wear) more than at the side end surfaces of the portions supported by the adapter 10, and accordingly when re-assembling using these links, the re-assembled body as a whole comes to be supported slantedly by the adapters 9 and 10 in the exactly same manner as mentioned above.
In addition thereto, the above mentioned device involves the following defects. In order to join the outer cylinders 15 and 16 rigidly to the tool bar 8 it is necessary to screw the rods 13 and 14 fully in the threaded holes 11 and 12 respectively, and therefore the locations of outer cylinders 15 and 16 in the peripheral direction relative to the tool bar 8 are always constant. On the other hand, in the joint portion shown in FIG. 3, the side end surface of the link 1 wears slantwise, for instance, as shown with a dotted line d in the left side of FIG. 3, owing to the long period of usage. When breaking up the thus slantly worn ones and using them for re-assembling the links 1 and 1', the slantly worn side end surfaces come to contact with the end surfaces of the outer cylinders 15 and 16. As the locations of outer cylinders 15 and 16 at this time are constant as aforesaid, said contact results in slant wear and deformation of the end surfaces of outer cylinders 15 and 16, too. In order to remedy this undesirable state, it is required to remove the adapters 9 and 10 from the tool bar 8 each time for evening the end surfaces of outer cylinders 15 and 16 by lathe turning or the like and to discontinue the track link assembling operation during said lathe turning operation, whereby the assembling efficiency is reduced.
SUMMARY OF THE INVENTION
One object of this invention is to provide an assembling jig which is capable of eliminating the above mentioned defects inherent in the conventional assembling jigs and is designed so that inner cylinders may move freely in outer cylinders even when the inner peripheral flanges of end openings of outer cylinders for adapters are deformed.
The above mentioned object can be achieved by providing a jig which comprises forming circular recesses in the sliding portions between the inner cylinders and the inner peripheral surfaces of the end openings of the outer cylinders for adapters of the conventional jig. This is because even when the inner peripheral flanges of end openings of outer cylinders are deformed, it only deforms the circular recesses formed at said portions and does not act to deform the sliding portions between the inner cylinders and the outer cylinders so that no obstacle is constituted to the movement of inner cylinders.
Another object of this invention is to provide a jig for assembling a track chain which is capable of readily adjusting the insertion distance of an inner cylinder against an outer cylinder in an adapter.
The above mentioned object can be achieved by providing an embodiment wherein a shim is exchangeably disposed between a biasing member and the bottom inner surface of an outer cylinder.
A further object of this invention is to provide a jig for assembling a track chain which is capable of readily controlling the distance between the fore end of an outer cylinder and the fitting face of a tool bar in an adapter.
The above mentioned object can be achieved by providing an embodiment wherein a shim is exchangeably disposed between the bottom outer surface of an outer cylinder and the fitting surface of a tool bar.
A still further object of this invention is to provide an assembling jig which is capable of eliminating the other defects inherent in the aforesaid conventional jigs and changes the location of an outer cylinder for at least one of the adapters in the peripheral direction relative to a tool bar.
The above mentioned object can be achieved by providing an assembling jig wherein at least one of adapters is designed so that a hole is provided in the bottom of an outer cylinder, a screw fitted member is provided which is inserted in this hole through a center hole of an inner cylinder and screwed in a threaded hole provided in a tool bar, and a tool for rotating said screw fitted member is inserted in the center hole of said inner cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a plan view showing the state of a known track press, to which the assembling jig according to this invention is applied, before a track chain is assembled.
FIG. 2 is a fragmentary plan view showing the state where the track chain is being assembled by the track press of FIG. 1.
FIG. 3 is an expanded sectional view showing the joint portion of the assembled track chain.
FIG. 4 is an enlarged vertical sectional plan view showing the state where a link has been attached, as shown with a chain line in FIG. 1, to the known assembling jig which is attached to said track press.
FIG. 5 is an enlarged vertical sectional plan view of the assembling jig portion shown in FIG. 2.
FIG. 6A and FIG. 6B are a front surface view of the tool bar shown in FIG. 4 and a back view of the tool bar shown in FIG. 5 respectively.
FIG. 7 is a sectional view similar to FIG. 4 illustrating the embodiment of the jig for assembling the track chain according to this invention.
FIG. 8 is a sectional view similar to FIG. 5 showing the embodiment of the assembling jig shown in FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 7 and FIG. 8 illustrate one embodiment of the assembling jig according to this invention. In this embodiment, like symbols will be affixed to the same parts as those of the conventional devices shown in FIG. 4 and FIG. 5 in order to shorten the explanation, and explanation will be chiefly made of the other parts.
Reference numerals 31 and 32 denote a pin adapter and a bushing adapter respectively, and a circular recess or counterbore 34 is provided in the inner peripheral surface of the fore end opening of an outer cylinder 33 in the pin adapter 31. Between the bottom inner surface of said outer cylinder 33 and a compression spring 19 there are exchangeably provided a desired number of shims 35. Between the bottom outer surface of the outer cylinder 33 and the fitting surface of a tool bar 8, furthermore, there are exchangeably provided a desired number of shims 36. A threaded rod 37 secured to the bottom outer surface of the outer cylinder 33 passes through each shim 36.
The fore end opening of an outer cylinder 40 in the bushing adapter 32 is provided at the inner peripheral surface with a circular recess or counterbore 41 as in the case of the adapter 31, and an outer cylinder 40 is provided at the bottom with a hole 42. A bolt 43 is inserted in this hole 42 from the inside of the outer cylinder 40 through a center hole 44 provided in an inner cylinder 45. The bolt 43 is screwed in a threaded hole 12 provided in the tool bar 8 by means of a tool (not shown) inserted in this center hole 44, whereby the outer cylinder 40 is rigidly coupled with the tool bar 8. Reference numerals 46 and 47 denote shims provided in the same manner as the shims 35 and 36 except for the difference of the shim 46 from the shim 35, namely the shim 46 is coupled by passing the bolt 43 through its center hole.
Referring to the respective adapters 31 and 32, since the inner peripheral surfaces of the fore end openings of outer cylinders 33 and 40 are provided, as mentioned above, with circular recesses 34 and 41, even if the fore ends of openings of outer cylinders 33 and 40 urge the links 1 and 1', are deformed thereby and expand inwards, the expanded portions will locate within the circular recesses 34 and 41. Accordingly, there is no possibility of the sliding motion of inner cylinders 17 and 45 being disturbed by said deformation, and further the occurrence of deformation can be found easily. In case the deformation is thus found, adapters 31 and/or 32 are removed from the tool bar 8 and can be put back in their original places after having removed the deformed portions by lathe turning or the like. Therefore, the sliding motion of inner cylinders 17 and 45 can be ensured.
In the above jig embodying this invention, the thickness adjustment of shims 35, 36 and 46, 47 is made by replacing them with shims of different thickness or changing the number of shims of the same thickness used.
The thickness adjustment of shims 35 and 46 is carried out by unscrewing screws 21 and 22 from outer cylinders 33 and 40 for dismantling inner cylinders 17, 45 and springs 19 and 20, and then replacing the shims 35 and 46 or changing the number of shims used. The thickness adjustment of these shims 35 and 46 is done with the intention of holding the insertion distances, l, L (FIG. 8) of inner cylinders 17 and 45 against outer cylinders 33 and 40 constant continuously irrespective of the friction between outer cylinders 33, 40 and inner cylinders 17, 45 and thus holding the length l (FIG. 3) of the portion of track pin 2 protruding from links 1 and 1' constant. That is, if the actual insertion distance becomes more distant than the normal distance l, shims 35 and 46 will be thickened, and in contrast with this, if the actual distance becomes less distant than the distance l, shims 35 and 46 will be thinned.
The thickness adjustment of shims 36 and 47 is carried out by dismantling the threaded rod 37 and the bolt 43 from the tool bar 8, then removing the outer cylinders 33 and 40 and thereafter replacing shims 36 and 47 or changing the number of shims used. The thickness adjustment of these shims 36 and 47 is conducted when it is inevitably necessary to adjust the distance between the fitting surface of tool bar 8 and the end surfaces of openings of outer cylinders 33 and 40 caused by friction or the like of outer cylinders 33 and 40 or of links 1 and 1'. That is, if it is desired to increase the distance between both surfaces, shims 36 and 47 will be thickened, while if it is desired to decrease said distance, shims 36 and 47 will be thinned. When using outer cylinders 33 and 40 whose opening end surfaces are unbalanced in wear, as they stand, as mentioned above, it becomes impossible to build up the pin 2 and bushing 3 at right angles relative to the links 1 and 1', whereby it will become necessary to compensate the worn portions of the outer cylinders 33 and 40 by using the shims 36 and 47. This procedure is carried out in the exactly same manner also when re-assembling is carried out using the links 1 and 1' which have been used to some extent. The reason is that as mentioned above, the side end surfaces of links 1 and 1' supported by the outer cylinder 33 (which are exposed always during the use) wear more heavily than side end surfaces of links 1 and 1' supported by the outer cylinder 40, and accordingly it becomes impossible to build up the pin 2 and bushing 3 at right angles relative to the links 1 and 1' without making the aforesaid compensation.
The pin adapter 31 is different from the bushing adapter 32 in that the former is fitted into the tool bar 8 by means of the threaded rod 37 and the latter is fitted into the tool bar 8 by means of the bolt 43. In this connection, however, it is to be noted that since this difference was made up only for the purpose of facilitating explanation, the threaded rod and bolt may be exchanged inversely and both may be threaded rods or bolts respectively.
In this case, the outer cylinder 40, arranged to be rigidly coupled with the tool bar 8 by means of the bolt 43, is turned before the bolt 43 is screwed up, so as to have a desired position in the circumferential direction relative to the tool bar 8. The reason for doing this is that as stated previously, when reassembling is carried out by using the links 1 and 1' whose side end surfaces have worn slantedly, the end surfaces of the outer cylinders 33 and 40 contacting with the links 1 and 1' likewise come to wear slantedly and deform, and therefore by changing the position of the outer cylinder 40 in the circumferential direction as mentioned above, it is rendered possible to wear and deform the opening end surfaces of the outer cylinders 33 and 40 uniformly throughout the whole circumference, whereby the number of restoring operations including the above mentioned lathe turning or the like can be reduced and the output efficiency can be increased by eliminating the waste that much.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | A jig is disclosed for assembling a track chain which includes pin adapters and bushing adapters attached detachably to tool bars. Each adapter is provided with an outer cylinder, an inner cylinder received slidably in the outer cylinder, a biasing device held within the outer cylinder for biasing the fore end of said inner cylinder so that it protrudes outwardly from the fore end opening of the outer cylinder, and a stop attached to the outer cylinder for preventing the inner cylinder from protruding excessively out of the outer cylinder. Circular recesses are formed in the inner peripheral surface of the fore end opening of the outer cylinder. | 1 |
This application is a continuation-in-part of co-pending patent application Ser. No. 12/456,289 filed on Jun. 15, 2009.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of protective gloves which are worn by an athlete while playing a sporting event. In particular, the present invention relates to the field of baseball batting gloves which are used by a baseball player while gripping a baseball bat during the time the player is at the plate to hit a baseball thrown at the player by a pitcher.
2. Description of the Prior Art
In general, protective material incorporated into wearing apparel and protective material incorporated in athletic gloves are known in the prior art. The following 23 patents and Published Patent Applications are relevant to the field of the present invention.
1. U.S. Pat. No. 3,862,919 issued to Siegfried Nitzsche et al. and assigned to Wacker-Chemie GmbH on Jan. 28, 1975 for “Oranopolysiloxane Compositions Having Resilient Properties” (hereafter the “Nitzsche Patent”); 2. U.S. Pat. No. 4,983,642 issued to Akio Nakano et al. and assigned to Shin-Etsu Chemical Co., Ltd. on Jan. 8, 1991 for “Foamable Silicone Rubber Composition And Foamed Silicone Rubber Body Therefrom” (hereafter the “Nakano Patent”); 3. U.S. Pat. No. 5,090,053 issued to Harry D. Hayes and assigned to Dalton Enterprise on Feb. 25, 1992 for “Composite Shock Absorbing Garment” (hereafter the “Hayes Patent”); 4. U.S. Pat. No. 5,498,640 issued to Michael Witt et al. and assigned to BASF Aktiengesellschaft on Mar. 12, 1996 for “Expandable Thermoplastic Polymers Containing Organic Boron-Silicon Compounds, And A Process For Their Preparation” (hereafter the “Witt Patent”); 5. U.S. Pat. No. 5,580,917 issued to Jeremi Maciejewski et al. on Dec. 3, 1996 for “Hydrostatically Damping Shock And Vibration Energy Absorbing Non-Vulcanizable Silicone Elastomer” (hereafter the “Maciejewski Patent”); 6. U.S. Pat. No. 6,701,529 issued to Lawrence J. Rhoades et al. and assigned to Extrude Hone Corporation on Mar. 9, 2004 for “Smart Padding System Utilizing An Energy Absorbent Medium And Articles Made Therefrom” (hereafter the “Rhoades Patent”); 7. United States Published Patent Application No. 2004/0171321 to Daniel Hames Plant on Sep. 2, 2004 for “Flexible Energy Absorbing Material And Methods Of Manufacture Thereof” (hereafter the “Plant Published Patent Application”); 8. United States Published Patent Application No. 2004/0173422 to Suraj S. Deshmukh et al. on Sep. 9, 2004 for “Fluid-Filled Cellular Solids For Controlled” (hereafter the “Deshmukh Published Patent Application”); 9. U.S. Pat. No. 6,913,802 issued to Daniel James Plant on Jul. 5, 2005 for “Energy Absorbing Protective Member” (hereafter the “Plant Patent”); 10. United States Published Patent Application No. 2005/0160626 to Herbert E. Townsend on Jul. 28, 2005 for “Shoe With Cushioning And Speed Enhancement Midsole Components And Method For Construction Thereof” (hereafter the “Townsend Published Patent Application”); 11. U.S. Pat. No. 7,000,259 issued to John M. Matechen and assigned to Impact Innovative Products, LLC on Feb. 21, 2006 for “Sports Glove With Padding” (hereafter the “'259 Matechen Patent”); 12. U.S. Pat. No. 7,100,216 issued to John M. Matechen et al. and assigned to Impact Innovative Products, LLC on Sep. 5, 2006 for “Garment With Energy Dissipating Conformable Padding” (hereafter the “'216 Matechen Patent”); 13. U.S. Pat. No. 7,171,697 issued to Robert A. Vito et al. and assigned to Sting Free Company on Feb. 6, 2007 for “Vibration Dampening Material And Method Of Making Same” (hereafter the “Vito Patent”); 14. United States Published Patent Application No. 2007/0029690 to Philip Green et al. on Feb. 8, 2007 for “Energy Absorbing Blends” (hereafter the “Green Published Patent Application”); 15. United States Published Patent Application No. 2007/0152117 to Randel Louis Byrd on Jul. 5, 2007 for “Viscoelastic Mounting Device” (hereafter the “Byrd Published Patent Application”); 16. World Intellectual Property Organization patent No. WO 2007/102020 issued to Graham Budden et al. and assigned to Dow Corning Corporation on Sep. 13, 2007 for “Impregnated Flexible Sheet Material” (hereafter the “Budden WIPO Patent”). 17. U.S. Pat. No. 4,911,433 issued to Walker on Mar. 27, 1990 for “Weighted Athletic Glove” (hereafter the “Walker Patent”); 18. U.S. Pat. No. 5,345,609 issued to Fabry on Sep. 13, 1994 for “Protective Glove Having Closed and Isolated Fluid Filled Cells” (hereafter the “Fabry Patent”); 19. U.S. Pat. No. 6,105,162 issued to Douglas on Aug. 22, 2000 for “Hand Protector” (hereafter the “Douglas Patent”); 20. U.S. Pat. No. 6,119,271 issued to Byron on Sep. 19, 2000 for “Golf Glove” (hereafter the “Byron Patent”). 21. U.S. Pat. No. 6,969,548 issued to Goldfine on Nov. 29, 2005 for “Impact Absorbing Composite” (hereafter the “Goldfine Patent”); 22. U.S. Pat. No. 6,961,960 issued to Gold on Nov. 8, 2005 for “High Strength Impact Resistant Hand Protector” (hereafter the “'960 Gold Patent”). 23. U.S. Pat. No. 2,975,429 issued to Donald J. Newman on Mar. 21, 1961 for “Golf Glove” (hereafter the “Newman Patent”); 24. U.S. Pat. No. 4,864,659 issued to Stephen M. Morris and assigned to GenCorp Inc. on Sep. 12, 1989 for “Sports Glove” (hereafter the “Morris Patent”); 25. U.S. Pat. No. 5,107,544 issued to Marc A. Capatosto on Apr. 28, 1992 for “Ice Hockey Goalie Glove Construction” (hereafter the “Capatosto Patent”); 26. U.S. Pat. No. 5,487,188 issued to Walter Micheloni et al. on Jan. 30, 1996 for “Glove With Means For Protecting The Ligaments And Articulations Of The Hand” (hereafter the “Micheloni Patent”); 27. U.S. Pat. No. 5,720,047 issued to Thomas Spitzer and assigned to Uhlsport GmbH on Feb. 24, 1998 for “Sports Glove, In Particular A Goalie Glove” (hereafter the “Spitzer Patent”); 28. U.S. Pat. No. 5,898,938 issued to Don Edward Baylor et al. on May 4, 1999 for “Hand Protecting Device” (hereafter the “Baylor Patent”); 29. U.S. Pat. No. 5,924,137 issued to Danny Gold on Jul. 20, 1999 for “Finger End Protection Construction” (hereafter the “'137 Gold Patent”); 30. U.S. Pat. No. 6,305,022 issued to Noboru Oomura et al. and assigned to Mizuno Corporation on Oct. 23, 2001 for “Glove For Baseball Or Softball” (hereafter the “Oomura Patent”); 31. U.S. Pat. No. 6,389,601 issued to James Kleinert and assigned to Hillerich & Bradsby Co., on May 21, 2002 for “Batting Glove” (hereafter the “'601 Kleinert Patent”); 32. U.S. Pat. No. 6,715,152 issued to Giovanni Mazzarolo and assigned to Alpinestars SpA on Apr. 6, 2004 for “Motorcycling Glove” (hereafter the “Mazzarolo Patent”); 33. U.S. Pat. No. 6,772,441 issued to Alfred W. Lucas, Jr. on Aug. 10, 2004 for “Soccer Goalkeeper Glove” (hereafter the “Lucas Patent”); 34. U.S. Pat. No. 7,000,256 issued to James M. Kleinert and assigned to Hillerich & Bradsby Co. on Feb. 21, 2006 for “Work Glove” (hereafter the “'256 Kleinert Patent”); 35. U.S. Pat. No. 7,007,308 issued to Charles A. Howland et al. and assigned to Warwick Mills, Inc. on Mar. 7, 2006 for “Protective Garment And Glove Construction And Method For Making Same” (hereafter the “Howland Patent”); 36. United States Published Patent Application No. 2007/0226873 to Henry Mattesky on Oct. 4, 2007 for “Stretchable, Multi-Layered Gloves” (hereafter the “Mattesky Published Patent Application”); 37. United States Published Patent Application No. 2008/0000009 to Daisuke Kogawa et al. on Jan. 3, 2008 for “Glove” (hereafter the “Kogawa Published Patent Application”); 38. United States Published Patent Application No. 2008/0078011 to James M. Kleinert on Apr. 3, 2008 for “Glove” (hereafter the “Kleinert Published Patent Application”); 39. World Intellectual Property Organization Patent No. WO 2006/068381 issued to Dong-suk Song and assigned to Hyong-choi Kim on Jun. 29, 2006 for “Hand Protection Device For Fighting Games” (hereafter the “Song WIPO Patent”); 40. Patent Abstract of Japan No. 2008007904 issued to Usami Kimie and assigned to Eito K K on Jan. 17, 2008 for “Business-Use Glove” (hereafter the “Kimie Patent Abstract of Japan”).
The Nitzsche Patent discloses a composition having a high degree of elasticity under suddenly applied stress. The composition is used to absorb impact such as couplings, door closing devices, and re-coiled dampers. Also, it can also be placed in use with physical therapy devices.
The Nakano Patent is a chemical composition patent which goes into a detailed chemical description of the product.
The Hayes Patent discloses a composite shock absorbing material for use in ballistic projectile protective garments. This is best illustrated in FIG. 1 . FIG. 5 is a transverse, cross-sectional view, which illustrates the internal construction of each of the elongated strands forming them into composite shock absorbing materials 10 ′. The inner-core 18 ′ is preferably filled with a liquid, although a gas may also be employed within the scope of the invention. The preferred material is polydimetysil oxane, which is commonly called fluid silicon. Claim 1 is a fairly broad claim and reads: “A composite shock absorbing material for use in protective garments, comprising: an open mesh array formed by a plurality of intersecting interconnected strands, wherein each of said strands has a cores surrounded by a visco-elastic polymer material, the cores of said strands being formed by a liquid material.”
The Witt Patent discloses an elastic energy absorbing chemical patent. It's very broad claim 1 claims, “an expandable thermoplastic polymer in particle form, comprising a) at least one boron-siloxane elastomer, b) at least one thermoplastic polymer, and c) a blowing agent.”
The Maciejewski is a chemical patent and discloses a hydrostatically damping, shock and vibration energy absorbing, non-vulcanisable silicone elastomer comprised of a methylphenylsilicone polymer which has a matrix of a condensation of polydimethyl- or/and methylhydrosiloxane diols condensed with reactive compounds of silicon, boron or nitrogen giving the viscous polymer an appropriate elasticity coefficient by forming mobile hydrogen bonds. The elastomer according to the invention also contains fillers and lubricants.
The Rhoades Patent discloses a smart padding system utilizing an energy absorbing medium and articles made therefrom. The invention relates to an energy absorbent medium which is compliant and conformable in the absence of an applied force, and stiffens in response to the rate of an applied force to dissipate energy. The medium comprises a blend of polymer and lubricant incompatible with the polymer to produce a conformable absorbent which exhibits dilatant (shear thickening) characteristics under high rates of force or stress. The polymer has reformable sacrificial chemical bonds which are broken under a high rate of deformation and which reform under static conditions. Suitable polymers for the invention include polyborosiloxanes. Applications for the medium include absorbent for sports padding, athletic equipment, motor vehicle seats, bulletproof vests, medical equipment, industrial equipment, weaponry, and playing fields. This is incorporated into gloves as set forth in FIG. 4( a ) and FIG. 4( b ). A suitable polymer is one that exhibits hydrogen bonding. These hydrogen bonds result from dipole interaction between polymer chains. The hydrogen bonds formed are not permanent covalent bonds, but are liable or reformable bonds which provide the dilatant behavior characteristic of polyborosiloxanes. Suitable fillers are typically inert materials which range from free-flowing to caking powders, micropheres, pulp, fibers, microcellular foams, closed-cell foams and other materials. An example of an energy absorbent medium made in accordance with this invention is a 100 pph (parts per hundred) of polyborosiloxane polymer, 60 pph of a metal soap gelled paraffinic lubricant, and 20 pph of plastic microspheres. This is equivalent to a composition of 60%, 30%, and 10% respectively. This inherent property of the composition is ideal for use as a shock absorber or energy attenuating pad for protection of the human body as well as other objects. The shock absorbing material composition is suitable for packaging or encapsulation is a containment or envelop for use in high impact energy absorbent or protective gear.
The Plant Published Patent Application discloses a flexible energy absorbing sheet material in which a dilatant material ( 6 ) is impregnated into or supported by a resilient carrier ( 1 ). The dilatant material remains soft until it is subjected to an impact when its characteristics change rendering it temporarily rigid, the material returning to its normal flexible state after the impact. The carrier can be a spacer fabric, a foam layer or modules or threads of dilatant material contained between a pair of spaced layers. Methods of manufacturing the energy absorbing sheet are also disclosed. As illustrated in FIG. 25 , the materials are intended to be incorporated into shoes. The energy absorbing dilatent compound material within the modules absorbs the impact force and spreads the load thereof during the impact. The preferred material is a dimethyl-siloxane-hydro-terminated polymer such as the material sold by Dow Corning under the catalogue number 3179 or a lightweight version thereof containing Duolite spheres. The siloxane groups in the preferred borosiloxane copolymers are of the formula —(OSiR 1 R 2 )—, wherein R 1 and R 2 can be the same or different and each, independently, can be substituted or unsubstituted alkyl or aryl group. Preferred such alkyl groups contain 1 to 6 carbon atoms and, more preferably, 1, 2, 3, 4, or 5 carbon atoms. The preferred substituted alkyl groups are hydrofluoroalkyl groups. In preferred embodiments, one or both of R 1 and R 2 is a methyl, phenyl, or 1,1,1, trifluoropropyl group. Preferred siloxane groups include the following: —(OSiMePh)—, —(OSiMe 2 )—, —(OSiPh 2 )— and —(OSi(CH 2 CH 2 CF 3 )Me)—; wherein Me is a methyl group and Ph is a phenyl group. The preferred borosiloxane copolymers for use in the present invention are those included in Dow Corning 3179 Dilatant Compound and Dow Corning) Q2-3233 Bouncing Putty.
The Deshmukh Patent Published Patent Application discloses an impact absorber using an energy-absorbing, fluid-impregnated material consisting of a porous interconnected network of solid material forming edges and faces of cells, preferably an open-cell reticulated or partially closed-cell foam, or formed form fibers or other cellular solids. The matrix is impregnated with a field responsive fluid such as a magneto-or electro-rheological fluid, or with a shear-rate responsive fluid such as a dilatant (shear-thickening) fluid. The material is placed under compression during impact, and may be housed within a cylinder and compressed by a piston. The stiffness of the composite material consisting of a matrix filled with a field responsive fluid can be controlled by varying the field intensity and spatial gradients of the applied field to vary the rheological properties of the fluid. In one embodiment as shown in FIG. 11 , it is used for a passenger head rest. Claim 1 reads as follows: “an impact absorber comprising composite material consisting of a cellular solid or fibrous matrix, impregnated with a fluid, that stiffens under predetermined conditions, and means for compressing said composite material in response to an impact to dissipate the energy of said impact.
The Plant Patent discloses an energy absorbing protective member primarily for use as an energy absorbing pad for incorporation into garments to protect the wearer against accidental impacts. The member comprises a putty-like energy absorbing material ( 2 ) encapsulated in a flexible envelope ( 3 , 4 ). The energy absorbing material is normally soft and flexible but changes to become temporarily rigid when an impact force is applied thereto, thereby absorbing the impact energy, the material returning to its normal flexible condition after the impact. The energy absorbing member preferably comprises a series of connected corrugations to increase its energy absorbing properties. The preferred material is a Dimethyl siloxane hydroterminated polymer such as the material sold by DOW CORNING under their Catalogue or Trade number 3179. The unique multi-layer energy absorbing member can flex with movement of the body when protection is not needed and thus is very comfortable to wear. When impacted however, the strain rate sensitive polymer in the energy absorbing member reacts instantaneously to form a semi-rigid structure that absorbs and dissipates the blow giving maximum protection.
The Townsend Published Patent Application discloses a cushioning member inside of a shoe to absorb shock. In the preferred embodiment, the dilatant compound is derived from a mixture of dimethyl siloxane, hydro-terminated polymers with boric acid, Thixotrol ST brand organic rheological additive manufactured by Elementis Specialties, Inc., polydimethysiloxane, decamethyl cyclopentasiloxane, glycerine, and titanium dioxide. This compound is sold by Dow Corning as Dilatant Compound No. 3179. Other dilatant compounds that could be used are available on the market and described in the prior art. This is primarily focusing on shock absorbing materials in a runner's shoe.
The '259 Matechen Patent discloses a sports glove padding. Specifically, it discloses a vibration dissipating sports glove for use in holding a bat while hitting a baseball having an energy-absorbing front pad between the index finger and the thumb. The glove also has a back padding covering some portions of the metacarpal portion of the hand and may furthermore have knuckle padding for covering the middle knuckle of each of the fingers. By using padding in a discriminate fashion, the glove maintains adequate flexibility and feel while, at the same time, protects the batter from bat-induced vibration, and furthermore, from pitched balls which may hit the batter's hand. Additionally, the front pad conforms between the batter's hand and the bat to provide the batter a more secure grip upon the bat.
As illustrated in FIG. 3 , the pad 180 may be comprised of energy dissipating conformable media 182 , such as polyborosiloxane, encapsulated in a non-porous flexible sheath 184 , such as PVC or polyurethane having a thickness of approximately 12 gauge. A second embodiment of the invention further includes back padding 190 at the back portion 170 of the glove 100 , whereby the back padding 190 covers only the region defined by the top of the metacarpal bones of the fingers and, in particular, covers portions of the index finger metacarpal bone 32 , middle finger metacarpal bone 42 , ringer finger metacarpal bone when the glove 100 is positioned upon the wearer's hand. The back padding 190 may be comprised of an energy dissipating conformable media encapsulated in a flexible layer. As an example, the media may be polyborosiloxane while the flexible layer may be PVC or polyurethane having a thickness of approximately 12 gauge. The back padding 190 may be comprised of a single flat pad, as illustrated in FIG. 5 . There is no padding on the side of the hand adjacent the metacarpal bone aligned with the pinkie finger. In addition, no wrist bones are protected.
The '216 Matechen Patent discloses a garment which has a piece of clothing with at least one pad of conformable, energy dissipating media. The pad is positioned at a location on the clothing of the wearer to dissipate the energy resulting from a sudden impact at that location. The pad may be retained against the garment by a connector attached to the surface of the clothing or may be secured within a pocket on the garment. Additionally, the pad may be used in conjunction with the hard shell padding. The padding material is light weight, viscoelastic polymer that exhibits fluid-like characteristics in the absence of a sudden impact, and acts as a solid when subjected to a sudden impact. Polyborosiloxane is a preferred polymer material. Directing attention to FIGS. 2-4 , the pad 20 is comprised of a conformable media 50 confined within an encasement 55 . In a preferred embodiment, the media is a polymer composition such as polyborosiloxane.
The Vito Patent is a vibration dampening material and a method of making it. The material is incorporated into numerous products including the handle of the baseball bat in the area where the bat is gripped. The preferred cross-section of the glove panels 305 is also shown in FIG. 23 . FIG. 35 illustrates a glove 436 suitable for both baseball and softball that uses panels 305 to provide protection to a palm area 437 . FIG. 36 illustrates a weightlifting glove 438 having panels 305 of the material 10 thereon. 9 illustrates a golf glove 446 having at least one panel 305 thereon. FIG. 40 illustrates the type of glove 448 used for rope work or by rescue services personnel with panels 305 of the material 10 of the present invention. FIG. 41 shows a batting glove 450 with panels 305 thereon.
The Green Published Patent Application discloses a composite material which is elastic, which exhibits a resistive load under deformation, which is unfoamed or foamed, comminuted or uncomminuted and which comprises I) a first polymer-based elastic material and II) a second polymer-based material, different from I), which exhibits dilatancy in the absence of I) wherein II) is entrapped in a solid matrix of I), the composite material being unfoamed or, when foamed, preparable by incorporating II) with I) prior to foaming. Any polymer-based material, different from I), which exhibits dilatancy and can be incorporated into the chosen elastic constituents) of first material I) may be used as second material II). By a polymer-based material which exhibits dilatancy is meant a material in which the dilatancy is provided by one or more polymers alone or by a combination of one or more polymers together with one or more other components, e.g. finely divided particulate material, viscous fluid, plasticiser, extender or mixtures thereof, and wherein the polymer is the principal component. In one preferred embodiment, the polymer comprising the second material II) is selected from silicone polymers exhibiting dilatant properties. For example, the dilatant may be selected from filled or unfilled polyborodimethylsiloxanes (PBDMSs) or any number of polymers where PBDMS is a constituent. The dilatancy may be enhanced by the inclusion of other components such as particulate fillers.
The energy absorbing composite material of the invention may be employed in a wide variety of applications; for example in protective pads or clothing for humans and animals, in or as energy absorbing zones in vehicles and other objects with which humans or animals may come into violent contact, and in or as packing for delicate objects or machinery. Specific examples of application are in headwear and helmets; protective clothing or padding for elbows, knees, hips and shins; general body protection, for example for use in environments where flying falling objects are a hazard; vehicle dashboards, upholstery and seating. Other potential uses are in garments or padding to protect parts of the body used to strike an object e.g. in a sport or pastime; for example in footwear, such as running shoe soles, football boots, boxing gloves and gloves used in the playing of fives.
The dilatant materials were selected for blending trials in different ratios. The three dilatant materials were the Dow Corning silicone dilatant 3179, Polastosil AMB-12, and pure PBDMS.
The Byrd Published Patent Application discloses a vicoelastic mounting device, presumably mounting for cameras. The viscoelastic material preferably includes an R.T.V.-type silicon-based compound, a dimethyl siloxane compound, [or] a borosilicone rubber combination with silicone oil. The viscoelastic material 60 preferably includes an R.T.V.-type silicon-based compound, a dimethyl siloxane compound, a borosilicone rubber combination with silicone oil, a silicone polymer combination with boric oxide, or a combination thereof, for example. 65.0% Dimethyl Siloxane, hydroxy-terminated polymers with boric acid. Claim 1 of the patent reads: an apparatus for selectively holding a device to a surface, the apparatus comprising: an internal frame having an attachment means at one end for selectively attaching the device to the apparatus; and a viscoelastic material fixed about the internal frame and extending beyond a second end of a frame, the viscoelastic material temporarily adhered to the frame and capable of selectively adhering the apparatus to the surface.
The Budden WIPO Patent discloses a flexible sheet material useful as an energy absorbing material is impregnated with a dilatant silicone composition comprising the reaction product of a polydiorgansiloxane and boron compound selected from boric oxide, boric acid, a boric acid precursor, a borate or a partially hydrolysed borate. The silicone composition can be modified by reaction with a hydrophobic compound reactive with silanol groups to improve the resistance to washing. The flexible sheet can be a material, e.g. a fabric, having a negative Poisson's ratio. The impregnated flexible sheet material according to the invention can be used in any of the constructions of energy absorbing material based on fabric or other flexible sheet material described in WO-A-03/022085. Impregnated fabrics according to the invention are particularly suitable for energy absorbing garments for potentially dangerous sports such as motorcycling, skiing, skating, skateboarding, or snowboarding. 60 parts of a dilatant composition formed from a silanol-terminated PDMS and boric acid were dissolved in 40 parts isopropanol to form a dilatant impregnating solution. Various amount of n-octyl branched silicone resin, as set out in Table 4, were dissolved in the solution by mixing with a propeller mixer and 0.05% TIPT was added to each composition. Claim 1 reads as follows: a flexible sheet material impregnated with a dilatant silicone composition comprising the reaction product of a polydiorgansiloxane and a boron compound selected from boric oxide, boric acid, a boric acid precursor, a borate or a partially hydrolysed borate, characterized in that the silicone composition is modified by reaction with a hydrophobic compound reactive with silanol groups.
The Walker Patent discloses a weighted athletic glove. The concept is to have weighted members positioned throughout the glove on the fingers and also on the back of the glove. All of the claims of invention deal with having a weighted feature to the attachments to the glove.
The Fabry Patent discloses a protective glove. In this case the protection deals with an array of shock absorbing hollow sealed cells disposed on various areas of the glove including the back of the glove and the fingers. The protective cells basically have fluid inside them to cushion the blow.
The Douglas Patent is for a hand protector and has various protective elements located on different portions of the glove including the back of the glove. Claim 1 has the protection being a cushioning pad which is releasably connected to the underside of the glove. Claim 2 has the same limitation. Claim 3 has the cushioning pad releasably attached to the back of the glove. Claims 9 and 10 have a hook and loop fastening mechanism by which the cushioning pad is attached.
The Byon Patent discloses a golf glove which basically has various weight segments positioned on different portions of the glove including the back of the glove and along the wrist to protect the pinkie area.
The Goldfine Patent basically deals with an impact absorbing composite.
The '960 Gold Patent discloses a device which has various protective elements along the fingers, the back of the hand and between the fingers but it discloses pocket elements that retain various cushioning material within the pocket.
The Newman Patent has now expired and is a patent for a golf glove. As set forth in Column 2 beginning on Line 35, the patent states:
“Still another and more specific object of the invention is to provide a golf glove which is so designed as to provide maximum protection to the little finger and ring finger, which are the primary gripping fingers while allowing the thumb, index and middle fingers to be free so that the proper sense of touch may remain, not only with respect to the shaft but also with respect to the other hand.”
The Morris Patent has now expired and is for a sports glove.
The Capatosto Patent discloses a hockey glove but it discloses padding 40 on the back side of the inner glove.
The Micheloni Patent discloses a glove for protecting the ligaments, articulations and bones of the hand. The patent discloses:
“A glove for protecting the ligaments, articulations and bones of the hand, has a glove body, to which is associated a plate for protecting the hand palm, at the proximal region of the forearm, which is provided, at one end, with an annular element encompassing the attachment region of the thumb. To the plate there is articulated a shield which is engaged with the forearm, tie-straps being moreover provided connecting the fingers of the glove with the plate.”
The Spitzer Patent discloses a sports glove and in particular a goalie glove.
The '137 Gold Patent basically shows a glove where the tips of the fingers are protected by extra padding as best illustrated in FIG. 1 . There is also a side panel 103 which protects portions of the pinkie finger. Specifically, the patent states:
“The various panels of the glove 100 are sewn together utilizing seams at various points to connect the panels. Again with reference to FIG. 4 , side panel 103 is pre-curved panel. Top panel 101 is secured to side panel 103 with a side seam 172 which extends around top panel 101 , also securing top panel 101 to the fourchette (not shown) forming the inner surface of pinkie finger portion 104 . Likewise, seam 174 connects lower panel 102 to side panel 103 and the corresponding fourchette (not shown) on the other side of finger 103 . Finally, there is a seam (not shown) at the tip of the finger between top panel 101 and bottom panel 102 connecting side panel 103 and the adjacent fourchette (not shown). In some embodiments there is no seam at the tip of the finger. Rather, the seam between fourchettes is at the crotch between fingers.”
The Baylor Patent discloses a hand protecting device which includes several examples where there is a padding on the back of the glove 102 and also along the side of the pinkie finger, 25 and 26 .
The Oomura Patent discloses a glove for baseball where there is padding but the padding is within the glove as best illustrated in the cross-sectional view of FIG. 4 .
The '601 Kleinert Patent discloses a batting glove with padding along the fingers and on all other portions of the glove. This patent has only one independent claim which reads as follows:
“A glove to unload bony prominences, of the hand comprising: a covering for said hand with separate elongated sections to receive a plurality of fingers therein, said covering having a top portion for covering a back side of the hand including a top side of said elongated sections to receive a plurality of fingers and a lower portion to cover a palm side of a hand including a bottom side of said elongated sections to receive said plurality of fingers; and, at least one protective pad attached to a bottom portion of the covering for location below the center axis of rotation of a proximal interphalangeal joint and above the center axis of rotation of the metacarphalphalangeal joint of an index finger, said covering at said proximal interphalangeal joint and said metacarpalphalangeal joint of said index finger being absent of padding.”
The Mazzarolo Patent discloses a motorcycle glove where the invention is to connect two or more fingers with straps so that they are better able to withstand a blow should there be an accident with the motorcycle.
The Lucas Patent discloses a soccer goal keeper glove which includes as shown in FIG. 8 , side folds of mesh material to protect certain fingers.
The '256 Kleinert Patent is for a work glove with a protective material. This is a continuation-in-part of the previously discussed '601 Kleinert Patent. There is only one independent claim in this invention and here the protective padding is to protect the thumb and the palm.
The Howland Patent is for a protective glove and the basic concept of this glove is that it is puncture resistant.
The Mattesky Published Patent Application is for a glove which includes thermo plastic rubber to protect against shock. The patent application involves various protective elements throughout the glove including a fabric secured to at least the back portion of the glove.
The Kogawa Published Patent Application discloses protective members on all parts of the glove including the fingers, on the front of the glove and on the back of the glove.
The Kleinert Published Patent Application is an extension of the previously discussed Kleinert patents.
The WIPO Patent discloses a protection device for fighting games.
The Japanese Patent is in Japanese and clearly is a different type of protective device as best illustrated from the figures.
While the general concept of incorporating shock absorbing and protective material into clothing and athletic gloves is known, the prior art has not addressed the problem of providing protection to the most vulnerable part of a baseball player's hand and wrist when the player is at bat. There is a significant need for a protective glove which addresses this situation.
SUMMARY OF THE INVENTION
When a baseball player is gripping the end of a baseball bat while standing at the plate during his turn at bat, a pitcher is throwing a baseball in the direction of the batter with the intent to have the baseball travel over a portion of home plate so that the pitch will be a strike. The baseball is thrown with substantial velocity and movement so that the batter will miss the baseball when swinging at it with the bat. In an attempt to fool the batter or sometimes to intimidate the batter, the pitcher will throw the baseball at a location where it comes close to where the batter is standing. The image of a baseball traveling at a high rate of speed and also moving in a non-straight line can be intimidating. The batter will try to jump back of out of the way if there is sufficient time to react to the pitch. If the pitch is too fast or the batter does not react quickly enough to jump out of the way, the natural reaction is to raise the baseball bat with both hands so that the batter's hand which is closest to the direction from which the baseball is thrown in front of the batter's hand and face to protect the batter's head and face. If the batter is swinging the bat, during the swinging motion, the portion of the batter's hand and wrist which is closest to the pitcher after completion of a swing is also exposed to the fast moving baseball. As a result, the portion of the batter's hand and wrist which is most exposed during these situation can be hit with the baseball.
To help protect the batter's hands, the batter typically wears at least one batting glove and usually a pair of batting gloves. In the prior art, padding has been placed in the batting glove at a location of the fingers when the glove is worn, at a location on the back of the hand when the glove is worn and at a location on the palm when the glove is worn.
Referring to FIG. 1 , there is illustrated a skeleton of a left hand and wrist 20 which includes fingers, the hand and the wrist. The skeleton is viewed from the palm of the hand. The hand and wrist 20 consists of twenty-seven (27) bones as illustrated. The carpel bones of the wrist include the scaphold 1 , the lunate 2 , the triquetrum 3 , the pisiform 4 , the trapezium 5 , the trapezoid 6 , the capitate 7 and the hamate 8 . The hand has metacarpal bones respectively associated with a given finger. The bones of fingers have three sections for the thumb and four sections for the other four fingers. The thumb has a metacarpal bone 9 of the hand aligned with it and a proximal phalange 14 and a distal phalange 16 . The index finger has a metacarpal bone 10 of the hand aligned with it and three phalanges—proximal 14 , middle 15 and distal 16 . The middle finger has a metacarpal bone 11 and three phalanges—proximal 14 , middle 15 and distal 16 . The fourth finger has a metacarpal bone 12 of the hand aligned with it and three phalanges—proximal 14 , middle 15 and distal 16 . The pinkie finger has a metacarpal bone 13 of the hand aligned with it and three phalanges—proximal 14 , middle 15 and distal 16 . It is frequently the bones of the wrist and in particular the hamate 8 , the pisiform 4 and the lunate 2 as well as the metacarpal bone 13 in the hand which are aligned with the pinkie finger and which most frequency can sustain damage when a baseball hits the batter's hand as the batter is attempting to protect himself or when a batter's hand is vulnerable after a swing of the bat. In addition, the metacarpal bone 12 aligned with the fourth finger and metacarpal bone 11 aligned with the middle finger can sustain damage when a baseball hits the batter's hand as the batter is attempting to protect himself or when a batter's hand is vulnerable after a swing of the bat.
Referring to FIG. 2 , there are eight carpal bones in the wrist divided equally in two rows. The row closer to the arm consists of four bones: scaphoid 1 , lunate 2 , pisiform 4 and triquetrum 3 . The row closer to the hand consist of four bones called trapezium 5 , trapezoid 6 , capitate 7 and hamate 8 . These bones provide a connection between the two bones of the forearm, ulna 17 and radius 18 , and the bones making up the hand. There are three different joints in the wrist all contributing to the movement here: the radiocarpel (wrist) joint between the lower end of the radius and the carpel bones on the thumb side of the wrist; the midcarpal joint between the two rows of carpel bones.; and the carpometacarpal joint between the carpal ones closer to the hand and the metacarpal bones of the hand. These bones and joints are collectively referred to as “wrist bones”. It is also frequently the wrist bones that can sustain damage when a baseball hits the batter's hand and wrist as the batter is attempting to protect himself or when a batter's hand and wrist are vulnerable after a swing of the bat.
The present invention is a novel protective batting glove which is used specifically for protecting the most vulnerable parts of a batter's hands and wrists when the batter is standing at home plate and is gripping the end of a baseball bat and awaiting the arrival of a baseball which is thrown by the pitcher. The invention comprises a unique protective system of a design of a matched pair of batting gloves with one matched pair designed for a right handed batter and one matched pair designed for a left handed batter. For each matched pair of batting gloves, impact and shock absorbing material is incorporated onto selected portions of the exterior of the glove where the grip on the bat causes the hand to be most exposed to a pitch thrown at the batter. The specific one of the matched set of gloves for a right handed or left handed batter has impact and shock absorbing material incorporated onto the exterior of the glove which covers the area where the pinkie finger and its metacarpal bone 13 on the hand are located, and pinkie finger bones proximal bone 14 , middle bone 15 and distal bone 16 are located and also covers the area of the hand where the metacarpal bones 11 and 12 are located. In addition, another unique feature of the present invention is that impact and shock absorbing material extends so that they extend over the exposed area of the wrist which is aligned with the pinkie finger and includes carpal bones which are the hamate 8 , triquetrum 3 , pisiform 4 , and lunate 2 and further extends over a portion of the ulna bone 17 which is aligned with the pisiform 4 and lunate 2 bones of the wrist and connect the wrist to the forearm.
It has been discovered, according to the present invention, that if impact and shock absorbing material are incorporated into the top exterior of a baseball glove so that the impact and shock absorbing material covers the area of the hand and wrist including the pinkie finger and bones of the pinkie, metacarpal bones of the hand aligned with the pinkie finger and also with the fourth and middle fingers, and aligned wrist bones and ulna bone which is connected to the forearm, then the most vulnerable portions of the batter's hand and wrist and lower forearm are protected against impact if a thrown baseball hits these areas when a batter is protecting himself from a thrown pitch or most vulnerable after a swing is completed and these areas of the hand, wrist and lower forearm are exposed to the oncoming baseball.
It has further been discovered, according to the present invention, that one of the bones most at risk for injury from a thrown baseball is the ulna bone of the forearm adjacent the wrist of the hand. If a pitch is thrown at a batter, the most frequent initial response is for the batter to raise his arm to protect his face, thereby exposing the ulna bone to impact from a thrown baseball. A serious injury to the ulna bone can be a career ending injury. The present invention includes a protective glove having a cuff portion wherein the impact and shock absorbing material are incorporated into the to exterior of the baseball glove so that the impact and shock absorbing material extends sufficiently downward to cover the ulna bone from the exterior. It has further been discovered that because this bone is so at risk, it is advantageous to have an additional cushion of impact and shock absorbing material positioned on the interior of the glove in the cuff area to protect the ulna bone through a second interior shock absorbing material. In this way, the ulna bone is protected from both the outside of the glove and the inside of the glove. The interior shock absorbing material can be placed in an interior pouch sewn into the interior of the cuff, which pouch can be sewn shut so that the interior impact and shock absorbing pad cannot be removed or the pouch may have an opening so that the interior impact and shock absorbing pouch can be removed if the batter so desires. The interior shock absorbing material can be affixed directly affixed to the interior of the cuff by sewing, adhesive, etc without first being placed into a pouch.
It has been discovered, according to the present invention, that if impact and shock absorbing material are incorporated into the top exterior of a baseball glove so that the impact and shock absorbing material covers at least the area of the hand and wrist including the metacarpal bone 13 of the hand aligned with the pinkie finger and the wrist bones on the exterior most portion of the hand aligned with the pinkie finger which are the hamate 8 , triquetrum 3 and pisiform 4 , then the most vulnerable portions of the batter's hand and wrist are protected against impact if a thrown baseball hits these areas when a batter is protecting himself from a thrown pitch or most vulnerable during a swing of the bat and these areas of the hand and wrist are exposed to the oncoming baseball.
It has further been discovered, according to the present invention, that the maximum protection and flexibility of gripping the bat is afforded a batter if the gloves worn on the right hand and the left hand are matched so that the impact and shock absorbing material of each glove will be exposed in the direction of a thrown ball when a batter is gripping a baseball bat, if the batter raises the gripped bat to cause the batting gloves to protect the batter's face and head, and during and after the completion of a swing of a bat, and the gloves are designed so that the adjacent area of the second glove does not have shock absorbing material on it so that there is a smooth fit at the adjacent location of the two gloves as the batters grips the baseball bat. In this way, the primary glove which has the impact and energy absorbing material positioned at a location to receive an impact from a baseball is not interfered with by the second non-primary glove which is smooth and does not have any impact and shock absorbing material at the location where the gloves are adjacent to each other when the baseball bat is gripped by the batter, and this combination causes a lack of interference with the batter's normal grip of a baseball bat so that the batter's normal swing is not impaired. The secondary glove also has impact and shock absorbing material on it to cushion that hand of the player when the position of the batter causes that hand to be exposed to a thrown baseball.
It has also been discovered, according to the present invention, that if the impact and energy absorbing material is formed on the outside of the protective glove and is left exposed and uncovered, then the impact and absorbing performance of the material will be substantially increased to thereby more effectively receive the impact from the force of the object such as the baseball and cushion the blow against the wearer of the glove. It is also within the spirit and scope of the present invention to cover the impact and energy absorbing material with fabric, leather or other covering material
It has additionally been discovered, according to the present invention, that if the impact absorbing material is comprised of a multiplicity of impact absorbing cells which are separated from each other by a gap, then the gap facilitates flexibility of the glove so that the batter can grip the bat and swing the bat without interference from the batting glove. The shock absorbing material can be in the form of a matrix of cells of shock absorbing material formed in a lattice with an interconnecting layer onto which the shock absorbing cells are attached, which layer is integrally formed with the material of the glove to enhance retention of the shock absorbing material. Further, the interconnecting layer and shock absorbing cells are flexible so that they can flex with the glove as the gloved hand is wrapped around the bat handle and conform to the shape of the curved glove as it is wrapped around the bat handle to thereby provide maximum flexibility for the glove. By forming the flexible shock absorbing material so that it extends to protect the wearer's wrist bones and ulna bone which connects the wrist bones to the lower forearm, the most vulnerable bones, which if broken can cause substantial recovery periods of career ending injury, are most protected.
It is a key object of the present invention to prevent injury to the wrist bones of the batter when a pitch is thrown too close to a batter, and as the batter draws his hands into a defensive position to both get away from the ball and to protect the batter's head, the arrangement of the protective pads on the present invention gloves are such that the referenced bones in the wrist are protected by the padding arrangement, a benefit which prior art gloves do not provide.
It is an object of the present invention to have at least one batting glove which comprises impact and shock absorbing material incorporated into the top exterior of a baseball glove so that the impact and shock absorbing material covers at least the area of the hand aligned with the pinkie finger and the area of the wrist aligned with the pinkie finger and in addition may also cover the area of the pinkie finger and bones of the pinkie, metacarpal bones of the hand aligned with the pinkie finger and also with the fourth and middle fingers, and aligned wrist bones and ulna bone which is connected to the forearm, so that the most vulnerable portions of the batter's hand and wrist and lower forearm are protected against impact if a thrown baseball hits these areas when a batter is protecting himself from a thrown pitch or most vulnerable after a swing is completed or partially completed and these areas of the hand, wrist and lower forearm are exposed to the oncoming baseball.
Preferably, the glove which comprises the impact absorbing material is the glove which is higher on the baseball bat as the two hands grip the baseball bat so that the exposed impact and shock absorbing material is at a location where it affords maximum protection.
It is another object of the present invention to provide matching protective gloves so that maximum flexibility and lack of interference with a batter gripping the baseball bat is afforded a batter if the gloves worn on the right hand and the left hand are matched so that the impact and shock absorbing material of each glove will be exposed in the direction of a thrown ball when a batter is gripping a baseball bat and during and after the completion of a swing of a bat, and the gloves are designed so that the adjacent area of the second glove does not have shock absorbing material on it so that there is a smooth fit at the adjacent location of the two gloves as the batter grips the baseball bat. In this way, the primary glove which has the impact and energy absorbing material positioned at a location to receive an impact from a baseball is not interfered with by the second non-primary glove which is smooth and does not have any impact and shock absorbing material at the location where the gloves are adjacent to each other when the baseball bat is gripped by the batter.
It is a further object of the present invention to have matching gloves for a right handed batter and separately designed matching gloves for a left handed batter.
It is also an object of the present invention to create impact and energy absorbing material formed on the outside of the protective glove and to cause the impact and energy absorbing material to be exposed and not covered to thereby increase the impact and absorbing performance of the material so that it will more effectively receive the impact from the force of the object such as the baseball and cushion the blow against the wearer of the glove. It is also within the spirit and scope of the present invention to cover the impact and energy absorbing material with fabric, leather or other covering material
It is an additional object of the present invention for the impact absorbing material to be comprised of a multiplicity of impact absorbing cells which are separated from each other by a gap, to thereby increase flexibility of the glove and enhance the batter's ability to grip the baseball bat when wearing the protective gloves. The shock absorbing material can be in the form of a matrix of cells of shock absorbing material formed in a lattice with an interconnecting layer onto which the shock absorbing cells are attached, which layer is integrally formed with the material of the glove to enhance retention of the shock absorbing material. Further, the interconnecting layer and shock absorbing cells are flexible so that they can flex with the glove as the gloved hand is wrapped around the bat handle and conform to the shape of the curved glove as it is wrapped around the bat handle to thereby provide maximum flexibility. By forming the flexible shock absorbing material so that it protects the wearer's wrist bones and ulna bone which connects the wrist bones to the lower forearm, the most vulnerable bones are protected.
It is a further object of the present invention to provide a double layer of protection to the ulna bone since the ulna bone is one of the bones most at risk for injury from a thrown baseball. If a pitch is thrown at a batter, the most frequent initial response is for the batter to raise his arm to protect his face, thereby exposing the ulna bone to impact from a thrown baseball. A serious injury to the ulna bone can be a career ending injury. The present invention includes a protective glove having a cuff portion wherein the impact and shock absorbing material are incorporated into the to exterior of the baseball glove so that the impact and shock absorbing material extends sufficiently downward to cover the ulna bone from the exterior. It is a further object of the present invention to have an additional cushion of impact and shock absorbing matched positioned on the interior of the glove in the cuff area to protect the ulna bone through a second interior shock absorbing material. In this way, the ulna bone is protected from both the outside of the glove and the inside of the glove. The interior shock absorbing material can be placed in an interior pouch sewn into the interior of the cuff, which pouch can be sewn shut so that the interior impact and shock absorbing pad cannot be removed or the pouch may have an opening so that the interior impact and shock absorbing pouch can be removed if the batter so desires. Alternatively, the impact and shock absorbing material can be affixed directly onto the interior of the cuff without use of a pocket.
Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claims, taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated:
FIG. 1 is a drawing of the skeleton bones of a hand including the metacarpal bones of a hand and phalanges bones of the fingers, as well as the carpel bones in the wrist;
FIG. 2 is a drawing of the carpel bones in a wrist and the ulna bone which connects wrist bones to the lower forearm;
FIG. 2A is an insert to show the bones illustrated in FIG. 1 and how the wrist bones relate to the finger bones shown in FIG. 1 ;
FIG. 3 is a top plan view of a first embodiment of the BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE which is a right handed glove used by a right handed batter;
FIG. 4 is a bottom plan of the first embodiment;
FIG. 5 is a side elevational view when viewed from the left side of the first embodiment;
FIG. 6 is a side elevational view when viewed from the right side of the first embodiment;
FIG. 7 is a bottom end view of the first embodiment;
FIG. 8 is a top end view of the first embodiment;
FIG. 9 is a top plan view of a second embodiment of the BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE which is a left handed glove used by a right handed batter;
FIG. 10 is a bottom plan view of the second embodiment;
FIG. 11 is a side elevational view when viewed from the right side of the second embodiment;
FIG. 12 is a side elevational view when viewed from the left side of the second embodiment;
FIG. 13 is a bottom end view of the second embodiment;
FIG. 14 is a top end view of the second embodiment;
FIG. 15 is a perspective view of the first and second embodiments of the present invention as worn by a right handed batter when gripping the bottom end of a baseball bat while standing at home plate to await a pitch, the baseball bat is shown in dotted lines and is not a part of this invention and a portion of a batter's arm is also shown in dotted lines and is not a part of this invention;
FIG. 16 is a perspective view of the first and second embodiments of the present invention as worn by a right handed batter when gripping the bottom end of a baseball bat with the bat raised by the batter to protect his face and head from a baseball coming in a direction which will hit the batter, with both gloves having impact and shock absorbing material to protect the batter in various orientations depending on how the batter moves. The baseball bat is shown in dotted lines and is not a part of this invention and the batter is also shown in dotted lines and is not a part of this invention;
FIG. 17 is a perspective view of the first and second embodiments of the present invention as worn by a right handed batter when gripping the bottom end of a baseball bat being swung in the middle of a swing with a baseball coming in the direction of the batter's hands during the swing, with both gloves having impact and shock absorbing material to protect the batter in various swinging positions. The baseball bat is shown in dotted lines and is not a part of this invention and the batter is also shown in dotted lines and is not a part of this invention;
FIG. 18 is a top plan view of a third embodiment of the BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE which is a left handed glove for a left handed batter;
FIG. 19 is a bottom plan of the third embodiment;
FIG. 20 is a side elevational view when viewed from the right side of the third embodiment;
FIG. 21 is a side elevational view when viewed from the left side of the third embodiment;
FIG. 22 is a bottom end view of the third embodiment;
FIG. 23 is a top end view of the third embodiment;
FIG. 24 is a top plan view of a fourth embodiment of the BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE which is a right handed glove used by a left handed batter;
FIG. 25 is a bottom plan of the fourth embodiment;
FIG. 26 is a side elevational view when viewed from the left side of the fourth embodiment;
FIG. 27 is a side elevational view when viewed from the right side of the fourth embodiment;
FIG. 28 is a bottom end view of the fourth embodiment;
FIG. 29 is a top end view of the fourth embodiment;
FIG. 30 is a perspective view of the third and fourth embodiments of the present invention as worn by a left handed batter when gripping the bottom end of a baseball bat while standing at home plate to await a pitch, the baseball bat is shown in dotted lines and is not a part of this invention and a portion of a batter's arm is also shown in dotted lines and is not a part of this invention;
FIG. 31 is a perspective view of the third and fourth embodiments of the present invention as worn by a left handed batter when gripping the bottom end of a baseball bat with the bat raised by the batter to protect his face and head from a baseball coming in a direction which will hit the batter, with both gloves having impact and shock absorbing material to protect the batter in various orientations depending on how the batter moves. The baseball bat is shown in dotted lines and is not a part of this invention and the batter is also shown in dotted lines and is not a part of this invention;
FIG. 32 is a perspective view of the third and fourth embodiments of the present invention as worn by a left handed batter when gripping the bottom end of a baseball bat being swung in the middle of a swing with a baseball coming in the direction of the batter's hands during the swing, with both gloves having impact and shock absorbing material to protect the batter in various swing positions. The baseball bat is shown in dotted lines and is not a part of this invention and a portion of a batter's arm is also shown in dotted lines and is not a part of this invention;
FIG. 33 is a cross-sectional view illustrating the glove layers, a substrate material, a thermoplastic bonding layer and an impact and shock absorbing cell layer;
FIG. 34 is a bottom plan view or palm view of a right handed glove which can be either the first or fourth embodiment of the present invention BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE, with the cuff in the opened condition to illustrate the additional improvement of an interior pocket containing shock absorbing material within the pocket, the pocket located on the interior of the glove at the cuff area to protect the ulna bone, with the pocket permanently closed so that the shock absorbing material cannot be removed;
FIG. 35 is a top plan view of the first embodiment of a right handed glove of the present invention illustrating the stitching to retain the interior pocket.
FIG. 36 is a bottom plan view or palm view of a left handed glove which can be either the second or third embodiment of the present invention BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE, with the cuff in the opened condition to illustrate the additional improvement of an interior pocket containing shock absorbing material within the pocket, the pocket located on the interior of the glove at the cuff area to protect the ulna bone, with the pocket permanently closed so that the shock absorbing material cannot be removed;
FIG. 37 is a top plan view of the first embodiment of a left handed glove of the present invention illustrating the stitching to retain the interior pocket.
FIG. 38 is a bottom plan view or palm view of a right handed glove which can be either the first or fourth embodiment of the present invention BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE, with the cuff in the opened condition to illustrate the additional improvement of an interior pocket containing shock absorbing material within the pocket, the pocket located on the interior of the glove at the cuff area to protect the ulna bone, with the pocket having an open side so that the shock absorbing material can be removed;
FIG. 39 is a bottom plan view or palm view of a left handed glove which can be either the second or third embodiment of the present invention BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE, with the cuff in the opened condition to illustrate the additional improvement of an interior pocket containing shock absorbing material within the pocket, the pocket located on the interior of the glove at the cuff area to protect the ulna bone, with the pocket having an open side so that the shock absorbing material can be removed;
FIG. 40 is a bottom plan view or palm view of a right handed glove which can be either the first or fourth embodiment of the present invention BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE, with the cuff in the opened condition to illustrate the additional improvement of shock absorbing material located on and directly affixed to the interior of the glove by adhesive or comparable bonding means at the cuff area to protect the ulna bone;
FIG. 41 is a bottom plan view or palm view of a left handed glove which can be either the second or third embodiment of the present invention BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE, with the cuff in the opened condition to illustrate the additional improvement of shock absorbing material located on and directly affixed to the interior of the glove by adhesive or comparable bonding means at the cuff area to protect the ulna bone;
FIG. 42 is a bottom plan view or palm view of a right handed glove which can be either the first or fourth embodiment of the present invention BASEBALL BATTING GLOVE WITH PROTECTIVE SHOCK ABSORBING MEMBERS ON THE EXTERIOR OF THE GLOVE, with the cuff in the opened condition to illustrate the additional improvement of shock absorbing material located on and directly affixed to the interior of the glove by stitching at the cuff area to protect the ulna bone;
FIG. 43 is a top plan view of the first embodiment of a right handed glove of the present invention illustrating the location of the stitching to retain the interior with a dotted line to illustrate the location of the shock absorbing material located on and directly affixed to the interior of the glove by stitching;
FIG. 44 is a palm view of a left handed glove which can be either the second or third embodiment of the present invention baseball batting glove with protective shock absorbing members on the exterior of the glove, with the cuff in the opened condition to illustrate the additional improvement of shock absorbing material located on and directly affixed to the interior of the glove by stitching at the cuff area to protect the ulna bone; and
FIG. 45 is a top plan view of the first embodiment of a left handed glove of the present invention with a dotted line illustrating the location of the improved shock absorbing material located on and directly affixed to the interior of the glove.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims.
Referring to FIGS. 3 through 14 , there is illustrated a pair of protective baseball bating gloves for use by a right handed batter in accordance with the present invention. The glove worn on the right hand is illustrated in FIGS. 3 through 8 . The right handed glove 100 for a right hand batter is made of breathable synthetic or leather material such as leather, synthetic leather and stretchable nylon and includes a body 110 having a top or back section 120 which covers the back the hand and a palm section 122 . The back section 120 and palm section 122 extend to finger receiving sections including a thumb receiving section 124 , a forefinger receiving section 126 , a middle finger receiving section 128 , a fourth finger receiving section 130 and a pinkie finger receiving section 132 . The rear or bottom of the glove 100 has an opening 134 through which the right hand and fingers are inserted so that a thumb and respective fingers are respectively received within the a respective thumb receiving section and finger receiving sections. An adjustment or tightening strap 136 is located adjacent the bottom opening 134 to tighten the glove 100 around the wrist of the wearer. The glove is long enough so that the shock absorbing cells 154 can cover the wrist bones and a portion of the ulna bone.
The improvement of the present invention is the addition of a flexible matrix of impact and shock absorbing cells 150 which are formed on an interconnecting layer 152 and comprise a multiplicity of impact and shock absorbing cells 154 which are formed in spaced apart longitudinal rows 160 and transverse rows 170 , each shock absorbing cell attached onto the interconnecting layer 152 and separated from adjacent shock absorbing cells by a gap, the design also including a circular shock absorbing post 180 attached to the interconnecting layer 152 and at a location of a corner of each respective four spaced apart shock absorbing cells having a corner closest to each other. Each shock absorbing post 180 has a central opening 182 .
The preferred embodiment of the glove and shock absorbing material formation is illustrated in the cross-sectional view of FIG. 33 . The glove layer 102 has a substrate material 104 sewn into the glove material 102 . The glove layer 102 can be made of leather, synthetic leather, stretchable nylon, etc. The substrate material can also be made of leather, synthetic leather, stretchable nylon, etc. A thermoplastic bonding layer 106 is bonded to the substrate layer 104 and the impact absorbing cells 154 are bonded to the thermoplastic layer 106 . One method to create the bonding is radio frequency bonding. A conducting agent 105 is placed between the substrate layer 104 and the thermoplastic bonding layer 106 and another conducting agent 107 is placed between the thermoplastic bonding layer 106 and the impact absorbing cell 154 and the entire assembly is bonded together by radio frequency bonding. A multiplicity of gaps 162 are formed between the shock absorbing cells 154 and a multiplicity of shock absorbing posts 180 with central openings 182 are also formed. The gaps 162 and posts 180 enhance the flexibility of the gloves. In preferred embodiments, the impact and shock absorbing cells 154 are made of material selected from the group consisting of a soft polyvinyl chloride foam, soft polyvinyl chloride solid material, silicone foam, silicone solid material, flexible thermoplastic foam, flexible thermoplastic solid material, and flexible thermoplastic rubber. It is also within the spirit and scope of the present invention to change conducting agents 105 and 107 to a non-RF conducting agent and also to be replaced with a simple bonding agent. It is also within the spirit and scope of the present invention to have a single bonding agent 105 or 107 and not both 105 and 107 . In addition, it is also within the spirit and scope of the present invention to have the cells 154 connected to the substrate 104 and eliminate the thermoplastic bonding layer 106 and only have one layer of bonding agent, either 105 or 107 .
As illustrated in FIGS. 3 through 8 , the flexible matrix of shock absorbing cells 150 is on the outside or exterior surface of the glove 100 and extends over the area of the pinkie finger receiving section 132 and cover the entire length of the glove so as to cover the area of the glove which receives the pinkie finger including its three phalanges—proximal 14 , middle 15 and distal 16 and the metacarpal bone 13 of the hand aligned with the pinkie finger. Preferably the matrix of shock absorbing cells 150 also covers the metacarpal bone 12 of the hand associated with the fourth finger and the metacarpal bone 11 of the hand associated with the middle finger. The key innovation of the present invention is that the matrix of shock absorbing cells 150 extend over the area of the glove to cover a portion of the wrist bones aligned with the pinkie finger cover the wrist bones and may also cover the ulna bone. The wrist bones which are thereby covered are the carpal bones which are the hamate 8 , trequetrum 3 , pisiform 4 , and lunate 2 . The capitate bone 7 can also be covered.
The key innovation of the present invention is that the matrix of shock absorbing cells 150 is on the exterior of the glove 100 and at least covers the bone of the hand aligned with the pinkie finger which is the metacarpal bone 13 and at least covers the bones of the wrist aligned with this metacarpal bone 13 which bones are at least the hamate 8 , the triquetrum 3 and the pisiform 4 . Preferably the shock absorbing matrix 150 also covers the ulna bone 17 at its location adjacent the wrist. Although there are gaps to provide flexibility, the impact and shock absorbing protection is continuous to cover the metacarpal bone 13 on its top, side and bottom to cover the exposed top of the wrist bones. In this way, the bones which are most vulnerable to being hit by a pitch are covered and protected. Injury to these bones can be career ending or at least cause a player to be sidelined and undergo recovery for many weeks or months.
The glove worn on the left hand for a right handed batter is illustrated in FIGS. 9 through 14 . The glove worn on the left hand is illustrated in FIGS. 9 through 14 . The left handed glove 200 for a right hand batter is made of breathable synthetic or leather material such as leather, synthetic leather and stretchable nylon and includes a body 210 have a top or back section 220 which covers the back the hand and a palm section 222 . The back section 220 and palm section 222 extend to finger receiving sections including a thumb receiving section 224 , a forefinger receiving section 226 , a middle finger receiving section 228 , a fourth finger receiving section 230 and a pinkie finger receiving section 232 . The rear or bottom of the glove 200 has an opening 234 through which the left hand and fingers are inserted so that a thumb and respective finger are respectively received within the a respective thumb receiving section and finger receiving sections. An adjustment or tightening strap 236 is located adjacent the bottom opening 234 to tighten the glove 200 around the wrist of the wearer. The glove is long enough to cover the wrist bones and the ulna bone.
The improvement of the present invention is the addition of a flexible matrix of impact and shock absorbing cells 250 which are formed on an interconnecting layer 252 and comprise a multiplicity of impact and shock absorbing cells 254 which are formed in spaced apart longitudinal rows 260 and transverse rows 270 , each shock absorbing cell attached onto the interconnecting layer 252 and separated from adjacent shock absorbing cells by a gap, the design also including a circular shock absorbing post 280 attached to the interconnecting layer 252 and at a location of a corner of each respective four spaced apart shock absorbing cells having a corner closest to each other. Each shock absorbing post 280 has a central opening 282 .
The preferred embodiment of the glove and shock absorbing material formation is illustrated in the cross-sectional view of FIG. 33 and the formation is the same for the left handed glove as for the right handed glove. The glove layer has a substrate material sewn into the glove material. The glove layer can be made of leather, synthetic leather, stretchable nylon, etc. The substrate material can also be made of leather, synthetic leather, stretchable nylon, etc. A thermoplastic bonding layer is bonded to the substrate layer and the impact absorbing cells are bonded to the thermoplastic layer. One method to create the bonding is radio frequency bonding. A conducting agent is placed between the substrate layer and the thermoplastic bonding layer and another conducting agent is placed between the thermoplastic bonding layer and the impact absorbing cell and the entire assembly is bonded together by radio frequency bonding. As illustrated in FIGS. 9 through 14 , a multiplicity of gaps 262 are formed between the shock absorbing cells 254 and a multiplicity of shock absorbing posts 280 with central openings 282 are also formed. The gaps and posts enhance the flexibility of the gloves. In preferred embodiments, the impact and shock absorbing cells 154 are made of material selected from the group consisting of a soft polyvinyl chloride foam, soft polyvinyl chloride solid material, silicone foam, silicone solid material, flexible thermoplastic foam, flexible thermoplastic solid material, and flexible thermoplastic rubber.
As illustrated in FIGS. 9 through 14 , the flexible matrix of shock absorbing cells 250 is on the outside or exterior surface of the glove 200 and extends over the area of the pinkie finger receiving section 252 and cover the entire length of the glove so as to cover the area of the glove which receives the pinkie finger including its three phalanges—proximal 14 , middle 15 and distal 16 and the metacarpal bone 13 of the hand aligned with the pinkie finger. Preferably the matrix of shock absorbing cells 250 also covers the metacarpal bone 12 of the hand associated with the fourth finger and the metacarpal bone 11 of the hand associated with the middle finger. The key innovation of the present invention is that the matrix of shock absorbing cells 250 extend over the area of the glove to cover a portion of the wrist bones aligned with the pinkie finger cover the wrist bones and may also cover the ulna bone. The wrist bones which are thereby covered are the carpal bones which are the hamate 8 , trequetrum 3 , pisiform 4 , and lunate 2 . The capitate bone 7 can also be covered.
The key innovation of the present invention is that the matrix of shock absorbing cells 250 is on the exterior of the glove 200 and at least covers the bone of the hand aligned with the pinkie finger which is the metacarpal bone 13 and at least covers the bones of the wrist aligned with this metacarpal bone 13 which bones are at least the hamate 8 , the triquetrum 3 and the pisiform 4 . Preferably the shock absorbing matrix 250 also covers the ulna bone 17 at its location adjacent the wrist. Although there are gaps to provide flexibility, the impact and shock absorbing protection is continuous to cover the metacarpal bone 13 on its top, side and bottom and to cover the exposed top of the wrist bones. In this way, the bones which are most vulnerable to being hit by a pitch are covered and protected. Injury to these bones can be career ending or at least cause a player to be sidelined and undergo recovery for many weeks or months.
The right handed and left handed gloves for a right handed batter with the present invention are shown in use while gripping baseball bat 1000 as illustrated in FIGS. 15 , 16 and 17 . The right forearm 1110 is shown in dotted lines and the left forearm 1120 is shown in dotted lines. The right handed glove 100 is above the left handed glove 200 . As illustrated in FIG. 15 , the gloves 100 and 200 are matched so that the shock absorbing material 150 and 250 of each glove will be exposed in the direction of a thrown ball when a batter is gripping the baseball bat 1000 and during and after completion of a swing of a bat. The gloves are designed so that the area of the left handed glove 200 adjacent the right handed glove 100 does not have shock absorbing material on it so that there is a smooth fit at the adjacent location of the two gloves as the batter grips the baseball bat 1000 . This design facilitates the batter gripping the bat in the normal way and the shock absorbing material does not interfere with the way the batter grips the baseball bat. In this way, the primary right hand glove 100 which has the impact and energy absorbing matrix 150 is positioned at a location so that the impact and energy absorbing cells 154 are positioned to receive an impact of a baseball if the batter raises his right had to protect himself or if the swing is completed or partially completed so this portion of the glove faces the oncoming baseball. Therefore, through the present invention, the most vulnerable bones on the fingers, hand and wrist are protected. As illustrated in FIG. 15 , the shock absorbing members 154 from the right handed glove 100 are positioned to protect the batter's hands and wrist at its most vulnerable position when the batter is standing at home plate to await a pitch. FIG. 16 shows the bat raised by a batter in a normal reaction if a ball appears to be coming at the batter, so that the batter's face and head are protected with the shock absorbing material from the right handed glove facing the oncoming ball. FIG. 17 shows that if a batter misjudges a pitch and the batter's hands are facing an oncoming ball during a swing, the shock absorbing material on the right handed glove is facing the oncoming ball protect the most vulnerable parts of the batter's hand and wrist. The left hand glove 200 also has shock absorbing material to protect the corresponding vulnerable bones on the left hand.
Referring to FIGS. 18 through 29 there is illustrated a pair of protective baseball bating gloves for use by a left handed batter in accordance with the present invention. The glove worn on the left hand is illustrated in FIGS. 18 through 23 . The left handed glove 300 for a left handed batter is made of breathable synthetic or leather material such as leather, synthetic leather and stretchable nylon and includes a body 310 have a back section 320 which covers the back the hand and a palm section 322 . The back section 320 and palm section 322 extend to finger receiving sections including a thumb receiving section 324 , a forefinger receiving section 326 , a middle finger receiving section 328 , a fourth finger receiving section 330 and a pinkie finger receiving section 332 . The rear or bottom of the glove 300 has an opening 334 through which the right hand and fingers are inserted so that a thumb and respective finger are respectively received within the a respective thumb receiving section and finger receiving sections. An adjustment or tightening strap 336 is located adjacent the bottom opening 334 to tighten the glove 300 around the wrist of the wearer. The glove is long enough so that the shock absorbing cells 354 can cover the wrist bones and a portion of the ulna bone.
The improvement of the present invention is the addition of a flexible matrix of impact and shock absorbing cells 350 which are formed on an interconnecting layer 352 and comprise a multiplicity of impact and shock absorbing cells 354 which are formed in spaced apart longitudinal rows 360 and transverse rows 370 , each shock absorbing cell attached onto the interconnecting layer 352 and separated from adjacent shock absorbing cells by a gap, the design also including a circular shock absorbing post 380 attached to the interconnecting layer 352 and at a location of a corner of each respective four spaced apart shock absorbing cells having a corner closest to each other. Each shock absorbing post 380 has a central opening 382 .
The preferred embodiment of the glove and shock absorbing material formation is the same as illustrated in the cross-sectional view of FIG. 33 . The glove layer has a substrate material sewn into the glove material. The glove layer can be made of leather, synthetic leather, stretchable nylon, etc. The substrate material can also be made of leather, synthetic leather, stretchable nylon, etc. A thermoplastic bonding layer is bonded to the substrate layer and the impact absorbing cells are bonded to the thermoplastic layer. One method to create the bonding is radio frequency bonding. A conducting agent is placed between the substrate layer 104 and the thermoplastic bonding layer and another conducting agent is placed between the thermoplastic bonding layer and the impact absorbing cell and the entire assembly is bonded together by radio frequency bonding. As illustrated in FIGS. 18 through 23 , a multiplicity of gaps 362 are formed between the shock absorbing cells 354 and a multiplicity of shock absorbing posts 380 with central openings 382 are also formed. The gaps and posts enhance the flexibility of the gloves. In one preferred embodiment, the shock absorbing cells 354 are made of material selected from the group consisting of a soft polyvinyl chloride foam, soft polyvinyl chloride solid material, silicone foam, silicone solid material, flexible thermoplastic foam, flexible thermoplastic solid material, and flexible thermoplastic rubber.
As illustrated in FIGS. 18 through 23 , the flexible matrix of shock absorbing cells 350 is on the outside or exterior surface of the glove 300 and extends over the area of the pinkie finger receiving section 352 and cover the entire length of the glove so as to cover the area of the glove which receives the pinkie finger including its three phalanges—proximal 14 , middle 15 and distal 16 and the metacarpal bone 13 of the hand aligned with the pinkie finger. Preferably the matrix of shock absorbing cells 350 also covers the metacarpal bone 12 of the hand associated with the fourth finger and the metacarpal bone 11 of the hand associated with the middle finger. The key innovation of the present invention is that the matrix of shock absorbing cells 350 extend over the area of the glove to cover a portion of the wrist bones aligned with the pinkie finger cover the wrist bones and may also cover a portion of the ulna bone. The wrist bones which are thereby covered are the carpal bones which are the hamate 8 , trequetrum 3 , pisiform 4 , and lunate 2 . The capitate bone 7 can also be covered.
The key innovation of the present invention is that the matrix of shock absorbing cells 350 is on the exterior of the glove 300 and at least covers the bone of the hand aligned with the pinkie finger which is the metacarpal bone 13 and at least covers the bones of the wrist aligned with this metacarpal bone 13 which bones are at least the hamate 8 , the triquetrum 3 and the pisiform 4 . Preferably the shock absorbing matrix 350 also covers the ulna bone 17 at its location adjacent the wrist. Although there are gaps to provide flexibility, the impact and shock absorbing protection is continuous to cover the metacarpal bone 13 on its top, side and bottom and to cover the exposed top of the wrist bones. In this way, the bones which are most vulnerable to being hit by a pitch are covered and protected. Injury to these bones can be career ending or at least cause a player to be sidelined and undergo recovery for many weeks or months.
The glove worn on the right hand for a left handed batter is illustrated in FIGS. 24 through 29 . The right handed glove 400 for a left handed batter is made of breathable synthetic or leather material such as leather, synthetic leather and stretchable nylon and includes a body 410 have a top or back section 420 which covers the back the hand and a palm section 422 . The back section 420 and palm section 422 extend to finger receiving sections including a thumb receiving section 424 , a forefinger receiving section 426 , a middle finger receiving section 428 , a fourth finger receiving section 430 and a pinkie finger receiving section 432 . The rear or bottom of the glove 400 has an opening 434 through which the left hand and fingers are inserted so that a thumb and respective finger are respectively received within the a respective thumb receiving section and finger receiving sections. An adjustment or tightening strap 436 is located adjacent the bottom opening 434 to tighten the glove 400 around the wrist of the wearer. The glove is long enough to cover the wrist bones and the ulna bone.
The improvement of the present invention is the addition of a flexible matrix of impact and shock absorbing cells 450 which are formed on an interconnecting layer 452 and comprise a multiplicity of impact and shock absorbing cells 454 which are formed in spaced apart longitudinal rows 460 and transverse rows 470 , each shock absorbing cell attached onto the interconnecting layer 452 and separated from adjacent shock absorbing cells by a gap, the design also including a circular shock absorbing post 480 attached to the interconnecting layer 452 and at a location of a corner of each respective four spaced apart shock absorbing cells having a corner closest to each other. Each shock absorbing post 480 has a central opening 482 .
The preferred embodiment of the glove and shock absorbing material formation is illustrated in the cross-sectional view of FIG. 33 and the formation is the same for the right handed glove as for the right handed glove. The glove layer has a substrate material sewn into the glove material. The glove layer can be made of leather, synthetic leather, stretchable nylon, etc. The substrate material can also be made of leather, synthetic leather, stretchable nylon, etc. A thermoplastic bonding layer is bonded to the substrate layer and the impact absorbing cells are bonded to the thermoplastic layer. One method to create the bonding is radio frequency bonding. A conducting agent is placed between the substrate layer and the thermoplastic bonding layer and another conducting agent is placed between the thermoplastic bonding layer and the impact absorbing cell and the entire assembly is bonded together by radio frequency bonding. As illustrated in FIGS. 24 through 29 , a multiplicity of gaps 462 are formed between the shock absorbing cells 454 and a multiplicity of shock absorbing posts 480 with central openings 482 are also formed. The gaps and posts enhance the flexibility of the gloves. In preferred embodiments, the impact and shock absorbing cells 154 are made of material selected from the group consisting of a soft polyvinyl chloride foam, soft polyvinyl chloride solid material, silicone foam, silicone solid material, flexible thermoplastic foam, flexible thermoplastic solid material, and flexible thermoplastic rubber.
As illustrated in FIGS. 24 through 29 , the flexible matrix of shock absorbing cells 450 is on the outside or exterior surface of the glove 400 and extends over the area of the pinkie finger receiving section 452 and cover the entire length of the glove so as to cover the area of the glove which receives the pinkie finger including its three phalanges—proximal 14 , middle 15 and distal 16 and the metacarpal bone 13 of the hand aligned with the pinkie finger. Preferably the matrix of shock absorbing cells 450 also covers the metacarpal bone 12 of the hand associated with the fourth finger and the metacarpal bone 11 of the hand associated with the middle finger. The key innovation of the present invention is that the matrix of shock absorbing cells 450 extend over the area of the glove to cover a portion of the wrist bones aligned with the pinkie finger cover the wrist bones and may also cover the ulna bone. The wrist bones which are thereby covered are the carpal bones which are the hamate 8 , trequetrum 3 , pisiform 4 , and lunate 2 . The capitate bone 7 can also be covered.
The key innovation of the present invention is that the matrix of shock absorbing cells 450 is on the exterior of the glove 400 and at least covers the bone of the hand aligned with the pinkie finger which is the metacarpal bone 13 and at least covers the bones of the wrist aligned with this metacarpal bone 13 which bones are at least the hamate 8 , the triquetrum 3 and the pisiform 4 . Preferably the shock absorbing matrix 450 also covers the ulna bone 17 at its location adjacent the wrist. Although there are gaps to provide flexibility, the impact and shock absorbing protection is continuous to cover the metacarpal bone 13 on its top, side and bottom and to cover the exposed top of the wrist bones. In this way, the bones which are most vulnerable to being hit by a pitch are covered and protected. Injury to these bones can be career ending or at least cause a player to be sidelined and undergo recovery for many weeks or months.
The left handed and right handed gloves for a left handed batter with the present invention are shown in use while gripping baseball bat 2000 as illustrated in FIGS. 30 , 31 and 32 . The left forearm 2110 is shown in dotted lines and the right forearm 2120 is shown in dotted lines. The left handed glove 300 is above the right handed glove 400 . As illustrated in FIG. 30 , the gloves 300 and 400 are matched so that the shock absorbing material 350 and 450 of each glove will be exposed in the direction of a thrown ball when a batter is gripping the baseball bat 2000 and during and after completion of a swing of a bat. The gloves are designed so that the area of the right handed glove 400 adjacent the left handed glove 300 does not have shock absorbing material on it so that there is a smooth fit at the adjacent location of the two gloves as the batter grips the baseball bat 2000 . This design facilitates the batter gripping the bat in the normal way and the shock absorbing material does not interfere with the way the batter grips the baseball bat. In this way, the primary right hand glove 300 which has the impact and energy absorbing matrix 350 is positioned at a location so that the impact and energy absorbing cells 354 are positioned to receive an impact of a baseball if the batter raises his right had to protect himself or if the swing is completed or partially completed so this portion of the glove faces the oncoming baseball. Therefore, through the present invention, the most vulnerable bones on the fingers, hand and wrist are protected. As illustrated in FIG. 30 , the shock absorbing members 354 from the left handed glove 300 are positioned to protect the batter's hands and wrist at its most vulnerable position when the batter is standing at home plate to await a pitch. FIG. 31 shows the bat raised by a batter in a normal reaction if a ball appears to be coming at the batter, so that the batter's face and head are protected with the shock absorbing material from the right handed glove facing the oncoming ball. FIG. 32 shows that if a batter misjudges a pitch and the batter's hands are facing an oncoming ball during a swing, the shock absorbing material on the right handed glove is facing the oncoming ball protect the most vulnerable parts of the batter's hand and wrist. The right handed glove 400 also has shock absorbing material to protect the corresponding vulnerable bones in the right hand.
Referring to FIG. 34 , there is illustrated a bottom plan view of a right handed glove which can be either the first embodiment illustrated in FIG. 4 or the fourth embodiment illustrated in FIG. 25 . The glove 100 in FIG. 4 will be used for this discussion. The palm section 122 , thumb receiving section 124 , forefinger receiving section 126 , middle finger receiving section 128 , fourth finger receiving section 130 And pinkie finger receiving section 132 are illustrated. The interior 136 A of adjustment or tightening strap 136 is illustrated. The adjustment or tightening strap 136 is opened and the cuff section 140 is folded over to illustrate the interior 142 of the cuff section 140 . The additional innovation is the inclusion of an interior pocket 146 which is affixed to the interior 142 of the cuff section 140 at a location where the pocket will cover a portion of the ulna bone 17 when the glove 100 is closed with the cuff section 140 resting over a portion of the ulna bone when the adjustment strap 136 is closed and tightened as illustrated in FIG. 35 . The pocket 146 can be made of see-through mesh material as illustrated and can be sewn by stitches 146 A onto the interior 142 of the cuff 140 . Contained within the pocket is at least one interior flexible matrix of impact and shock absorbing cells 150 A which are made of the same material as illustrated in FIG. 33 . With the pocket 146 permanently closed, the at least one matrix of impact and shock absorbing cells 150 A cannot be removed from the pocket. Also illustrated is a mating hook or loop fastener 136 B on the interior 136 A of adjustment strap 136 and stitching 136 C which retains the mating hook or loop fastener on the exterior of the cuff 140 . The exterior of the glove 100 is illustrated in FIG. 35 and has the same components as discussed for FIG. 3 . The dotted lines 146 C are used to show the location of the pocket 146 when the glove 100 is closed and the adjustment strap 136 tightened. Therefore, a portion of the exterior flexible matrix of impact and shock absorbing cells 150 and the at least one interior flexible matrix of impact and shock absorbing cells 150 A both cover the most vulnerable portion of the ulna bone 17 of a batter's arm adjacent the wrist to provide a double layer of protection.
Referring to FIG. 36 , there is illustrated a bottom plan view of a left handed glove which can be either the second embodiment illustrated in FIG. 10 or the third embodiment illustrated in FIG. 19 . The glove 200 in FIG. 10 will be used for this discussion. The palm section 222 , thumb receiving section 224 , forefinger receiving section 226 , middle finger receiving section 228 , fourth finger receiving section 230 and pinkie finger receiving section 232 are illustrated. The interior 236 A of adjustment or tightening strap 236 is illustrated. The adjustment or tightening strap 236 is opened and the cuff section 240 is folded over to illustrate the interior 242 of the cuff section 240 . The additional innovation is the inclusion of an interior pocket 246 which is affixed to the interior 242 of the cuff section 240 at a location where the pocket will cover a portion of the ulna bone 17 when the glove 200 is closed with the cuff section 240 resting over a portion of the ulna bone when the adjustment strap 236 is closed and tightened as illustrated in FIG. 37 . The pocket 246 can be made of see-through mesh material as illustrated and can be sewn by stitches 246 A onto the interior 242 of the cuff 240 . Contained within the pocket is at least one impact matrix of impact and shock absorbing cells 250 A which are made of the same material as illustrated in FIG. 33 . With the pocket 246 permanently closed, the at least one interior flexible matrix of impact and shock absorbing cells 250 A cannot be removed from the pocket. Also illustrated is a mating hook or loop fastener 236 B on the interior 236 A of adjustment strap 236 and stitching 236 C which retains the mating hook or loop fastener on the exterior of the cuff 240 . The exterior of the glove 200 is illustrated in FIG. 35 and has the same components as discussed for FIG. 9 . The dotted lines 246 C are used to show the location of the pocket 246 when the glove 200 is closed and the adjustment strap 236 tightened. Therefore, a portion of the exterior flexible matrix of impact and shock absorbing cells 250 and the at least one interior flexible matrix of impact and shock absorbing cells 250 A both cover the most vulnerable portion of the ulna bone 17 of a batter's arm adjacent the wrist to provide a double layer of protection.
Referring to FIG. 38 , there is illustrated a bottom plan view of a right handed glove which can be either the first embodiment illustrated in FIG. 4 or the fourth embodiment illustrated in FIG. 25 . The glove 100 in FIG. 4 will be used for this discussion. The palm section 122 , thumb receiving section 124 , forefinger receiving section 126 , middle finger receiving section 128 , fourth finger receiving section 130 And pinkie finger receiving section 132 are illustrated. The interior 136 A of adjustment or tightening strap 136 is illustrated. The adjustment or tightening strap 136 is opened and the cuff section 140 is folded over to illustrate the interior 142 of the cuff section 140 . The additional innovation is the inclusion of an interior pocket 146 which is affixed to the interior 142 of the cuff section 140 at a location where the pocket will cover a portion of the ulna bone 17 when the glove 100 is closed with the cuff section 140 resting over a portion of the ulna bone when the adjustment strap 136 is closed and tightened as illustrated in FIG. 35 . The pocket 146 can be made of see-through mesh material as illustrated and can be sewn by stitches 146 A onto the interior 142 of the cuff 140 . However, in this variation, the pocket 146 has an opening 146 B. Contained within the pocket is at least one interior flexible impact matrix of impact and shock absorbing cells 150 A which are made of the same material as illustrated in FIG. 33 . With the pocket 146 having an opening 146 B, the at least one matrix of impact and shock absorbing cells 150 A can be removed from the pocket. Also illustrated is a mating hook or loop fastener 136 B on the interior 136 A of adjustment strap 136 and stitching 136 C which retains the mating hook or loop fastener on the exterior of the cuff 140 . The exterior of the glove 100 is illustrated in FIG. 35 and has the same components as discussed for FIG. 3 . The dotted lines 146 C by which the pocket 146 is retained on the interior 142 of the cuff 140 is also illustrated to show the location of the pocket 146 when the glove 100 is closed and the adjustment strap 136 tightened. Therefore, a portion of the exterior flexible matrix of impact and shock absorbing cells 150 and the at least one interior flexible matrix of impact and shock absorbing cells 150 A both cover the most vulnerable portion of the ulna bone 17 of a batter's arm adjacent the wrist to provide a double layer of protection.
Referring to FIG. 39 , there is illustrated a bottom plan view of a left handed glove which can be either the second embodiment illustrated in FIG. 10 or the third embodiment illustrated in FIG. 19 . The glove 200 in FIG. 10 will be used for this discussion. The palm section 222 , thumb receiving section 224 , forefinger receiving section 226 , middle finger receiving section 228 , fourth finger receiving section 230 and pinkie finger receiving section 232 are illustrated. The interior 236 A of adjustment or tightening strap 236 is illustrated. The adjustment or tightening strap 236 is opened and the cuff section 240 is folded over to illustrate the interior 242 of the cuff section 240 . The additional innovation is the inclusion of an interior pocket 246 which is affixed to the interior 242 of the cuff section 240 at a location where the pocket will cover a portion of the ulna bone 17 when the glove 200 is closed with the cuff section 240 resting over a portion of the ulna bone when the adjustment strap 236 is closed and tightened as illustrated in FIG. 37 . The pocket 246 can be made of see-through mesh material as illustrated and can be sewn by stitches 246 A onto the interior 242 of the cuff 240 . However, in this variation the pocket 246 has an opening 246 A. Contained within the pocket is at least one interior flexible matrix of impact and shock absorbing cells 250 A which are made of the same material as illustrated in FIG. 33 . With the pocket 246 having an opening 246 A, the at least one matrix of impact and shock absorbing cells 250 A can be removed from the pocket. Also illustrated is a mating hook or loop fastener 236 B on the interior 236 A of adjustment strap 236 and stitching 236 C which retains the mating hook or loop fastener on the exterior of the cuff 240 . The exterior of the glove 200 is illustrated in FIG. 35 and has the same components as discussed for FIG. 9 . The dotted lines 246 C are used to show the location of the pocket 246 when the glove 200 is closed and the adjustment strap 236 tightened. Therefore, a portion of the exterior flexible matrix of impact and shock absorbing cells 250 and, the at least one interior flexible matrix of impact and shock absorbing cells 250 A both cover the most vulnerable portion of the ulna bone 17 of a batter's arm adjacent the wrist to provide a double layer of protection.
Referring to FIG. 40 , there is illustrated a bottom plan view of a right handed glove which can be either the first embodiment illustrated in FIG. 4 or the fourth embodiment illustrated in FIG. 25 . The glove 100 in FIG. 4 will be used for this discussion. The palm section 122 , thumb receiving section 124 , forefinger receiving section 126 , middle finger receiving section 128 , fourth finger receiving section 130 And pinkie finger receiving section 132 are illustrated. The interior 136 A of adjustment or tightening strap 136 is illustrated. The adjustment or tightening strap 136 is opened and the cuff section 140 is folded over to illustrate the interior 142 of the cuff section 140 . The additional innovation is the inclusion of at least one interior flexible matrix of impact and shock absorbing cells 150 A which are made of the same material as illustrated in FIG. 33 affixed to the interior 142 of the cuff section 140 at a location where the pocket will cover a portion of the ulna bone 17 when the glove 100 is closed with the cuff section 140 resting over a portion of the ulna bone when the adjustment strap 136 is closed and tightened as illustrated in FIG. 35 . In FIG. 40 , the at least one interior flexible matrix of impact and shock absorbing cells is affixed by adhesive or comparable bonding means. Also illustrated is a mating hook or loop fastener 136 B on the interior 136 A of adjustment strap 136 and stitching 136 C which retains the mating hook and loop fastener on the exterior of the cuff 140 . Therefore, a portion of the exterior flexible matrix of impact and shock absorbing cells 150 and the at least one interior flexible matrix of impact and shock absorbing cells 150 A both cover the most vulnerable portion of the ulna bone 17 of a batter's arm adjacent the wrist to provide a double layer of protection.
Referring to FIG. 41 , there is illustrated a bottom plan view of a left handed glove which can be either the second embodiment illustrated in FIG. 10 or the third embodiment illustrated in FIG. 19 . The glove 200 in FIG. 10 will be used for this discussion. The palm section 222 , thumb receiving section 224 , forefinger receiving section 226 , middle finger receiving section 228 , fourth finger receiving section 230 and pinkie finger receiving section 232 are illustrated. The interior 236 A of adjustment or tightening strap 236 is illustrated. The adjustment or tightening strap 236 is opened and the cuff section 240 is folded over to illustrate the interior 242 of the cuff section 240 . The additional innovation is the inclusion of at least one interior flexible matrix of impact and shock absorbing cells 250 A which are made of the same material as illustrated in FIG. 33 affixed to the interior 242 of the cuff section 240 at a location where the pocket will cover a portion of the ulna bone 17 when the glove 200 is closed with the cuff section 240 resting over a portion of the ulna bone when the adjustment strap 236 is closed and tightened as illustrated in FIG. 43 . In FIG. 41 , the at least one interior flexible matrix of impact and shock absorbing cells is affixed by adhesive or comparable bonding means. Also illustrated is a mating hook or loop fastener 236 B on the interior 236 A of adjustment strap 236 and stitching 236 C which retains the mating hook and loop fastener on the exterior of the cuff 240 . Therefore, a portion of the exterior flexible matrix of impact and shock absorbing cells 250 and the at least one interior flexible matrix of impact and shock absorbing cells 250 A both cover the most vulnerable portion of the ulna bone 17 of a batter's arm adjacent the wrist to provide a double layer of protection.
Referring to FIG. 42 , there is illustrated a bottom plan view of a right handed glove which can be either the first embodiment illustrated in FIG. 4 or the fourth embodiment illustrated in FIG. 25 . The glove 100 in FIG. 4 will be used for this discussion. The palm section 122 , thumb receiving section 124 , forefinger receiving section 126 , middle finger receiving section 128 , fourth finger receiving section 130 and pinkie finger receiving section 132 are illustrated. The interior 136 A of adjustment or tightening strap 136 is illustrated. The adjustment or tightening strap 136 is opened and the cuff section 140 is folded over to illustrate the interior 142 of the cuff section 140 . The additional innovation is the inclusion of at least one interior flexible matrix of impact and shock absorbing cells 150 A which are made of the same material as illustrated in FIG. 33 affixed to the interior 142 of the cuff section 140 at a location where the pocket will cover a portion of the ulna bone 17 when the glove 100 is closed with the cuff section 140 resting over a portion of the ulna bone when the adjustment strap 136 is closed and tightened as illustrated in FIG. 35 . In FIG. 42 , the at least one interior flexible matrix of impact and shock absorbing cells is affixed by stitching 150 B. Also illustrated is a mating hook or loop fastener 136 B on the interior 136 A of adjustment strap 136 and stitching 136 C which retains the mating hook and loop fastener on the exterior of the cuff 140 . The exterior of the glove 100 is illustrated in FIG. 43 and has the same components as discussed for FIG. 3 . The dotted lines 150 C are used to show the location of the material 150 A. Therefore, a portion of the exterior flexible matrix of impact and shock absorbing cells 150 and the at least one interior flexible matrix of impact and shock absorbing cells 150 A both cover the most vulnerable portion of the ulna bone 17 of a batter's arm adjacent the wrist to provide a double layer of protection.
Referring to FIG. 44 , there is illustrated a bottom plan view of a left handed glove which can be either the second embodiment illustrated in FIG. 10 or the third embodiment illustrated in FIG. 19 . The glove 200 in FIG. 10 will be used for this discussion. The palm section 222 , thumb receiving section 224 , forefinger receiving section 226 , middle finger receiving section 228 , fourth finger receiving section 230 and pinkie finger receiving section 232 are illustrated. The interior 236 A of adjustment or tightening strap 236 is illustrated. The adjustment or tightening strap 236 is opened and the cuff section 240 is folded over to illustrate the interior 242 of the cuff section 240 . The additional innovation is the inclusion of at least one interior flexible matrix of impact and shock absorbing cells 250 A which are made of the same material as illustrated in FIG. 33 affixed to the interior 242 of the cuff section 240 at a location where the pocket will cover a portion of the ulna bone 17 when the glove 200 is closed with the cuff section 240 resting over a portion of the ulna bone when the adjustment strap 236 is closed and tightened as illustrated in FIG. 43 . In FIG. 44 , the at least one interior flexible matrix of impact and shock absorbing cells is affixed by stitching. Also illustrated is a mating hook or loop fastener 236 B on the interior 236 A of adjustment strap 236 and stitching 236 C which retains the mating hook and loop fastener on the exterior of the cuff 240 . The exterior of the glove 200 is illustrated in FIG. 45 and has the same components as discussed for FIG. 3 . The dotted lines 250 C are used to show the location of the material 250 A. Therefore, a portion of the exterior flexible matrix of impact and shock absorbing cells 250 and the at least one interior flexible matrix of impact and shock absorbing cells 250 A both cover the most vulnerable portion of the ulna bone 17 of a batter's arm adjacent the wrist to provide a double layer of protection.
Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment, or any specific use, disclosed herein, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention hereinabove shown and described of which the apparatus or method shown is intended only for illustration and disclosure of an operative embodiment and not to show all of the various forms or modifications in which this invention might be embodied or operated. | A novel protective batting glove which is used specifically for protecting the most vulnerable parts of a batter's hands and wrists when the batter is standing at home plate and is gripping the end of a baseball bat and awaiting the arrival of a baseball which is thrown by the pitcher. The invention comprises a unique protective system of a design of a matched pair of batting gloves with one matched pair designed for a right handed batter and one matched pair designed for a left handed batter. For each matched pair of batting gloves, impact and shock absorbing material is incorporated onto selected portions of the exterior of the glove where the grip on the bat causes the hand to be most exposed to a pitch thrown at the batter. Alternatively, the glove has a cuff with an affixed interior impact and shock absorbing material to provide double protection for the ulna bone of an arm. | 0 |
FIELD OF THE INVENTION
THIS INVENTION relates to agricultural apparatus, namely a ground engaging apparatus. The ground engaging apparatus is particularly suitable for, but not limited to, tillage applications and non-till seed planting.
BACKGROUND OF THE INVENTION
When planting seeds, in particular for large scale applications such as a commercial farm, a ground engaging apparatus such as a planter apparatus may be towed behind a tractor to cut channels or furrows into the soil which is followed by planting of a seed within the channel. Usually, a plurality of planter units are attached to a support towing bar that aligns the planter units at selected distances apart from each and the support bar is attachable to a tractor via a tow bar.
The ground engaging unit may comprise a frame having a pivotable parallelogram arrangement that maintains a ground opening tool in the ground while traversing level and uneven ground. A spring located between two pivotable arms of the parallelogram applies a force that maintains the ground opening tool at a pre-selected depth in the soil as the ground engaging unit encounters inclines and depressions. When the ground engaging unit encounters an obstacle such as a rock or stump, the shank is pivoted upward and away from the obstacle by a break-away or breakout mechanism to thereby prevent damage to the ground opening tool. The break-away mechanism comprises a spring that applies a force independent of the parallelogram as a separate break-away unit.
A ground engaging apparatus described in Australian patent AU 1996 60854 B2 (714157) (Techsearch Incorporated) comprises a single bias means for adjusting both a downward force to maintain the ground opening tool in the soil at a selected depth and a break-away force that maintains the ground opening tool in the soil unless the planter unit encounters an obstacle. This design is limited in that adjusting the downward force on a parallelogram arrangement also adjusts the break-away force, which is undesirable in situation where a user wishes to adjust each force independently of the other. Also, a minor adjustment of the bias means to the downward force of the parallelogram has a significant affect on the break-away force, which may result in excessive break-away force applied to the ground opening tool.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an alternative or improvement to the abovementioned background art.
In a first aspect, the invention provides a ground engaging apparatus comprising:
(i) a frame;
(ii) a support plate pivotally attached to the frame about a first point;
(iii) a first bias member attached at a first end to the frame and attached at a second end to the support plate;
(iv) at least two arms each pivotally attached at respective first ends to the support plate;
(v) a shank support to which respective second ends of the at least two arms are pivotally attached;
(vi) a second bias member attached at a first end to the frame and attached at a second end to one arm of the at least two arms;
(vii) a shank attached to the shank support;
(viii) a ground opening tool attached to a free end of the shank opposite the shank support; and
(ix) a ground follower attached to the shank support;
wherein:
said first bias member applies a first force to the support plate urging the support plate to rotate about the first point to thereby abut a stop that obstructs rotation thereof until a counter force is applied against the ground follower or ground opening tool that is greater than the first force such that the support plate rotates about the first point in a direction away from the stop; and
the second bias member applies a second force to the one arm thereby urging the ground follower against a surface and the ground opening tool into the surface.
Preferably, the apparatus comprises two arms.
Preferably, the ends of the two arms define pivotable corners of a parallelogram arrangement comprising linkages respectively comprising the two arms, the support plate and the shank support, each of which define a side of the parallelogram and respectively capable of uniform movement.
Preferably, a point at which the second end of the first bias member attaches the support plate and the respective first ends of the two arms define a first linkage of the parallelogram.
Preferably, the respective second ends of the two arms and the shank support comprise a second linkage of the parallelogram.
More preferably, the second linkage further comprises the ground follower and ground opening tool.
Preferably, the first ends of the respective two arms are capable of being vertically aligned.
Preferably, the second ends of the respective two arms are capable of being vertically aligned.
Preferably, the second bias member is attached intermediate the one arm.
Preferably, the first point is located intermediate the stop and the point at which the second end of the first bias member attaches to the support plate.
Preferably, the first bias member and second bias member each comprise a coiled spring or hydraulic cylinder.
More preferably, the first bias member is a coiled spring and the second bias member is a hydraulic cylinder.
Preferably, the first force of the first bias member and the second force of the second bias member are independently adjustable.
Preferably, the ground follower is located in front of the shank and below the at least two arms.
Preferably, the ground follower comprises a wheel.
Preferably, the frame comprises a towing attachment for attaching to a tow bar.
Preferably, one or more apparatus are attached to a tow bar via the towing attachment.
Preferably, the surface is a surface of ground for cultivation.
In a second aspect, the invention provides a ground engaging assembly comprising a plurality of ground engaging apparatus of the first aspect each attached to a same tow bar.
Preferably, the ground engaging assembly further comprises a seed dispenser located adjacent to each ground opening tool such that in use one or more seed may be placed within a channel formed in the ground by the ground opening tool.
More preferably, the seed dispenser is located behind the ground opening tool at an end opposite a cutting end.
It will be appreciated that the present invention comprises at least two bias members for respectively providing a downward force to maintain the ground opening tool in the ground when traversing level, risen or depressed ground and a breakout force that maintains the ground opening tool in the ground unless an obstruction or obstacle is encountered. The invention preferably has the advantage of adjusting the downward force and breakout force independently of each other. The invention in a preferred embodiment combines the two bias members in a compact and efficient configuration such that both bias members are located in front of a wheel or ground follower as described herein.
Throughout this specification unless the context requires otherwise, the word “comprise”, and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of the stated integers or group of integers or steps but not the exclusion of any other integer or group of integers.
DESCRIPTION OF THE DRAWINGS
In order that the invention may be readily understood and put into practical effect, preferred embodiments will now be described by way of example with reference to the accompanying drawings wherein like reference numerals refer to like parts and wherein:
FIG. 1 shows a side view of a ground engaging apparatus of the invention on level ground and first bias member in phantom;
FIG. 2 . shows a side view of the ground engaging apparatus traversing level ground without breakout;
FIG. 3 shows a side view of the ground engaging apparatus traversing a depression in the ground without breakout;
FIG. 4 shows a side view of the ground engaging apparatus traversing risen ground without breakout;
FIG. 5 shows a side view of the ground engaging apparatus retracted;
FIG. 6 shows a side view of the ground engaging apparatus traversing level ground in a breakout configuration;
FIG. 7 shows a side view of the ground engaging apparatus traversing a depression in a breakout configuration;
FIG. 8 is a side view of the ground engaging apparatus traversing risen ground in a breakout configuration;
FIG. 9 is a line diagram of the ground engaging apparatus traversing level ground without breakout;
FIG. 10 is another representation of a line diagram of the ground engaging apparatus traversing level ground without breakout;
FIG. 11 is a line diagram of the ground engaging apparatus traversing a depression without breakout;
FIG. 12 is a line diagram of the ground engaging apparatus traversing risen ground without breakout;
FIG. 13 is a line diagram of the ground engaging apparatus traversing level ground with breakout;
FIG. 14 is a line diagram of the ground engaging apparatus traversing a depression with breakout;
FIG. 15 is a line diagram of the ground engaging apparatus traversing risen ground with breakout; and
FIG. 16 is another diagram illustrating preferred structures and applied forces of the ground engaging apparatus.
DETAILED DESCRIPTION OF THE INVENTION
Terms used herein when referring to an item or integer are not intended to suggest or imply any limitation to the structure or function of the item or integer.
FIG. 1 shows a side view of a ground engaging apparatus 10 comprising a support plate 50 , a shank support 60 and two arms 30 , 40 each pivotally attached at opposites ends to said support plate 50 and shank support 60 thereby forming sides of a parallelogram 35 . Attachment points A, B, C and D of ends of arms 30 , 40 generally define corners of the parallelogram 35 . Accordingly, plate 50 and shank support 60 effectively form part of the parallelogram 35 . A shank 70 , also referred to as a tine, tyne, tine shank or tyne shank, is attached to the shank support 60 and is adjustable relative thereto by loosening and tightening bolts 61 . A ground opening tool 80 that is adapted to disrupt the ground 91 , preferably forming a channel suitable for planting seeds, is attached to the shank 70 at a free end opposite the shank support 60 . A ground follower 90 , shown as a wheel, is attached to shank support 60 and located in front of the ground opening tool 80 at a leading end digging tip 81 of the ground opening tool 80 . The wheel 90 contacts the ground 91 as shown and in use assists with guiding and positioning the ground engaging apparatus 10 , in particular the ground opening tool 80 .
The support plate 50 is pivotally attached to a frame 100 at attachment point A (also referred to herein as a first point). A first bias member 200 is attached to the support plate 50 at pivotable attachment point E and attached to the frame 100 at point 220 as shown in FIG. 1 . The first bias member 200 applies a downward force, referred to herein as an applied breakout force, against plate 50 that is countered by stop 210 when there is no reaction or counter breakout force applied to the ground opening tool 80 as discussed hereinafter. Point A is preferably located intermediate the stop 210 and point E, where the first bias member 200 attaches to the support plate 50 . Adjusting the distance of the pivot point A to the stop 210 and point E preferably adjusts a force applied by the second bias member 200 about point A. A second bias member 300 is attached at a first end 310 to the housing 100 by member 110 and at a second end 320 to arm 40 as shown in FIG. 1 . The second bias member 300 applies a downward force onto the parallelogram 35 at point 320 , which is preferably intermediate arm 40 . The applied downward force directs the ground opening tool 80 into the ground 91 and is countered by the ground follower 90 .
One or more ground engaging apparatus 10 may be attached to a towing cross bar via towing attachment 400 thereby forming a ground engaging assembly. It will be appreciated that preferably there are a plurality of ground engaging apparatus 10 attached to a towing cross bar, which is attachable to a tractor, car, truck, horse, mule, ox or other means for pulling the ground engaging apparatus 10 . Preferably, a seed dispenser 82 such as a planting tube 83 is located adjacent to the ground opening tool 80 so that one or more seeds may be deposited within a channel or furrow 92 cut by the ground opening tool 80 when in use. Other substances may be deposited into the channel 92 , for example fertiliser and the like.
FIGS. 2 to 5 and 10 to 12 show side views and line diagrams of the ground engaging apparatus 10 in various configurations when traversing different ground levels and when retracted. In these configurations, points A and C are substantially vertically aligned and points B and D are substantially vertically aligned as shown and arms 30 , 40 pivot about points A, B, C and D. First bias member 200 maintains a constant applied downward breakout force that is countered by stop 210 . The second bias member 300 applies a downward force against the parallelogram 35 and a change in ground elevation 91 results in extension and retraction of a hydraulic cylinder of the second bias member 300 .
The parallelogram 35 is defined by points A, B, C and D and sides of the parallelogram comprise arms 30 , 40 , support plate 50 and shank support 60 . As shown in FIGS. 10-15 , points E, A and C form a first single linkage that is capable of uniform movement and points B, D and shank 60 form a second single linkage that is capable of uniform movement.
FIGS. 2 and 10 show the ground engaging apparatus 10 in a configuration wherein the ground engaging apparatus 10 is on level ground. As shown, the arms 30 , 40 are substantially parallel with the surface of the ground 91 and attachment points A and C are substantially aligned vertically with each other and attachment points B and D are also substantially aligned vertically with each other thereby forming a generally rectangular configuration of the parallelogram 35 . A downward second force 300 a applied by second bias member 300 directs the ground opening tool 80 into the ground 91 and is countered by the ground follower 90 . An applied breakout first force 200 a applies a force preventing the ground opening tool 80 from breakout unless a sufficient reaction breakout force 200 b is encountered as described hereinafter.
FIGS. 3 and 11 show a ground engaging apparatus 10 in a configuration wherein the ground engaging apparatus 10 is traversing a depression in the ground. In this configuration, arms 30 , 40 are pivoted downward thereby lowering points B and D respectively below points A and C. Points B and D are each attached to shank support 60 such that shank support 60 effectively forms an end of the parallelogram defined by points A, B, C and D. Accordingly, when the arms 30 , 40 are lowered as shown in FIG. 3 , shank support 60 is lowered thereby maintaining the ground opening tool 80 in the ground 91 . The shank 70 remains substantially vertical. The second bias member 300 is shown extended.
FIGS. 4 and 12 show the ground engaging apparatus 10 in a configuration when traversing risen ground 91 . The second bias member 300 is shown retracted and arms 30 , 40 are angled upward such that points B and D are above respective points A and C as shown.
FIG. 5 shows the ground engaging apparatus 10 retracted such that the ground opening tool 80 no longer contacts the ground 91 . This is useful, in particular, when a plurality of ground engaging apparatus 10 are attached to a support towing bar and only selected ground opening tools 80 are in use. This may be suitable for example when adjusting spacing between planting rows of a crop. The present invention has the advantage of being compact in horizontal length, preferably when the ground opening tool 80 is retracted. As shown, the shank support 60 is lifted substantially vertically with minimum or no outward horizontal extension of the shank 70 . This provides a compact configuration of the ground engaging apparatus 10 , which is advantageous when compared with other ground engaging apparatus. For example, this configuration is preferred if seed boxes are fitted as the boxes are maintained horizontally level.
FIGS. 6 to 8 and 13 to 15 show the ground engaging apparatus 10 in a configuration wherein the ground opening tool 80 encounters an obstacle such as a rock, branch, stump or the like. It is desirable that the ground opening tool 80 is moved away from the ground 91 and obstacle or obstruction to prevent or minimise damage to any part of the ground engaging apparatus. This movement of the ground opening tool 80 away from the ground 91 is referred to herein as a “breakout” or “breakaway” as the support plate 50 is rotated about point A thereby moving an end 51 of the support plate 50 away from the stop 210 . The first bias member 200 applies a breakout force 200 a as shown in FIGS. 9 and 10 - 15 that prevents the ground opening tool 80 from breaking away unless the ground opening tool 80 encounters a reaction force 200 b greater than the applied breakout force 200 a applied at point E by the first bias member.
FIGS. 6 and 13 show the ground engaging apparatus 10 in a breakout configuration when traversing level ground. An applied breakout force 200 a prevents the ground opening tool 80 from breakout unless a sufficient reaction breakout force 200 b is encountered, e.g. hitting an obstacle such as a rock or stump. When an obstacle is encountered, a reaction breakout force 200 b shown in FIG. 13 moves shank 70 as shown thereby shifting arm 30 rearward thereby causing the support plate 50 to rotate counter clockwise about point A. As the wheel 90 and shank 70 are attached to shank support 60 , the breakout force is transferred via a side of the parallelogram 35 defined by points B and D effectively as a single link as shown in FIG. 13 .
FIGS. 7 and 14 show the ground engaging apparatus 10 in a breakout configuration when traversing a depression and FIGS. 8 and 15 show the ground engaging apparatus 10 in a breakout configuration when traversing risen ground. Similar applied and breakout forces as previously illustrated are shown.
FIG. 16 shows another diagram representing the structural components of the invention with applied forces indicated. As shown in FIG. 16 , a first bias member applies a dominant breakout force 200 a to resist breakout away from abutment point 210 , which is represented in FIG. 1 as stop 210 . The breakout force 200 a is applied to a vertical link defined by points E, A and C, wherein point A is a fixed pivot point. A second bias means applies a smaller downward force 300 a to the parallelogram 35 , preferably via arm 40 . The second bias member 300 provides independent adjustment of the downward force 300 a without affecting the applied breakout force 200 a . In a preferred embodiment wherein the second bias member 300 comprises a hydraulic cylinder, another benefit is an ability to adjust the second bias member 300 without a need to manually adjust the mechanism.
First bias member 200 and second biased member 300 may comprise a spring, hydraulic cylinder or other bias member. Preferably, the first bias member 200 is a coiled spring and the second bias member 300 is a hydraulic cylinder as shown. Use of a hydraulic (or pneumatic) cylinder is advantageous in that adjustment of a force applied by the bias member may be performed remotely for one or more bias members by adjusting a fluid pressure. The fluid may be air, oil, water or any other suitable fluid. In a preferred form of the invention, in use a user is capable of driving a tractor that is towing one or more ground engaging apparatus 10 and the force of the first bias member 200 and/or second bias member 300 may be adjusted from the tractor without needing to manually adjusting an applied force for each bias member.
It will also be appreciated that the ground follower comprises a wheel, sled, cutting disc, roller or other suitable device. In one embodiment, the ground engaging apparatus comprises both a wheel and a cutting disc for slicing through weeds and other plant material in a path of the apparatus.
The ground opening tool comprises devises and configurations including for example seed shoes, plough shares, seed openers, furrow openers, disc openers, cutting edges and the like. It will also be appreciated that the present invention is preferably used with a seed dispenser such as a seed tube or planter tube that releases one or more seeds in a channel 92 formed by the ground opening tool 80 . Although there is no need to deposit any material in the channel, preferably seeds, fertiliser, wetting agent or other agricultural material is dispensed in the channel. The seeds may be for any crop, including for example, a vegetable or fruit including a cereal crop, wheat, rice, barley, corn, lettuce and the like.
Although the invention has been shown and described with exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto without departing from the scope of the invention.
The disclosure of each patent and other document referred to in this specification is incorporated by reference in its entirety. | A ground engaging apparatus ( 10 ) has a support plate ( 50 ) pivotally attached to a frame ( 100 ); a pair of arms ( 30, 40 ) interconnecting the support plate ( 50 ) and a shank support ( 60 ), which supports a shank ( 70 ) and ground follower ( 90 ) and first and second biasing rams or springs ( 200, 300 ), to maintain the ground follower ( 90 ); against the ground ( 91 ) but allow controlled break out of a ground opening, or tillage, tool ( 81 ) if an obstruction is engaged. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to provisional application No. 60/215,557 filed Jun. 30, 2000.
TECHNICAL FIELD
[0002] This invention relates generally to filtering and reducing the transmission of undesirable vibrations and signals. More specifically, this invention relates to the filtering of undesirable vibrations and signals by a mechanical means to reduce noise in signals produced by electronic components such as audio/visual components.
BACKGROUND OF THE INVENTION
[0003] Noisy music is difficult to enjoy. Similarly, it can be difficult to view a blurry picture on a television screen or video monitor. Electronic devices designed to convey information typically have inherent noise. Generally, as used herein “noise” refers to various properties such as physical vibrations, electrical signals and the like, and similarly, to any other vibrations and/or signals which are generally undesirable and interfere with the intended operation of the device.
[0004] Numerous commonplace electronic devices are similarly affected by vibration. For instance, record players, radios, CD players, DVD players, microphones, amplifiers, preamplifiers, power transformers, magnetic resonance imaging equipment, high-speed cameras, and high definition televisions are all susceptible to degradation in reproducing sound and/or visual images because of the interference of vibrations. When these devices are subjected to vibration, vibrational noise can become electrical noise interfering with the intended operation of the electronic device. Often manufacturers of these devices include signal processing filters in the devices to attempt to remove these unwanted signals or noise; however, these signal processing filters may not sufficiently reduce the transmission of and interference caused by undesired signals.
[0005] In this respect, the effectiveness of the medium carrying the information is generally proportional to its signal-to-noise ratio; typically an amplitude or a frequency ratio, expressed in percentage of noise-to-signal level or peak. For example, analog circuitry and components generate electronic noise when vibrating. Magnetic-core displacement and capacitor-bank separation movement in a common circuit are examples of electromagnetic field and current generation or modification. Semiconductor components are also subject to mechanical vibration sensitivity. Similarly, diodes and transistors may also be noisy.
[0006] However, in general, analog electronics are typically the most susceptible to vibration. This is generally because noise is additive in analog circuitry. The noisier the components of the circuit, the noisier is the circuit itself is. Large-scale circuit integration, common in modern electronics, is the enemy of signal clarity. This raises the need for noise filtering, reduction, or elimination, especially in signal transmission devices.
[0007] Equipment use classifies signal transmission as either external or internal. Signals are externally transmitted between equipment via electrical conductors, fiber optics or other means, such as electromagnetic field, which propagates through vacuums, solids, liquids and gases. For example, one external transmission is a typical radio with a broadcasting station and a remote tuner or receiver. Television broadcasts are similar examples.
[0008] Undesirable vibrations can arise from both sources within the electronic device and external sources. External vibrational sources abound in our present environment. These vibrations may be transmitted through the ground and building structures from sources such as vehicles passing on nearby roads and construction. Vibrations may also be transmitted through the air in the form of sound from sources such as airplanes, motors, and other sources of sounds. Many other sources of vibrations exist in buildings, such as the air handling systems, pumps, water running in pipes, and appliances. These vibrations combine, overlap and interfere with each other. Regardless of the original source of the external vibrations, these vibrations may be transmitted through the supporting structure to the tool or electronic device that is resting on the support structure.
[0009] Vibrations may also originate from within the device itself Many modern-day electronic devices contain fans and other mechanical devices which can generate various amounts of vibrations. Tape players and CDs/DVDs include motors to spin the CD/DVD or turn the tape. Many people have heard the familiar hum associated with the working of electronic equipment such as power transformers or amplifiers.
[0010] The internal signal transfer between electronic components or units, which does not leave the equipment, is an internal source of noise. Electronic, optical and RF transmissions, both external and internal, are further classified by waveforms and bandwidth. Narrow band RF transmission is achieved by transmitting a single frequency wave, modulated either by amplitude (AM) or by frequency (FM). Digital transmission may be either AM or FM. Digital data however are more efficiently transmitted in ultra wide band (UWB) as pulse or wavelet train, which is modulated by the pulse separation time, which is analogous to FM, but referenced as PM or pulse modulation..
[0011] The modulation frequency to base frequency ratio is noise level limited. For example, one can fit more channels into a given broadcasting bandwidth if the signal-to-noise ratio of the channels are smaller. UWB broadcast is less limited by bandwidth, than by noise level to pulse amplitude ratio itself. AM, FM or PM applied in different fields based on their characteristic power need, propagation path or penetration capability. For example, AM waves can travel around the globe, but are easily distorted and decay fast. The FM transmitting and receiving antennas need to “see” each other, since FM wave travels straight, remains strong and less prone for distortion.
[0012] In contrast, PM waves thus need very little energy to penetrate solids, and therefore can penetrate structure such as walls. However, its transmitter and receiver are bulky and cumbersome. PM technology is emerging quickly, because it needs no precious bandwidth sharing. Regardless of its nature and type though, to be efficient, the transmissions are preferably noiseless. One way to achieve that goal is to eliminate, or at least reduce, the noise generated or strongly affected by mechanical vibrations.
[0013] Micro vibrations also affect semiconductor tool operations in unique ways. For example, roentgen or deep ultra violet (UV) lithographic tools mask or etch nanometer wide wires onto complementary metal oxide (CMOS), silicon, germanium or other semiconductor wafer surface. The printed integrated circuit (IC) quality is strongly affected by direct vibration of the tool's optics but also by the signal-to-noise ratio of the very fine picture. Scanning electron microscopy (SEM) and probing tools in semiconductor fabs are other examples of common micro- or nano-vibration sensitivity. Similar noise-vibration problems arise in modern biotechnology, where tweezers need to manipulate microorganisms, cells and molecules. In these, last category of complex equipment, sometimes it s hard to separate the effects of mechanical noise from electronic, optical and signal transmission noises. Nonetheless, mechanical noise reduction, however, invariably improves performance.
[0014] In an effort to reduce electronic and mechanical vibration within equipment, isolation of electronic devices with rubber feet, air bearings, rigid cone legs and high damping elastomeric or felt or cork pads has been attempted. Some of these vibration or noise mitigation techniques intend to reduce noise propagation pathway by cross section or by length. Some form dead-end wave-guides or echo-aside chambers. Others attempt to absorb, dissipate, convert to heat, or otherwise attenuate vibration. Still others simply provide elastic support to the chassis to limit equipment-housing resonance.
[0015] While these earlier attempts to reduce equipment vibrations are somewhat successful, they fall short in efficiency and even more in reducing electronic noise. They mostly damp and attenuate (shift the phase of) mechanical vibration without evading it. Unfortunately, however, they often add their own signal to the noise at characteristic frequencies.
[0016] Therefore, it has long been recognized that a need exists to prevent external vibrations from interfering with the operation of sensitive devices such as those mentioned above. It is well known that it is desirable to isolate the various components that make up, for example, an audio system, so that the vibrations of one component of the audio system do not interfere with the operation of other components of the audio system. Furthermore, it is desirable to reduce the vibrations that are generated internally by the electronic devices.
SUMMARY
[0017] This invention generally relates to reducing electronic noise by mechanical means, in order to improve signal quality. More specifically, this invention relates to reducing small amplitude vibrations of electronic circuit components, which electronically respond to mechanical movements, such as vibrations. For example, in accordance with an exemplary embodiment of the present invention, a signal-to-noise ratio is improved by gravity-restoring mechanical isolation and transmission-path evasion of signal generating, processing, transmitting, broadcasting, receiving or detecting electronics.
DESCRIPTION OF THE DRAWINGS
[0018] Additional aspects of the present invention will become evident upon reviewing the non-limiting embodiments described in the specification and the claims taken in conjunction with the accompanying figures, wherein like numerals designate like elements, and:
[0019] [0019]FIG. 1 is a cross-sectional view of an exemplary embodiment of a filter in accordance with the present invention;
[0020] Figures is a cross-sectional view of an alternative embodiment of a filter in accordance with the present invention;
[0021] [0021]FIG. 3 is a cross-sectional view of another alternative embodiment of a filter in accordance with the present invention; and
[0022] [0022]FIG. 4 is a cross-sectional view of still another alternative embodiment of a filter in accordance with the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0023] In accordance with the present invention, a mechanical signal filter 100 is provided to filter vibrations and reduce noise in devices supported by filter 100 . It should be appreciated by one skilled in the art, that the following description is of exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description merely provides convenient illustrations for implementing various embodiments of the invention. For example, various changes may be made in the design and arrangement of the elements described in the exemplary embodiments herein without departing from the scope of the invention as set forth in the appended claims.
[0024] Thus, in accordance with an exemplary embodiment of the present invention and with reference to FIG. 1, mechanical signal filter 100 comprises a rolling bearing 150 in contact with at least two surfaces such that rolling bearing 150 may translate between the surfaces in a manner which assists in filtering noise between the surfaces. In accordance with various aspects of the present invention, the invention achieves its objectives by providing a plurality of rigid balls 150 between similarly hard and rigid corresponding circular raceways 113 in a base plate 110 and a top plate 120 . In the preferred embodiment, three balls 150 are provided. Additionally, in accordance with various embodiments of the present invention, an optional spacer 130 retains balls 150 within filter 100 . For example, with continuing reference to the non-limiting embodiment of FIG. 1, roller bearing 150 comprises a ball bearing manufactured from 440 Rc 60 stainless steel. Of course, as mentioned above, other materials having similarly desirable properties now known or as yet unknown may likewise be substituted and still fall within the ambit of the appended claims. Additionally, other modifications of bearing 150 may be useful. For example, a ceramic coated or carbide bearing 150 may be mated with steel raceways 113 having ceramic linings or inserts.
[0025] Additionally, although rolling bearing 150 is described in various embodiments herein as a ball bearing 150 with a substantially spherical shape, in accordance with various alternative embodiments, various other configurations of rolling bearing 150 may be used. Thus, it should be appreciated that any rolling bearing that allows the two structures to translate with a substantially reduced area of contact between the touching components is within the ambit of the present invention.
[0026] In the presently described embodiment, signal filter 100 comprises base plate 110 and top plate 120 both of a substantially rigid nature in contact with bearings 150 such that bearing 150 may translate between base and top plates 110 , 120 . Base plate 110 and top plate 120 each have corresponding circular and conical raceways 113 a,b oriented around a center 101 of filter 100 . Bearings 150 reside in raceways 113 a,b . As mentioned above, spacer 130 for retaining balls 150 within filter 100 may be provided. Generally, spacer 130 is configured from Delrin® and takes the form of a circular “washer” shape around filter 100 . Of course it should be appreciated that spacer 130 may be configured from any material and the Delrin® is merely exemplary.
[0027] In accordance with various aspects of the present invention, base and top plates 110 , 120 are suitably secured together during use. For example, in the present exemplary embodiment, plates 110 , 120 are held together using a large shoulder assembly screw 140 . Additionally, a setscrew 141 may be used to stop large shoulder screw 140 at an appropriate distance to clear top plate 120 before bearing 150 hits screw 140 when filter 100 is displaced during use. Moreover, set screw 141 counter locks, securing filter 100 for shipping. Optionally, a counter bore 122 for screw 140 is provided for clearance and/or to act as a stroke limiter on the displacement of filter 100 . Similarly, a bore 131 may be provided in spacer 130 for clearing and retaining bearing 150 .
[0028] In accordance with the present invention, means for returning bearing 150 to a starting point within raceways 113 a,b is also provided. That is, when no external forces are being applied to filter 100 , bearings 150 return to a rest state or starting point 102 . Although many different methods could be used to return bearing 150 to starting point 102 , in accordance with various embodiments of the present invention, the circular or conical shape of raceways 113 a,b suitably allow gravity to return bearing 150 to starting point 102 . In these embodiments, starting point 102 is the position of lowest potential energy; i.e., the lowest point on raceways 113 a,b.
[0029] Additionally, as described in additional detail below, in accordance with various aspects of the present invention, bearings 150 are in substantially constant contact with raceways 113 at contact points 151 , 152 . When a load is placed on filter 100 , bearings 150 and raceways 113 slightly indent at contact points 151 , 152 , expanding the contact area between bearing 150 and raceways 113 , but are generally very small relative to the size of bearing 150 .
[0030] In accordance with various aspects of the present invention a lower raised perimeter 111 is provided on base plate 110 to aid in reducing the contact area between filter 100 and the structure upon which it rests. Similarly, an upper raised perimeter 112 may be provided on top plate 120 to aid in reducing the contact area between filter 100 and the structure which rests upon filter 100 .
[0031] With reference now to FIG. 2, an alternative embodiment of the present invention is illustrated. Generally, this embodiment of filter 100 is similar to that of FIG. 1, but is capable of being secured to support equipment rigidly. This exemplary embodiment is particularly suited to small equipment or for internal signal filtering in equipment, for example, to isolate electronic printed circuit boards and breadboards.
[0032] The present exemplary embodiment has a threaded stud 210 to attach filter 100 to the base of the equipment it is supporting. Filter 100 again generally comprises top plate 120 , base plate 110 , bearings 150 and spacer 130 . Additionally, in accordance with this exemplary embodiment, a locking screw 260 is provided for securing filter 100 to its base (e.g., a floor or table).
[0033] With reference now to FIG. 3, another alternative embodiment of the present invention is illustrated. Again, this embodiment of filter 100 is similar to that of FIGS. 1 and 2, but is for floor mounting and has additional dust and debris protection. This exemplary embodiment is particularly suited to carpet floor mounting and also provides echo chambers 370 for enhancing filter 100 performance. Filter 100 again generally comprises top plate 120 , base plate 110 , bearings 150 and spacer 130 . This embodiment also includes assembly screw 350 for retaining plates 110 , 120 together. Additionally, a threaded hole 360 for attachment to equipment is provided. In accordance with another aspect of the this non-limiting embodiment, a dust cap 380 for keeping the internal portion of filter 100 clear is provided. Dust cap 380 may comprise any material, and, in the present embodiment comprises 304 stainless steel.
[0034] With reference now to FIG. 4, still another alternative embodiment of the present invention is illustrated. Again, this embodiment of filter 100 is similar to that of FIGS. 1 - 3 , but is modified to include an optional dust bell/kick cover 410 and wide base support plate for carpet mounting. Filter 100 again generally comprises top plate 120 , base plate 110 , bearings 150 and spacer 130 . This embodiment also has echo chambers 470 , though in this particular embodiment, echo chambers 470 are vented 415 . This embodiment is also suited to distributing a payload to larger floor area on soft floor, such as carpet or soil (also called the concert leg) because of the addition of a spreader plate 460 . This embodiment also includes a mounting surface 414 , which optionally has a raised perimeter to reduce contact area and/or may be lined with elastomer or felt or cork or other soft material to aid in effectiveness of filter 100 .
[0035] Thus, in accordance with the present invention, due to ambient and equipment vibrations, bearings 150 are in a constant oscillation of small, variable amplitude in random directions. Body waves 170 , for example, in the form of dynamic pressure variations or sound, pass through bearing 150 only at contact points 151 , 152 . As mentioned above, the contact areas at contact points 151 , 152 are very small, allowing only a narrow clear passage pathway for waves 170 passing through filter 100 . Accordingly, a sound wave 171 beginning to pass through filter 100 which does not align with contact points 151 , 152 center will refract and disperse in multiple reflections inside bearing 150 , without leaving bearing 150 . The dispersed wave energy is thus dissipated (largely through heat), and most of wave 171 will never pass through filter 100 . This is largely because by the time an exiting wave 172 would have a chance to realign so as to pass through contact point 152 , it will likely interfere with other oncoming waves and bearing will have already moved from a position which would allow it to escape bearing 150 . Herein, this is called wave return path evasion or transmission path evasion and filter 100 functioning this way can be referred to as an evader.
[0036] In this regard, mechanical signal filter 100 suitably allows a supported device (such as a DVD player) to float and roll in response to vibrations either internal to the device or from the structure supporting the device. Vibrations in the supporting structure cause filter 100 to vibrate in all three directions. Vibrations in the two horizontal directions (perpendicular to gravity) cause bearing 150 to displace from 152 starting point and roll up the incline of raceways 113 , increasing bearings 150 potential energy and reducing the kinetic energy that otherwise would have been transmitted to the supported device resting on top plate 120 . Eventually, gravity returns bearing 150 to starting point 152 and bearing 150 returns to its lowest state of potential energy. In this manner, a reduced amount of energy in the horizontal component of the external vibrations is transmitted to the supported device as vibrations. Similarly, as bearing 150 moves in raceways 113 , friction dissipates the energy that has been transmitted to filter 100 and, if the external vibrations cease, bearing 150 will eventually come to rest.
[0037] The vibrations which this invention is designed to filter and keep from reaching the supported device supply a harmonic-like force and cause bearing 150 to oscillate and continuously roll within its confined parameters. The rolling motion makes it even more difficult for signals to communicate back and forth between the supported device and the supporting structure. As the vertical vibration component enters bearing 150 , bearing 150 is already in motion and corresponding contact points 151 , 152 on opposite sides of bearing 150 are shifting out of contact. Therefore, there is no straight path of constant communication between the supported structure and the supporting structure from one moment to the next. And furthermore, a vibration from the supported device that is transmitted to the supporting structure will be less likely to be able to reflect back along the same path to return to the supported device. The frequency of the vibrations correspond to the frequency of oscillation of bearing 150 , and therefore bearing 150 is likely to be moving fast enough to interrupt the transmission path of the vibrations.
[0038] In this manner, the supported structure and the supporting structure are effectively decoupled and noise from the surrounding environment can be efficiently filtered before reaching the supported structure. This noise can be removed at a very high efficiency and has been tested to remove between 95% and 99.9% of noise and vibration.
[0039] In accordance with various aspects of the present invention, some embodiments make evader more efficient than others. For instance, a harder bearing and/or raceway is typically more efficient than softer one. Additionally, the bearing radius to raceway radius ratio and other geometrical and material property conditions can change the performance.
Descriptive Examples
[0040] As mentioned above, in operation, when filter 100 is in use, bearings 150 displace (oscillate) within raceways 113 . A pseudo natural period of the oscillation is equal to the natural period of a pendulum of length L is:
4(R−r)
[0041] where R is the radius of the curvature of raceway 113 and r is half the distance between contact points (in the various exemplary embodiments, herein, the radius of bearing). Pendulums can be in resonance forced by vibration of a period matching the pendulum period. Therefore, the pendulum's period (equal to the inverse frequency) is natural. However, nonlinear pendulums have no real or natural periods. They oscillate around a frequency, but generally not in resonance. Therefore, the frequency around which a nonlinear pendulum oscillates is called pseudo natural frequency.
[0042] Three or more bearings 150 in “doughnut shape” raceways 113 act like a nonlinear pendulum. The pendulum frequencies are independent of the pendulum's bob weight (mass). Thus, the pseudo frequency of filter 100 is also independent of the support load or payload, the equipment weight, placed upon said assembly. However, since the evasion condition calls for the indentation diameter, which is a function of the payload, the evader is load dependent. Thus, the same distinguishes filter 100 in accordance with the present invention from an isolator, which would be non-load dependent.
[0043] An optimally performing filter 100 in accordance with the present invention satisfies a transmission evasion condition where a sound propagation constant is greater than a circular frequency constant, or:
2 d v > s ω L
[0044] where d is the distance between contact points (in the various exemplary embodiments, herein, the bearing diameter), v is the sound propagation velocity of the bearing material, s is the indentation diameter of the ball at contact, and ω is the circular frequency of the filter as a gravity restoring isolator of equivalent pendulum of length L, and, as mentioned above, L is four times the difference of the raceway cavity radius R and the bearing radius r. This inequality is in time units (e.g., seconds). It states that the time needed for a sound wave to enter into the bearing and return to an entry location is longer than the time needed for the sound wave to travel across the passage line—the line connecting the two contact points—by the mechanical oscillation of the bearing.
[0045] 1. Embodiment 1
[0046] In a first embodiment, filter 100 has an overall diameter of about 1 ⅝ inch and is made of 440 stainless steel. This embodiment has bearings 150 of the same material and have a diameter of {fraction (5/16)} inch [d], with a sound propagation velocity of 318 mile/sec [v]. This same embodiment with a load ranging from 5 lbs. to 100 lbs. has an indentation diameter of 34 micro-inch [s] and a circular frequency of 18 Hz [ω]. For this embodiment, the curvature of raceways 113 is ⅝ inch [R].
[0047] Thus, the sound propagation constant:
2 d v
[0048] is 311 nanoseconds (ns)
[0049] and the circular frequency constant:
s ω L
[0050] and therefore the inequality is satisfied.
[0051] 2. Embodiment 2
[0052] In a second embodiment, filter 100 has an overall diameter of about ⅞ inch and is made of 440 stainless steel. This embodiment has bearings 150 of the same material and have a diameter of {fraction (3/16)} inch [d], with a sound propagation velocity of 318 mile/sec [v]. This same embodiment with a load ranging from 2 lbs. to 33 lbs. has an indentation diameter of 0.47 micro-inch [s] and a circular frequency of 9 Hz [ω]. For this embodiment, the curvature of raceways 113 is {fraction (1.4)} inch [R].
[0053] Thus, the sound propagation constant:
2 d v
[0054] is 19 ns
[0055] and the circular frequency constant:
s ω L
[0056] is 11 ns
[0057] and therefore the inequality is satisfied.
[0058] 3. Embodiment 3
[0059] In a third embodiment, filter 100 has an overall diameter of about 3 ⅜ inch and is made of 440 stainless steel. This embodiment has bearings 150 of the same material and have a diameter of ⅜ inch [d], with a sound propagation velocity of 318 mile/sec [v]. This same embodiment with a load ranging from 9 lbs. to 330 lbs. has an indentation diameter of 45 micro-inch [s] and a circular frequency of Hz [ω]. For this embodiment, the curvature of raceways 113 is ¾ inch [R].
[0060] Thus, the sound propagation constant:
2 d v
[0061] is 37 ns
[0062] and the circular frequency constant:
s ω L
[0063] is 19 ns
[0064] and therefore the inequality is satisfied.
[0065] 4. Embodiment 4
[0066] In a fourth embodiment, filter 100 has an overall diameter of about 3 ⅝ inch and is made of 440 stainless steel. This embodiment has bearings 150 of the same material and have a diameter of ¼ inch [d], with a sound propagation velocity of 318 mile/sec [v]. This same embodiment with a load ranging from 5 lbs. to 100 lbs. has an indentation diameter of 52 micro-inch [s] and a circular frequency of 8.8 Hz [ω]. For this embodiment, the curvature of raceways 113 is 1 ½ inch [R].
[0067] Thus, the sound propagation constant:
2 d v
[0068] is 24 ns
[0069] and the circular frequency constant:
s ω L
[0070] is 12 ns
[0071] and therefore the inequality is satisfied.
[0072] Lastly, while the principles of the invention have been described in illustrative embodiments, many combinations and modifications of the structures described above, as well as arrangements, proportions, elements, materials and components, used in the practice of the invention—in addition to those not specifically described—may be varied and particularly adapted for specific environment or operating equipment, without departing from those principles. | This invention generally relates to reducing electronic noise by mechanical means, in order to improve signal quality. More specifically, this invention relates to reducing small amplitude vibrations of analog electronic circuit components, which electronically respond to mechanical movements, such as vibrations. For example, in accordance with an exemplary embodiment of the present invention, a signal-to-noise ratio is improved by gravity-restoring mechanical isolation and transmission-path evasion of signal generating, processing, transmitting, broadcasting, receiving or detecting electronics. | 5 |
PRIOR APPLICATION
This application is a continuation-in-part of my prior copending application Ser. No. 07/589,995filed Sep. 28, 1990 entitled ESOPHAGEAL DISPLACEMENT ELECTRODE. That application is incorporated by reference herein.
FIELD OF THE INVENTION
This invention relates to esophageal electrodes and, more particularly, comprises such an electrode that may be inserted down a patient's esophagus and into the stomach with a portion of the electrode in contact with the stomach wall in a position most favorable for electrically stimulating the ventricle of the heart in cooperation with an external electrode placed on the patient's chest.
There are a number of medical procedures in which esophageal electrodes are used for such purposes as defibrillating and pacing the heart as well as for stimulating breathing. Examples of the use of esophageal electrodes in such procedures are shown in several United States patents and pending applications including Nos. 4,574,807, 4,683,890, 4,735,206, and 4,960,133; and Ser. Nos. 421,807 filed Oct. 16, 1989; 214,778 filed Jul. 5, 1988; and 812,015 filed Dec. 23, 1985 (now abandoned). An esophageal electrode may also be used as an ECG pickup. Those patents and applications are herein incorporated by reference. Many of these procedures may be substantially enhanced and facilitated if the electrode is capable of being moved close to the organ of the body being treated such as the ventricles of the heart.
Frequently patient care in a hospital and emergency care outside a hospital require ventricular pacing. Customarily, this is an invasive procedure and must therefore be performed in a sterile atmosphere, and the procedure requires a considerable period of time to perform. Many of the patents and applications identified above disclose a method and apparatus employing an internal, noninvasive esophageal electrode in combination with an external chest electrode, which are much more convenient to use, more efficient in performing the intended function, and do not require the presence of a physician.
The techniques described in the above identified patents and applications relating to pacing and/or defibrillation may be made more efficient if the electrode is positioned as close to the ventricle of the heart as possible. The closer the electrode is to the ventricle, the less electrical energy is needed to perform the pacing or defibrillating functions, and the more confident the attendant may be that the current flow between the internal and external electrodes is along the desired path.
The prior application Ser. No. 07/589,995, supra is directed to an esophageal displacement electrode to achieve greater efficiency in the practice of such procedures. The device includes a semi rigid plastic tube that may be inserted either orally or nasally into the esophagus. The tube carries an electrode at its distal end and has a mechanism incorporated into it which enables the user to cause the distal end of the tube to bend and press against the wall of the esophagus. The mechanism is of sufficient strength to cause the esophagus to displace under the pushing force of the electrode. To enable the tube to bend readily under the action of the mechanism, the tube is crimped so as to define a hinge at the distal region of the tube. The mechanism for deflecting the distal end of the tube includes a rigid pin having a cord connected at each end and which is aligned generally parallel to the axis of the tube and positioned at the distal portion thereof in the vicinity of the hinge. One cord attached to the proximal end of the pin extends out the proximal end of the tube, while the other cord attached to the distal end of the pin extends through a port located distally of the hinge in the tube and reenters the tube through a second port proximal of the hinge and then extends out the proximal end of the tube. By pulling on the cord attached to the distal end of the pin, the pin may be positioned beyond the hinge adjacent the distal port, and continued pulling of the cord will cause the tube t bend at the hinge.
The present invention is directed to an esophageal-stomach electrode to achieve greater efficiency in the performance of such procedures. The closer an electrode is positioned to the heart, the less electrical power is needed to control the heart and more consistent control of the heart is achieved. In accordance with the present invention a thin semi rigid plastic tube with the electrode on the distal end similar to the tube in the 07/589,995 application is used, but of sufficient length to be passed down the esophagus into the stomach. A mechanism, also similar to that in the earlier application, is incorporated into the tube which enables the user to cause the last couple of inches of the distal end of the tube to bend back on itself approximately 135 degrees from its original position. The user then withdraws the electrode until the bent back section of the distal end impacts on the stomach wall and displaces the stomach wall toward the heart. This action places the electrode in its operative position closest to the ventricle of the heart so as to cooperate with an external electrode on the chest to impress a pulse upon the heart. The bent back section of the distal end also prohibits further withdrawal of the electrode.
This invention will be better understood and appreciated from the following detailed description of a preferred embodiment thereof, selected for purposes of illustration and shown in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a diagrammatic frontview of a patient suggesting the heart, esophagus and stomach and showing without details of esophageal-stomach displacement electrode of the present invention extending through the esophagus and into the stomach;
FIG. 2 is an enlarged cross-sectional view of the distal end of displacement electrode disposed in the stomach and with the distal end in the undisplaced position;
FIG. 3 is a view similar to FIG. 2 but showing the distal end of the electrode in its displaced position;
FIG. 4 is a view similar to FIG. 3 and showing the electrode elevated so that its tip engages the wall of the stomach and displaces the wall so that it essentially engages the heart;
FIG. 5 is a side view of the control mechanism for the electrode shown in FIGS. 1 4 and showing one of the positions for the control slide; and
FIG. 6 is a cross-sectional view of the control mechanism taken along section line 6 6 in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 the torso and head of a patient are shown along with the patient's heart H, esophagus E and stomach S. The stomach is located posterior and spaced from the ventricle V. The esophageal-stomach displacement electrode shown extends through the patient's mouth, through the esophagus and into the stomach with its distal end located relatively close to the ventricle V. The present invention enables the distal end of the esophageal-stomach displacement electrode to displace angularly within the stomach and subsequently be pulled slightly back out of the esophagus, or alternatively, further angularly displaced, upwardly into pressurized contact with the stomach wall to position the wall closer than normal to the heart (see FIG. 4) and thereby place the stomach displacement electrode in closer proximity to it. This is illustrated in FIGS. 2, and 3 and 4.
The electrode includes a semi rigid plastic tube 10 made of nylon or other suitable material which may be approximately 20 inches long and approximately 3/16 inch in diameter. The tube should be semi rigid, much like a gastric tube, and be relatively torque free. The distal end 12 of the tube carries an electrode 14, preferably spherical in shape and having a stem 16 that fits within the distal end of the tube. The electrode may be pressed in place or suitably fastened by other means. In the preferred form, the electrode 14 is 1/4 inch in diameter, which just exceeds the diameter of the tube 10 so that the ball will make positive contact with the stomach wall when the distal end 12 of the tube 10 is displaced. The distal end 12 may be then further displaced or the complete electrode pulled back out of the esophagus to cause a bulge 50 (FIG. 4) in the stomach wall to place the wall and the electrode 14 closer to heart ventricle V. At this point, the electrode is prevented from further displacement by resistance of the stomach wall.
The tube 10 is carried by a control mechanism 20 shown in FIG. 4 which is connected to a displacement mechanism 22 disposed in the tube. The control mechanism is located at the proximal end of the tube outside the mouth when the esophageal-stomach displacement electrode is placed in the stomach as shown in FIG. 1.
The tube 10 is crimped as suggested at 26 in FIGS. 2, 3 and 4 so as to form a hinge 27 in the tube, which enables it to bend readily at that point. In the wall 25 of the tube 10, ports 28 and 30 are formed on opposite sides of the hinge 27, each spaced approximately an inch therefrom. While in the embodiment shown, each of the two ports is approximately one inch from the crimp 26, that dimension as well as others given may be varied to suit the particular application, as is more fully described below.
A rigid pin 32 is disposed in the tube 10 and extends generally parallel to the tube axis. The pin may be made of metal, rigid plastic, or any other material having sufficient rigidity to prevent the tube 10 from bending at the crimped area 26 when the pin spans the hinge.
A pair of cords 34 and 36 are connected to the proximal and distal ends 38 and 40, respectively, of pin 32 and extend proximally in the tube 10 out its proximal end 42 and into the control mechanism 20. Cord 34 extends directly from the proximal end of the pin 32 within the tube 10 to the control mechanism 20, while cord 36 extends from the distal end 40 of the pin, out the tube 10 through port 28 and from that point it extends proximally externally of the tube, spanning the crimped portion 26 to the port 30 where the cord reenters the tube 10 and extends in the tube to the control mechanism 20. As is evident from FIGS. 2, 3 and 4, the location of the pin 32 may readily be changed by pulling one or the other of the cords 34 or 36 in a proximal direction.
Pin 32 is somewhat shorter than the distance between the crimped portion 26 of the tube and the lower port 28. Travel of the pin 32 in the tube 10 in a distal direction is limited by the location of port 28. The size of pin 32 is such that it cannot be drawn through port 28 and, therefore, when the pin 32 reaches its lowermost point and a continued pull is exerted on cord 36, the distal portion of the tube 10 is caused to deflect (in this example approximately 135°) from the position shown in FIG. 2 to that shown in FIG. 3. At this point the tube must still be further deflected or pulled back out of the stomach to place it into pressurized contact with the stomach wall to cause a bulge 50 as shown in FIG. 4. While the tube 10 is displaced or bent about the hinge 27 by pulling on cord 36 when pin 32 has reached its lowermost position, merely by releasing tension on the cord 36, the natural bias of the tube 10 to the configuration of FIGS. 1 and 2 will cause it to return to the shape shown therein.
The control mechanism 20 shown in FIG. 5 is connected to the distal ends of the cords 34 and 36 to operate the displacement mechanism 22 by taking up one cord and playing out the other. The control mechanism 20 includes a sleeve 50, rectangular in cross section in the embodiment shown, and containing a slide 52. A bracket 54 is secured to the bottom wall 56 of sleeve 50 and retains the proximal end 42 of tube 10 in place. The bracket 54 includes a bar 62 and clamping plate 58 that sandwich the tube end, and the plate 58 is secured to the bar 62 by screws 60.
The cords 34 and 36 enter the sleeve 50 through a port 64 in bottom wall 56, aligned with the proximal end 42 of the tube 10 when the tube is secured to the bracket 54. The proximal ends 66 and 68 of the cords are respectively connected to flanges 70 and 72 carried by the slide 52. In FIG. 5, slide 52 is shown in the position that places the pin 32 in the tube in the position shown in FIG. 2. When the slide is moved to the right as viewed in FIG. 5, the pin 32 moves to its lowermost position in tube 10 and the tube is deflected, as shown in FIG. 3. Because the slide 52 is generally U shaped with an opening 74 in its bottom wall 76 that rests upon the bottom wall 56 of sleeve 50, movement of the slide 52 in the sleeve 50 does not in any way interfere with the movement of the cords 34 and 36 in response to displacement of the slide.
The electrode typically may be used in the following manner. Assume that the electrode is part of a pacing mechanism as shown in U.S. Pat. No. 4,735,206, supra. The tube 10 is inserted into the esophagus either through the mouth or the nasal passage to a depth wherein the electrode 14 is disposed out the lower end of the esophagus into the stomach at a depth sufficient to enable displacement of the tube's distal end 12 to approximately 135 degrees from its straighten or insertion position as shown in FIG. 3. The external electrode also forming part of the pacer is mounted on the chest of the patient and the controls, etc. are properly set. In order to reduce the amount of electrical energy required to effect pacing, the operator moves the slide 52 to the right as shown in FIG. 5 which will cause the pin 32 to move downwardly in the tube 10 so that its distal end 40 is immediately adjacent the port 28. Further movement of the slide 52 in that direction will cause the distal portion of the tube 10 to deflect and place the electrode 14 in proximity to the upper stomach wall near the heart ventricle V., as shown in FIG. 3. Further deflecting the distal end 12 or pulling back the tube 10 at its proximal portion then places the electrode 14 in pressurized displacable contact with the upper stomach wall causing a bulge that places the electrode closer to the ventricle V (FIG. 4). With the electrode in the displaced position of FIG. 4, the pacing pulses are imposed across the electrodes. When the procedure is completed, the operator may move the slide 52 back to the position of FIG. 5, which will relieve the tension on the cord 36 and allow the tube 10 to return to the position of FIG. 2. Thereafter the tube 10 may be withdrawn.
From the foregoing description, those skilled in the art will appreciate that the present invention provides a very convenient means of enabling an operator to place the esophageal stomach displacement electrode very close to the heart or other organ by means of a noninvasive procedure and thereby reduce the energy required to carry out the particular procedure such as pacing or defibrillation upon the patient. It will also be appreciated that while a specific embodiment is shown in the drawings, modifications may be made thereof without departing from this invention. For example, while a pin is shown as applying the bending force to the interior of the tube, other configurations for the device may be employed. Any structure which will not pass through the lower port 28 and will not interfere with the action of the hinge 27 will cause the tube 10 to deflect when the cord attached to it and exiting the tube through the port 28 is tensioned. It should, if necessary, also stiffen the hinge portion of the tube when it is being inserted in the esophagus and stomach. The member which applies the bending force must be capable of moving freely in the tube under the operation of the control 20 so as to be readily movable in response to actuation of the control. The tube 10 could, of course, carry more than one electrode. For example, in the earlier patents, supra, a number of spaced contact rings are shown carried by the tube.
Because modifications may be made of the invention without departing from its spirit, it is not intended that the scope of this invention be limited to the specific embodiment illustrated and described. Rather, the scope of this invention is to be determined by the appended claims and their equivalents. | An esophageal-stomach displacement electrode comprises a flexible tubular member designed to be inserted through the esophagus into the stomach. An electrode is carried by the tube in the region of its distal end. The tube is hinged near the distal end which enables that end of the tube to displace angularly in the stomach and displace the stomach wall. The stomach wall displacement may occur by angularly displacing the distal end or by otherwise pulling the tube partially out of the esophagus after its distal end partially displaced toward the stomach wall. A displacement mechanism is disposed in the tube in the region of the hinge and is controlled from a point externally of the body for causing the distal end of the tube to displace angularly, and to be positioned to engage and displace the stomach. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a manufacturing process of semiconductor device, and, more particularly, to a manufacturing process of semiconductor device having a multi-level wiring structure.
2. Description of the Related Art
As an integrated circuit is integrated in higher and higher density, it is essential to employ multi-level wiring in constituting a semiconductor device. A silicon oxide type dielectric film is frequently used for an inter-level dielectric film of a semiconductor device with multi-level wiring to reduce parasitic capacitance between wiring. A silicon oxide film formed by a plasma chemical vapor deposition is widely used as an inter-level dielectric film for aluminum type wiring because it can be formed at a relatively low temperature of 500° C. or less, and has good film quality. Description is given in the following on a process for forming a multi-level wiring structure presented by B. M. Somero et al. on the VLSI Multilevel Interconnection Conference, 1993.
As shown in FIG. 9(a), underlying wiring is formed on a semiconductor substrate 201. The wiring has a multi-level structure. First, a first titanium film 202 and a first titanium nitride film 203 are continuously formed in a same processing chamber. The titanium film and the titanium nitride film are used for improving migration resistance characteristics of the wiring. Then, a copper containing aluminum film 204 and a second titanium nitride film 205 are formed by a sputtering process. Containing copper in the aluminum film is also aimed at improving migration resistance characteristics. The top titanium nitride film 205 is used for preventing optical reflection since a desired pattern cannot be obtained if light is reflected on an aluminum film during exposure in a photolithography process for forming wiring.
After the underlying wiring is formed, as shown in FIG. 9(b), a plasma silicon oxide film 206 is formed by a parallel-plate type plasma chemical vapor deposition using tetraethylorthosilicate and oxygen as materials.
Since the surface of plasma silicon oxide film 206 is non-planar reflecting the profile of underlying wiring, if the upper level wiring is formed as it is, reliability of the wiring is deteriorated due to physical breakdown (disconnection) of the wiring. Therefore, to obtain good planarity, this example comprises applying photoresist on the plasma silicon oxide film 206, and heat treating it, followed by etch back to obtain the profile of FIG. 9(c). Although the conventional process employs the above approach, it may employ other approaches such as a spin-on-glass film or chemical mechanical polishing.
After the surface of the first silicon oxide film is planarised, contact holes (via holes) 209 are formed for electrically connecting the underlying wiring by photolithography, whereby the structure shown in FIG. 9(d) is obtained. In opening a via hole, the second titanium nitride film 205 on the top of underlying wiring is also etched to reduce contact resistance so that the first copper containing aluminum film 204 is exposed to the bottom of via hole.
Then, as shown in FIG. 10(a), a second titanium film 210 and a third titanium nitride film 211 are formed with a sputtering process. The second titanium film 210 is essential to reduce contact resistance at the bottom of via hole. Since aluminum is very easily oxidized, via hole resistance increases if aluminum oxide is formed on the copper containing aluminum wiring at the bottom of the via hole. On the other hand, titanium exhibits strong reduction (deoxidizing) characteristics. Accordingly, when a thin titanium film is formed, the titanium reduces aluminum oxide, so that increase of resistance is suppressed. Oxide of titanium also has high resistance, but, unlike aluminum, is not formed all over the bottom of via hole, but aggregates on one area, so that there is no increase of resistance.
The third titanium nitride film 211 is used for preventing a subsequently formed tungsten film from being peeled off, and as a stopper layer in a case where the global etch back is performed after the tungsten film is formed. If the tungsten film is directly formed on the titanium film 210, the tungsten film may be peeled off. In addition, since there is a large difference in the etching rate between titanium nitride and tungsten during dry etching, it becomes possible to etch tungsten without leaving it on areas other than the via hole when the etch back is performed to leave tungsten only in the inside of via hole.
Then, the via hole 209 is filled with tungsten 212 to obtain a structure shown in FIG. 10(b). The structure shown in FIG. 10(b) can be obtained by first forming tungsten on the entire surface of a wafer by chemical vapor deposition, and leaving the tungsten only in the inside of via hole 209 by etching back the entire surface.
Subsequently, similar to the underlying wiring, a second copper containing aluminum film and a fourth titanium nitride film are formed by sputtering, then a desired wiring pattern is formed, thereby a multi-level wiring structure as shown in FIG. 10(c) can be obtained.
However, according to this approach, a void 207 is generated in the underlying wiring of the plasma silicon oxide film 208 as spacing between the wirings become narrow This is caused from the fact that the film formation rate of the plasma oxide silicon film is higher at the upper corner of the wiring than on the side wall of the wiring or the valley between the wiring. If a void is caused between the wiring, gas contained in the void is repeatedly expanded and contracted in heating and cooling in the subsequent steps. Since the inter-level dielectric film does not have flexibility enough to absorb such expansion or contraction of the volume of gas in the void, such force would be applied to the wiring. If a large force is applied to the wiring during heating and cooling, the reliability of the wiring deteriorates significantly due to stress migration or the like. Accordingly, it is necessary to have a technique for forming an inter-level dielectric film so that no void is generated between the wiring.
The process not to generate the void includes a high density plasma CVD process which forms a film while applying high frequency power to a substrate. This process performs sputter etching at the same time while the film is formed. In the sputter etching, the upper comer of the wiring is more effectively etched than at other areas. Consequently, the upper comer of the wiring has a lower film formation speed so that the void does not tend to be generated between the wiring.
Since this process performs etching at the same time as the film formation, the film formation speed would be lowered. Thus, it is a typical approach to effectively decompose the film forming material by generating high density plasma, thereby increasing the film formation speed (high density plasma CVD process). In the following, a process for forming a film with the high density plasma CVD process while applying bias to the substrate is simply called a high density plasma CVD process.
The high density plasma CVD process includes an ECR plasma CVD process using electron cyclotron resonance which was reported by S. E. Lassig et al. on the VLSI Multilevel Interconnection Conference, 1993; a helicon plasma CVID plasma using helicon wave which was reported by T. Tamura et al. on the Dielectric for VLSI/ULSI Multilevel Interconnection Conference, 1995; and an ICP-CVD process using inductively coupled plasma which was reported by W. van den Hoek et al. on the SEMI Technology Seminar, 1994.
When the inter-level dielectric film is formed by the high density plasma CVD process, it is possible to obtain a multi-level wiring structure free from a void in the silicon oxide film even in a narrow wiring spacing as shown in FIG. 11. However, this process has various problems.
When the inter-level dielectric film formed by the high density plasma CVD process is used for the multi-level wiring structure described in conjunction with the related art, the reliability is degraded for a contact hole (via hole) electrically connecting an upper wiring and an underlying wiring.
It is because the silicon oxide film of the high density plasma CVD used as the inter-level dielectric film contains much amount of hydrogen, and the hydrogen is out-diffused and desorbed after the multi-level wiring structure is formed.
A dual-level wiring structure shown in FIG. 11 was formed by using a silicon oxide film, which was formed by the high density plasma CVD process described in conjunction with the related art, as an inter-level dielectric film. Then, its via hole-electrical resistance characteristics were evaluated by the following method.
To evaluate the reliability of the structure shown in FIG. 11 after it was formed, via hole resistance immediately after formation of a via hole was measured. Then, heat treatment (raised temperature test) was conducted for 60 minutes at 450° C. in nitrogen atmosphere, for 60 minutes at 500° C., 10 hours at 500° C. in this order. The via hole resistance was measured every time. The via holes were arranged in a chain of 2000 holes. The represented resistance was the value per hole. As shown in FIG. 12, after the raised temperature test was conducted in nitrogen atmosphere at 500° C. for 10 hours, the via bole resistance increased by about 22 times in comparison with that before the raised temperature test. The reason appears to lie in the following.
First, to determine change of the inter-level dielectric film during the heat treatment, a silicon oxide film was formed on a silicon substrate in a thickness of 600 nm by the ICP-CVD process which was one of the high density plasma CVD process, and then, a Theremal Desorption Spectrum analysis (TDS method) was conducted. A six-inch silicon substrate was used for film formation. The film was formed by using monosilane, oxygen and argon at flow rate 30 sccm, 40 sccm and 30 sccm, respectively. High frequency wave of a frequency of 2.0 MHz and with power of 3000 V was applied to a plasma source so as to generate high density plasma. In addition, high frequency bias current was applied to the substrate so as to generate self-bias. The bias frequency at the moment was 1.8 MHz, and the power was 1500 W.
As seen from theTDS shown in FIG. 13, an element with mass number of 2, i.e. hydrogen was desorbed in a much amount. The desorption of hydrogen caused a peak at 400° C. or less. Accordingly, it is believed that the silicon oxide film formed by the high density plasma CVD process contains much hydrogen, and much amount of hydrogen is desorbed during the raised temperature test. The hydrogen appears to be taken into the silicon oxide film during the high density plasma CVD. That is, in the high density plasma CVD process, high RF power is applied to the substrate during film formation. This applies high self-bias on the substrate. The self-bias is applied in such a manner that the substrate is negatively charged with respect to the plasma. Since hydrogen ion generated through decomposition of the film material SiH 4 is a positive ion, it is strongly attracted toward the substrate, whereby much ion is taken into the silicon oxide film.
It is known that, when hydrogen reacts with titanium, volatile TiH x is generated. Accordingly, if a semiconductor device has a structure where an inter-level dielectric film contacts titanium, there is a possibility of risk that, when much hydrogen is generated, titanium becomes fragile around the boundary between them.
In addition, when reliability is measured for the multi-level wiring structure shown in FIG. 12, warp was measured for wafers before and after the raised temperature test. As shown in FIG. 14, the warp is significantly varied before and after the raised temperature test. The warp of wafer was about 27 μm before the raised test, while it was about 16 μm immediately after the raised temperature test was conducted in nitrogen environment at 450° C. for 60 minutes. The warping was reduced by about 11 μm. Furthermore, the warp of wafer was about 4 μm after the raised temperature test at 500° C. for 10 hours, which showed reduction of about 23 μm compared with that before the test. It is believed that, as described above, when the heat treatment is conducted, much hydrogen is desorbed from the silicon oxide film formed by the high density plasma CVD process. On the other hand, the reason why the warp increases when the wafer is left after the raised temperature test believingly lies in that water in the atmosphere where the wafer is left is absorbed to bonds which are broken when hydrogen desorbed, thereby the warp being released. Accordingly, it can be seen that warp of a wafer is significantly varied by conducting the raised temperature test, and very high force is applied to the via hole.
After the via hole resistance was measured after the raised temperature test at 500° C. for 10 hours, the cross section of the via hole was observed with a scanning electron microscope (SEM). It was found that, as shown in FIG. 15, although the bottom of via hole was not peeled off from the underlying layer when compared with the state before the raised temperature test (FIG. 11), the bottom of via hole which should exist below an anti-reflection coating of the underlying wiring existed above the anti-reflection coating. This is believingly caused by the fact that mechanical force is applied to the via hole when the raised temperature test is conducted at 500° C., so that the bottom of via hole is raised. Since the measurement pattern consists of a chain of 2000 via holes, it is difficult to confirm all the via holes. Accordingly, it is expected that, while there is no broken wire at the area where the observation is conducted, there are via holes exhibiting high resistance due to partial peeling.
In view of the above results, the reason why the via hole resistance is significantly varied when a wafer is maintained at a high temperature for an extended period of time is believed to lie in the fact that titanium becomes fragile within a via hole as excess hydrogen is desorbed from the high density plasma CVD silicon oxide film, thereby deteriorating adherence at the interface between the bottom of via hole and aluminum wiring. Further, as large force is applied to the via hole due to the warping of the wafer being significantly varied during heat treatment, the bottom of via hole is cause to raise from the underlying wiring, so that the via hole resistance is increased. When the silicon oxide film is formed with the high density plasma CVD process, it is unavoidable that excess hydrogen is contained in the film, as described above. Therefore, when the silicon oxide film formed by the high density plasma CVD process is used as the inter-level dielectric film, it is expected to be effective that hydrogen in the film is previously removed after formation of the film.
BRIEF SUMMARY OF THE INVENTION
It is therefore, an object of the present invention to provide a multi-level wiring structure formed with via holes providing high reliability when a silicon oxide film is used as an inter-level dielectric film, the silicon oxide film being capable of burying minute spaces between wiring and being formed by a high density plasma CVD process.
A manufacturing process of a semiconductor device according to the present invention is to form a plurality of multi-level wiring on the surface of the semiconductor device through a dielectric film, the method comprising the steps of forming an underlying wiring; forming an inter-level dielectric film on the underlying wiring using at least one silicon oxide film, the silicon oxide film being formed by a high density plasma chemical vapor deposition process using at least monosilane and oxygen as materials while applying high frequency power to a semiconductor substrate; removing at least part of excess hydrogen in the silicon oxide film; forming contact holes in the inter-level dielectric film and reaching the underlying wiring; and forming an upper layer with a laminated structure using a titanium layer as the lowermost level. The process for generating high density plasma is any one of a process using electron cyclotron resonance, a process using helicon wave, or a process using inductively coupled plasma. Preferably, the step of removing excess hydrogen in the silicon oxide film is heat treatment in atmosphere containing at least one of nitrogen, argon and helium, or heat treatment in atmosphere containing oxygen. In addition, preferably, the heat treatment is conducted at a temperature of 350° C. or more but 500° C. or less for 10 minutes or more. Still preferably, after the contact holes are formed, the heat treatment is conducted in inert gas atmosphere containing at least one of nitrogen, argon, or helium at a temperature of 350° C. or more but 500° C. or less for 10 minutes or more.
In accordance with the present invention, after a silicon oxide film was formed on the silicon substrate in a thickness of 600 nm by the high density plasma CVD process with inductively coupled plasma (ICP-CVD process), heat treatment was conducted in nitrogen atmosphere at 400° C. for 60 minutes, or in oxygen atmosphere at 400° C. for 60 minutes. The hydrogen concentration in the silicon oxide film was evaluated by SIMS analysis. In this case, the conditions for forming the silicon oxide film was to use monosilane, oxygen and argon at flow rates of 30, 40 and 30 sccm, respectively. The plasma was generated by supplying power of 3000 W at a high frequency of 2.0 MHz. In addition, 1.8 MHz RF bias of 1500 W was applied to the silicon substrate.
As shown in FIG. 1, the hydrogen concentration was significantly reduced from about 3×10 20 atoms/cc before the heat treatment to about 8×10 19 atoms/cc after the heat treatment in nitrogen atmosphere at 400° C. for 60 minutes, or to about 5×10 19 atoms/cc after the heat treatment in oxygen atmosphere at 400° C. for 60 minutes. Accordingly, it was found that excess hydrogen in the silicon oxide film could be removed by conducting the heat treatment after the film formation. The effect is particularly significant when the heat treatment is conducted in oxidizing atmosphere such as oxygen.
Desorption of hydrogen in the silicon oxide film was characterized by a thermal desorption spectroscopy (TDS) technique after the silicon oxide film was formed at a thickness of 600 nm on the silicon substrate by the ICP-CVD process. The temperature was raised from the ambient temperature to 350° C. in 10 minutes, and, when 350° C. was reached, maintained at that temperature for 10 minutes. Then, as shown in the TDS curve of FIG. 2, the desorption of hydrogen diminished after maintaining for 10 minutes. Therefore, it is necessary to maintain the raised temperature for at least 10 minutes in order to remove hydrogen from the silicon oxide film.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other objects, features and advantages of this invention will become more apparent by reference to the following detailed description of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a depth profile of H atoms obtained by Secondary Ion Mass Spectroscopic (SIMS) analysis;
FIG. 2 is a Thermal Desorption Spectrum;
FIG. 3(a) to FIG. 3(c) are schematic sectional views of steps for manufacturing a semiconductor device illustrating an embodiment of the present invention;
FIG. 4(a) to FIG. 4(c) are schematic sectional views of steps for manufacturing a semiconductor device illustrating an embodiment of the present invention;
FIG. 5(a) and FIG. 5(b) are schematic sectional views of steps for manufacturing a semiconductor device illustrating an embodiment of the present invention;
FIG. 6 is schematic sectional views of a semiconductor device at various manufacturing steps for showing an alternative embodiment of the present invention;
FIG. 7 is schematic sectional views of a semiconductor device at various manufacturing steps for showing an alternative embodiment of the present invention;
FIG. 8 is a graph for illustrating an effect of the present invention, and showing the result of evaluation on reliability of via hole resistance;
FIG. 9(a) to FIG. 9(d) are schematic sectional views showing the manufacturing steps in the conventional process;
FIG. 10(a) to FIG. 10(c) are schematic sectional views showing the manufacturing steps in the conventional process;
FIG. 11 is schematic sectional views showing the manufacturing steps in the conventional process;
FIG. 12 is a graph showing the result of reliability test on via hole resistance for illustrating problems in the conventional process;
FIG. 13 is a Temperature Programmed Desorption (TPD) spectrum;
FIG. 14 is a diagram showing changes of warp of a wafer in the reliability test for illustrating problems in the conventional process; and
FIG. 15 is a schematic representation of an SEM cross section of a via hole after the reliability test for illustrating problems in the conventional process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 3-5 show sectional views of a semiconductor device at various manufacturing steps for illustrating an embodiment of the present invention.
First formed and laminated on a semiconductor substrate (silicon substrate) 101 by a sputtering process in a same chamber are a first titanium film 102 and a first titanium nitride 103, as well as first copper containing aluminum wiring 104 and a second titanium nitride film 105. Thickness is 50 nm for the first titanium film 102, 100 nm for the first titanium nitride film 103, 500mn for the first copper containing aluminum wiring 104, and 50 nm for the second titanium nitride film 105. Therefore, the underlying wiring has a height of 700 nm. The first titanium film 102 and the first titanium nitride film 103 are formed for improving migration resistance of the wiring. Containing copper in aluminum is also intended to improve the migration resistance. In addition, the second titanium nitride film 105 is used as an anti-reflection coating because, if light is reflected in performing subsequent photolithography, a desired pattern cannot be obtained. Accordingly, any film which can suppress reflection of light may be used. Then, a desired underlying wiring structure is formed by the photolithography to obtain a structure shown in FIG. 3(a).
Then, a structure shown in FIG. 3(b) is obtained by forming the silicon oxide film 106 in a thickness of 2 μm with the high density plasma CVD process with inductively coupled plasma (ICP-CVD process) and using monosilane, oxygen and argon as materials. Flow rate of each material during film formation is 30 sccm for monosilane, 40 sccm for oxygen and 30 sccm for argon. In addition, during film formation, high frequency wave is applied to the substrate at a power of 1500 W and a frequency of 1.8 MHz.
Although the embodiment uses the ICP-CVD process as the high density plasma CVD process, it is a matter of course that any other process may be used. In such case, different film formation conditions are naturally used, and conditions suitable for the process are used.
Then, the surface of the substrate is polished by chemical. mechanical polishing (CMP) to planarize the surface, whereby a structure of FIG. 3(c) is obtained. The silicon oxide film 107 has a thickness of 1 μm on wide wiring of 100 μm wide after planarzation by the CMP.
Then, as shown in FIG. 4(a), heat treatment is conducted in a nitrogen atmosphere at 400° C. for 60 minutes. A vertical heat treating furnace is used for the heat treatment.
Subsequently, as shown in FIG. 4(b), contact holes (via holes) 109 are opened by photolithography and dry etching. When they are opened by the dry etching, the anti-reflection coating on the upper level of the underlying wiring is also etched to expose the copper containing film 104 on the bottom of via hole.
After the via hole 109 is opened, a second titanium film 110 and a third titanium nitride film 111 are continuously formed in a same apparatus by sputtering. In this case, the titanium film 110 has a thickness of 50 nm, while the titanium nitride film 111 has a thickness of 100 nm. In this case, the titanium film is formed to reduce resistance at the bottom of via hole. In addition, the titanium nitride film 111 is used for preventing a tungsten film subsequently formed from being peeled off, and as a stopper layer when etch back is conducted after the tungsten film is formed. If the tungsten film is directly formed on the titanium film 110, it would be peeled off. In addition, since there is a large difference in etching rate for titanium nitride and tungsten in the dry etching, when the etch back is performed to leave tungsten only within the via hole, etching can be performed without leaving tungsten in areas other than the via hole.
Then, a tungsten film is formed on the entire surface of the substrate including the via hole, and then, the tungsten is left only within the via hole by using etch back, whereby a structure shown in FIG. 5(a) is obtained.
After the inside of via hole is buried with tungsten, a second copper containing aluminum layer and a fourth titanium nitride film are formed by sputtering, and upper wiring with a desired pattern is formed by photolithography and dry etching, whereby a structure shown in FIG. 5(b) is obtained. In the dry etching, the second titanium film 110 and the third titanium nitride film 111 are also simultaneously etched. The second copper containing aluminum wiring 113 has a thickness of 500 nm, while the anti-reflection coating has a thickness of 50 nm. In addition, the fourth titanium nitride film 114 is to prevent reflection as in the underlying wiring. Therefore, any material does not cause a problem as long as it can suppress reflection of light in the photolithography.
Via hole resistance was measured on the multi-level wiring structure formed by the embodiment described above immediately after its formation and after raised temperature test in nitrogen atmosphere at 500° C. for 60 minutes. In this case, the sample to be measured has 2000 via holes which were continuous through the upper and underlying wiring. The resistance was indicated as the resistance per via hole.
Consequently, as shown in FIG. 8, the via hole resistance increased only by 4.5 times before and after the raised temperature test. This exhibits that the reliability was significantly improved over the conventional process by heat treating the silicon oxide film formed by the high density plasma CVD process after its formation.
Now, a second embodiment is described. In the second embodiment of the present invention, the heat treatment for the silicon oxide film performed in the first embodiment is performed in oxygen atmosphere as shown in FIG. 6. When the heat treatment is performed in oxygen atmosphere as shown in FIG. 1, hydrogen in the silicon oxide film becomes less than in the case of heat treatment performed in nitrogen atmosphere as shown in FIG. 1, so that a via hole with higher reliability can be formed.
As the result of the heat treatment for the silicon oxide in oxygen atmosphere, the via hole has a slightly higher resistance before the raised temperature test. This increase of resistance is at magnitude not to cause a problem in adaptation for the device. The raised temperature test in nitrogen atmosphere at 500° C. for 60 minutes revealed that the via hole resistance increased by about 2.8 times than that before the raised temperature test, as shown in FIG. 8. Thus, it was possible to form a via hole with further higher reliability than when the heat treatment was performed in nitrogen atmosphere.
Then, in a third embodiment of the present invention, in addition to the heat treatment in the first and second embodiments, heat treatment is performed after the via holes are opened as shown in FIG. 7, so that it becomes possible to form via holes with further higher reliability. In this case, atmosphere for the heat treatment is required to be of inert gas. This is because the underlying wiring is exposed after the via holes are opened, and, if the heat treatment is performed in oxidizing atmosphere, the underlying wiring is oxidized to increase the resistance.
The via hole resistance after the heat treatment in nitrogen atmosphere at 400° C. for 60 minutes was measured before and after raised temperature test. The measurement revealed that the resistance increased by about 3.5 times when the silicon oxide film was heat treated in nitrogen atmosphere, and by about 2.5 times when it is performed in oxygen atmosphere, as shown in FIG. 8. Thus, further higher improvement can be attained.
A major advantage of the present invention lies in that the reliability of via hole is not deteriorated even when a silicon oxide film formed by the high density plasma-bias CVD process is used as an inter-level dielectric film.
A silicon oxide film formed by the high density plasma-bias CVD process contains much amount of excess hydrogen therein, and the reliability is deteriorated when the hydrogen is desorbed. However, if hydrogen is removed through heat treatment in inert gas or oxygen atmosphere subsequent to film formation, hydrogen can be suppressed from being desorbed from the silicon oxide film during heat treatment in the process steps that come after the film formation. If the silicon oxide film used as the inter-level dielectric film contains much amount of excess hydrogen, the hydrogen is desorbed during the heat treatment after the formation of the silicon oxide film. Titanium forms volatile TiH x reacting hydrogen. In addition, warp of the wafer is significantly varied as hydrogen is desorbed. If a titanium film exists on the bottom of via hole, contact on the bottom of via hole is weakened, and a large force is applied to the bottom of via hole as the warp of wafer is changed, so that a part of the bottom of the via hole is peeled off and the resistance of the via hole is increased. Accordingly, previously removing excess hydrogen in the silicon oxide film makes it possible to form a multi-level wiring structure in which the resistance of via hole is not increased.
While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims. | Disclosed is a method of manufacturing a semiconductor device aimed at improving reliability of wiring, more particularly, of a via hole when a silicon oxide film formed by a high density plasma CVD process is used as an inter-level dielectric film in an integrated circuit having a multi-level wiring structure. When the multi-level wiring structure is formed on a semiconductor substrate, after underlying wiring is formed, a silicon oxide film is formed on the entire surface of the substrate by a high density plasma CVD process, and heat treated in inert gas or oxygen atmosphere at a temperature of 300° C. or more but 500° C. or less for 10 minutes or more. Excess hygrogen incorporated in the silicon oxide during the CVD process is removed by the above heat treatment. Subsequently, via holes are opened, and upper wiring is formed. | 7 |
TECHNICAL FIELD
[0001] The present system and method relates generally to a Data Management System for graphically visualizing patient data and particularly, but not by way of limitation, to such a system adapted for rapid visualization of temporally periodic attributes of patient health, rapid identification of singularities in a patient's health, and rapid identification of trends in a patient's health.
BACKGROUND
[0002] It is said that a picture is worth a thousand words. However, more often than not, word and numbers are used to explain complex ideas and problems because they represent the most common denominator of understanding such ideas and problems. Even in esoteric scientific circles, where formulae often represent very complex ideas, traditional ways of conveying ideas are nevertheless employed to put complex ideas in a form suitable for mass consumption. Thus, advances in technology, while often increasing our ability to understand complex problems, challenges us to use new paradigms of explaining that understanding—paradigms that allow us to quickly perceive and understand complex technological output. This challenge holds true even in the context of diagnosing and treating disease.
[0003] As the diagnosis and treatment of disease struggles to keep pace with advances in medical technology, clinicians often face the daunting task of trying to assimilate vast amounts of patient and medical data into a coherent form the clinician can quickly access and utilize to efficiently diagnose patient health. More often than not, patient data and other medical information are presented to the clinician in the form of cumbersome patient charts and other paper documents or graphs. Traditionally, clinicians were tasked with the burden of wading through this sea of patient biometric data or had to rely on the expertise and input of colleagues to properly assess the clinical relevance of medical information. The use of computers has somewhat lessened this burden. However, even with computers, electronically presented clinical data is often no more sophisticated than an electronic reproduction of hard copy. So, while computers have greatly improved medical information access and storage, novel ways of presenting such information using computers or other electronic technologies are still being explored.
[0004] One novel way of presenting information is to present it in the form or representation of a three-dimensional structure. As the users of information presented in this fashion become more accustomed with how the data has been subsumed within the structure, they become better equipped to understand the complexities of the data and more attuned to quickly recognizing data deviations or trends. In addition, the more data subsumed within the structure, the more revealing the structure's shape or morphology in assisting the user in interpreting the data. In other words, the structure's form (its morphology) tends to illustrate more clearly data trends or deviations much in the way that a bell curve graph is more revealing than the table of variables that form the curve. However, the prior art does not focus on the morphology of graphically represented data as a way to interpret the data.
[0005] For example, U.S. Pat. No. 5,867,165 to Neill discloses a diary display and storage device using a three-dimensional helical structure onto which visual data can be appended. Alternatively, the three-dimensional structure can be created by a series of interlocking data units. This allows the visual representation of data according to the sequence in which the information occurs. However, Neill's mechanical device limits the amount of data a user can efficiently comprehend because of the obvious physical constraints of the device—the more data included on the Neill helix, the more physically cumbersome the device.
[0006] This problem is partially solved in U.S. Pat. No. 5,917,500 to Johnson et al. Johnson uses a computer-generated model that facilitates and enhances the comprehension of relationships, structures, patterns or trends within a data set or sets of data. However, the Johnson presentation is essentially linear and may require more intense scrutiny by the user before the user can recognize and interpret meaningful data correlations.
[0007] U.S. Pat. No. 6,212,509 to Poa et al. attempts to capture and display multidimensional data using computer-generated structures. Poa discloses the visualization of large bodies of complex multidimensional data in a so-called “topologically correct” low-dimension approximation.
[0008] However, none of the above references capture the idea of giving the morphology of the structure interpretive meaning in a way that assists the user, in this case a medical clinician, in viewing and understanding the clinical significance of the data. In other words, the graphical forms of the present invention provide not only an efficient way to present multi-dimensional data, but the multiple dimensions of the form itself, as created by the underlying data or configured by the user, confers interpretive meaning to the data.
[0009] Thus, for these and other reasons, there is a need for a system adapted for rapid visualization of large amounts of patient data in a graphical form that clearly shows the multi-dimensional aspect of the data and allows the clinician to clinically interpret the data based on the morphology of the graphical form. In this way, the system provides for a rapid and accurate analysis of temporal, qualitative and quantitative attributes of patient health and patient health trends. The system also reduces the analytical burden placed on clinicians by reducing vast amounts of clinical data to a more easily understood visual form.
SUMMARY
[0010] According to one aspect of the invention, there is provided a system and method for representing multi-dimensional patient health using a system that graphically presents patient health data in a way that the structure of the graphical form illustrates the clinical significance of the medical data. The system comprises a Data Management System (“DMS”) adapted to contain large amounts of patient information and data, a graphical data presentation device accessible by a clinician or patient, and a presentation engine adapted to collapse the large amount of DMS data into a temporally coherent visual presentation that can be manipulated by commonly available three-dimensional visualization tools. As used herein, “patient data,” “patient health data,” “medical information” and “biometric data” are substantively synonymous terms as are the words “data” and “information.” Also, as used herein, a “clinician” can be a physician, physician assistant (PA), nurse, medical technologist, or any other patient health care provider.
[0011] In one embodiment, the Data Management System comprises a data management module, an analysis module, a presentation engine, and user means to resolve and manipulate the presented data. The System is configured to accommodate large amounts of patient health or biometric data and present that data as a graphical display.
[0012] In another embodiment, the data management module is adapted to receive, store and archive large amounts of patient health data. Patient health data may comprise any physiological parameter suitable for quantitative or qualitative measurement. By way of non-limiting example only, such physiological parameters might include a patient's body temperature, heart rate, heart rate variability, body weight, cardiovascular efficiency or level of physical activity.
[0013] In a further embodiment, the analysis module is adapted to analyze patient health data for efficient presentation to the presentation engine. The analysis component includes the use of clinically derived algorithms to analyze biometric data in a way that yields clinically relevant information. By using clinically derived algorithms to analyze biometric data, there is consistent delivery of quality of care. Such consistency serves to improve the cost-effectiveness and efficiency of medical care by offloading at least part of the diagnostic burden placed on the clinician to the Data Management System. Analysis may also include the correlation of patient health data using known data correlation techniques or statistical analysis of patient health data. In addition, the analysis of biometric data may comprise identifying singularities in patient health and/or trends in patient health.
[0014] In yet another embodiment, the presentation engine is adapted to collapse the large amounts of analyzed patient health data into a temporally coherent visual presentation in which the morphology of the displayed presentation provides a multi-dimensional representation of patient health. The visual presentation comprises a higher order geometric figure presented on a conventional two-dimensional display where the two-dimensional display has significantly higher resolution than the displayed geometric figure. The higher order geometric figure may comprise a representation of biometric data in the form of a series of stacked doughnut shapes.
[0015] In a preferred embodiment of the system and method for graphically representing multi-dimensional patient health, the visual presentation graphic comprises a high-resolution helical structure further comprising fast and slow temporal axes. The helical structure is adaptable for manipulation by commonly available three-dimensional visualization tools. In this way, a clinician may configure a presentation of specific biometric data, or a combination of biometric data sets, best suited for the clinical situation.
[0016] The various embodiments described above are provided by way of illustration only and should not be construed to limit the invention. Those skilled in the art will readily recognize various modifications and changes that may be made to the present invention without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the present invention, which is set forth in the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the drawings, which are not necessarily drawn to scale, like numerals describe substantially similar components throughout the several views. Like numerals having different letter suffixes represent different instances of substantially similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
[0018] [0018]FIG. 1 is a schematic/block diagram illustrating generally, among other things, one embodiment of the system and method for representing multi-dimensional patient health.
[0019] [0019]FIG. 2 is a schematic/block diagram illustrating generally, among other things, another embodiment of the system and method for representing multi-dimensional patient health that illustrates the system interacting with an implantable medical device and a clinician or patient.
[0020] [0020]FIG. 3 is a state diagram illustrating generally, among other things, another embodiment of the functional components of the system and method for representing multi-dimensional patient health that illustrates the functional components of the system interacting with an external computer system and a clinician or patient.
[0021] [0021]FIG. 4 is a schematic/block diagram illustrating generally, among other things, various forms or dimensions of presenting patient health data in another embodiment of the system and method for representing multi-dimensional patient health.
[0022] [0022]FIG. 5 is a schematic/block diagram illustrating generally, among other things, other various forms or dimensions of presenting patient health data in another embodiment of the system and method for representing multi-dimensional patient health.
[0023] [0023]FIG. 6 is a schematic/block diagram illustrating generally, among other things, a helical form or dimension of presenting patient health data in another embodiment of the system and method for representing multi-dimensional patient health.
DETAILED DESCRIPTION
[0024] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration, specific embodiments or examples. These embodiments may be combined, other embodiments may be utilized, and structural, logical, and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
[0025] The present system and method are described with respect to a Data Management System capable of representing a graphical view of multi-dimensional patient health. The system and method can provide clinicians with a means for rapid visualization of temporally periodic attributes of patient health, rapid identification of singularities in a patient's health and rapid identification of patient health trends. In providing such an overview of patient health in graphical format, the system is adapted to condense vast amounts of patient health or biometric data to a form that allows the clinician to rapidly identify correlations and trends. This helps reduce the burden on the clinician to analyze and synthesize reams of patient data most often kept in the form of voluminous and awkward paper documents.
[0026] [0026]FIG. 1 is a schematic/block diagram illustrating generally an embodiment of the Data Management System 100 capable of graphically representing multi-dimensional patient health. The system further comprises data management module 101 , analysis module 102 , presentation engine 103 , and user means 104 to resolve and manipulate the graphical representation.
[0027] [0027]FIG. 2 is a schematic/block diagram illustrating generally an embodiment of the data management module 101 of the Data Management System 100 . In this embodiment, the data management module 101 is adapted to receive, store and archive vast amounts of biometric data in a temporal fashion. Data for the data management module may be obtained automatically through the sensing function of an implantable medical device 200 or manually through input by a clinician 201 or patient 201 , or both. In either automatic or manual mode, the data management module 101 is adapted to electronically receive, store and archive biometric data. By way of non-limiting example only, such data may comprise a temporal record of a patient's body temperature, heart rate, heart rate variability, body weight, cardiovascular efficiency or level of physical activity.
[0028] [0028]FIG. 3 is a state diagram illustrating generally the function of analysis module 102 . Analysis module 102 is adapted to electronically receive temporal biometric data from data management module 101 . Analysis module 102 is further adapted to analyze the biometric data. Analysis may comprise the use of clinically derived algorithms to analyze the biometric data in a way that yields a clinically relevant output. The algorithms can be the result of the extraction, codification and use of collected expert knowledge for the analysis or diagnosis of medical conditions. For example, the algorithms can comprise institutional diagnostic techniques used in specific clinical settings. By reducing the diagnostic methodologies of institutions like the Cleveland Clinic, the Mayo Clinic or the Kaiser Permanente system to algorithmic expression, a patient will enjoy the benefit of the diagnostic expertise of a leading medical institution without having to visit the institution. Analysis module 102 is further adapted to electronically communicate with presentation engine 103 . As further illustrated in FIG. 3, presentation engine 103 is adapted to collapse the large amounts of analyzed patient health data into a temporally coherent visual presentation that can be manipulated by commonly available three-dimensional visualization tools. User means 104 may comprise a personal computer or other visual display device adapted to display the multi-dimensional representation of patient health to the patient or clinician.
[0029] As illustrated in FIG. 4, such common visual manipulation tools may include CAD/CAM software or other computer software tools that allow the user to manipulate the view and further analyze the visual presentation 400 . By way of non-limiting example only, a manipulated view may include rotating the visual presentation 400 in relation to a selected temporal axis to view a temporal series of biometric data points. By temporally arranging the presentation 400 , the presentation of biometric information is visually coherent allowing the clinician or other user to visually observe the evolution of biometric variables. By further non-limiting example, a user, in this case a clinician, may further analyze the visual presentation 400 by focusing or zooming in on a segment 401 of the presentation 400 . By selecting a segment 401 of the presentation 400 , the clinician can view finer-grain biometric data of clinical interest. Further analysis might also include selecting a segment or data point 402 of a previously selected segment to view even finer-grain biometric data of interest. In this embodiment, the presentation engine is robust enough so that fine-grain selections of increasingly finer magnitudes 403 can themselves be graphically represented. In addition, by selecting a segment 401 or 402 , a clinician may elect to view temporal biometric data in tabular form 404 instead of a graphical presentation 400 .
[0030] [0030]FIG. 5 is a schematic/block diagram illustrating generally an embodiment of the graphical representation of multi-dimensional patient health. In this embodiment, the presentation is in the form of a series of stacked doughnut shapes 500 . The doughnuts can be offset 501 from center to represent additional dimensions of biometric data. By way of non-limiting example only, such additional dimensions may comprise representations of cardiac output, chamber pressure, blood chemistry, ejection fraction or thyroid or gastric markers. Each doughnut 502 may comprise a temporal snapshot of biometric data. By way of non-limiting example only, the outside radius 503 of the doughnut represented by radius HR may comprise a 24-hour representation of a patient's heart rate. As a patient's heart rate changes throughout the day, radius HR would lengthen or shorten as shown by varying radius HR 506 . By way of further non-limiting example only, the inside radius of the doughnut represented by radius HRV 504 may comprise a 24-hour representation of a patient's heart rate variability or blood pressure. Using the blood pressure example, the length of radius HRV would lengthen or shorten depending on variations 508 in the patient's blood pressure. The width or thickness 505 of each doughnut may comprise a measurement of the patient's body mass index or weight during a 24-hour period. By way of non-limiting example only, the width 505 of the doughnut would increase as the patient's body mass increases and decrease as body mass decreases. Thus, a clinician could quickly and easily recognize a weight trend by viewing a succession of doughnut shapes 500 . A clinician could also quickly and easily recognize other trends or changes 509 by observing changes in the form of the temporal, graphical representation. Other clinical events 510 may be displayed on the doughnut surface in temporal context. By way of non-limiting example only, such events might comprise cardiac arrhythmias, a fall suffered by the patient, dyspnea, anxiety or depression, a patient's sleeping habits and core body temperature in excess of a clinically determined range. Those skilled in the art will appreciate that a host of biometric data or clinical events may be shown by the graphical representation of FIG. 5.
[0031] [0031]FIG. 6 is a schematic/block diagram illustrating generally an embodiment of the graphical representation of multi-dimensional patient health. In this embodiment, the presentation is in the form of a helical structure 600 comprising a finite coil. Finite space is utilized to capture bounded analog values within a reasonable range of variation. As further illustrated in FIG. 6, the helix comprises logical fast and slow axes that are temporally coherent. The fast axis is shown by the helical curve of the helix moving generally in the direction of line 601 . The slow axis is parallel to line 602 and traverses the length of the helix 600 from end to end. By way of non-limiting example only, movement along the fast axis 601 may illustrate temporal relations in terms of hours. In contrast, movement along the slow axis 602 may illustrate temporal relations in terms of days. In this embodiment, each complete turn of the helix represents 24 hours. Within a 24-hour period, day and night can be represented by subtle coloration 603 changes on the surface of the fast axis 601 of the helix. The helical structure 600 comprises adjustable dimensions in the pitch 608 of the helix and offset of the helix from a central axis. In this embodiment, the central axis may comprise a line parallel to axis 602 traversing the center of the helix 600 (of constant or varying pitch) from end to end. In addition, and by way of further non-limiting example only, more pronounced coloration 604 changes can be imposed on the fast axis 601 of the helix 600 to indicate, for instance, a cardiac arrhythmia. Other clinical events may be represented by other shape or size images imposed on the fast axis 601 of the helix 600 . Subtle texture 605 changes can also be imposed on the fast axis 601 of the helix 600 to signify other clinical events, such as a sudden rise in body weight. As further illustrated on FIG. 6, other surface microstructure 606 can be imposed on the fast axis 601 of the helix to convey other clinical information upon zoomed-in viewing. The color 604 and texture 605 changes, and other surface microstructure 606 may indicate binary or roughly graduated clinical events. By way of non-limiting example only, a binary clinical event is of the type that can be represented as either existing or not, much in the way that binary computer language consists of zeros and ones. In contrast, and by way of non-limiting example only, a roughly graduated clinical event is of the type best represented as a continuum. In this embodiment, a binary clinical event may be imposed on the surface of the helix 600 in the form of a red dot or patch 604 representing, for example, the occurrence of an arrhythmia. A roughly graduated clinical event in this embodiment may be temporally imposed on the surface of the helix 600 in the form of a continuous change in color from, for example, yellow to orange to red to represent a deteriorating physical condition of an urgent nature. Fiducials 607 can also be imposed along the fast axis 601 of the helix to guide coarse interpretation of presented dimensional data or quickly recognize variances. Other dimensions of biometric data can be represented along pitch axis 608 . In this embodiment, the radius in relation to a central axis traversing the length of the helix 600 would increase or decrease in relationship to the other dimension of biometric data. By assigning biometric data to a dimension relative to a radius from the central axis, a clinician or other user may analyze an instantaneous cross-section of the helical coil 600 . Such an instantaneous cross-section may comprise a data point on the coil 600 . Such analysis of an instantaneous cross-section of the helix 600 may assist the clinician or other user in drawing statistical conclusions from the biometric data or defining statistical parameters of biometric data for further analysis.
[0032] It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments may be used in combination with each other. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including,” “includes” and “in which” are used as the plain-English equivalents of the respective terms “comprising,” “comprises” and “wherein.” | Methods and systems for graphically representing a multi-dimensional view of patient health are disclosed. A preferred embodiment uses a helical display of temporal attributes of patient health that allows a clinician to view not only a comprehensive representation of patient health, but also view fine-grain or customized representations of patent health data using commonly available techniques to manipulate the data points of the helical structure. | 6 |
BACKGROUND OF THE INVENTION
[0001] Protein kinases are involved in the signal transduction pathways linking growth factors, hormones and other cell regulation molecules to cell growth, survival and metabolism under both normal and pathological conditions. One such protein kinase, protein kinase B (also known as AKT), is a serine/threonine kinase that plays a central role in promoting the proliferation and survival of a wide range of cell types, thereby protecting cells from apoptosis (programmed cell death) (Khwaja, Nature 33-34 (1990)). Three members of the AKT subfamily of second-messenger regulated serine/threonine protein kinases have been identified and are termed AKT-1; AKT-2, and AKT-3. A number of proteins involved in cell proliferation and survival have been described as substrates of AKT in cells. Two examples of such substrates include glycogen synthase kinase-3 (GSK3) and Forkhead transcription factors (FKs). See Brazil and Hemmings, Trends in Biochemical Sciences 26, 675-664.
[0002] A number of protein kinases and phosphatases regulate the activity of AKT. For instance, activation of AKT is mediated by phosphatidylinositol 3-kinase (PI3-K), which generates second messenger phospholipids that then bind to the pleckstrin homology (PH) binding domain of AKT. The binding attracts AKT to the plasma membrane where AKT is phosphorylated by phosphatidylinositol dependent kinase 1 (PDK1) at Thr308, which then triggers phosphorylation of AKT at Ser473 and activation of the enzyme. Amplifications of the catalytic subunit of PI3-K, p110α, or mutations in the PI3-K regulatory subunit, p85α lead to activation of AKT in several types of human cancer. (Vivanco and Sawyers, Nature Reviews in Cancer (2002) 2: 489-501).
[0003] The tumor suppressor, PTEN, is a critical negative regulator of AKT activation by PI3-K (Myers et al. Proc. Nat. Acad. Sci 95, USA (1998) 13513-13518). Inactivating mutations in the Pten gene have been found at high frequencies in a large number of human tumors and tumor cell lines, including prostate cancer, breast cancer, ovarian cancer, glioblastoma, melanoma and other cancer types. Inactivation of the PTEN protein results in elevated levels of phosphorylated AKT and increased AKT activity in tumor cells (Li, et al., Science (1997) 275: 1943-1947; Guldberg, et al., Cancer Research (1997) 57: 3660-3663; Risinger, et al., Cancer Research (1997) 57: 4736-4738; Vivanco and Sawyers, Nature Reviews in Cancer (2002) 2: 489-501). In addition to overactivation of AKT due to defects in PTEN, direct amplification and/or overexpression of AKT-2 and AKT-3 have been found in human neoplasia, for example ovarian, pancreatic, prostate and breast cancer cells (Cheung et al., Proc. Nat. Acad. Sci. USA (1992) 89:9267-9271; Cheung et al., Proc. Nat. Acad. Sci. USA (1996) 93:3636-3641; Nakatani et al., J. Biol. Chem. (1999) 274:21528-21532).
[0004] The critical role of AKT in cell proliferation and survival is further strengthened by studies showing that germline knockout of AKT-1 results in partial embryonic lethality. The surviving littermates display stunted growth, increased organismal apoptosis, and early deaths. (Cho et al., J. Biol. Chem . (2001) 276: 38349-38520; Chen et al., Genes Dev . (2001) 15: 2203-2208). It has also been demonstrated that pharmacological inactivation of AKT induces apoptosis in cultured human ovarian cancer cells (Yuan et al., Oncogene 19, 2324-2340, 2000) and decreases growth of a human ovarian carcinoma xenograft in mice (Hu et al., Clin. Cancer Res. 6, 880-886, 2000).
[0005] Recent studies have also demonstrated the role of the PI3-K/AKT pathway in the life cycle of numerous viruses. Some viral proteins have been shown to directly activate the PI3-K/AKT pathway, thus providing an environment favorable for viral replication. These include the Tat protein of human immunodeficiency virus (HIV), Protein X of hepatitis B virus, and NS5A of hepatitis C virus (Borgatti et al., Eur. J. Immunol . (1997) 27: 2805-2811; Lee et al., J. Biol. Chem . (2001) 276: 16969-16977; He et al., J. Virol . (2002) 76: 9207-9217). The PI3-K/AKT pathway is also required for initiation and completion of the replication cycle of human cytomegalovirus (HCMV). In fact, pharmacological inactivation of this pathway results in abortive production of HCMV and survival of the host cells (Johnson et al., J. Virol . (2001) 75: 6022-6032).
[0006] Because of its pivotal role in the regulation of cell survival, the PI3 kinase/AKT pathway provides a novel therapeutic target for the effective treatment of various disorders, particularly cancer and viral infections. However, such treatment requires the development of potent, selective inhibitors of kinases within this pathway. The present invention provides methods of using known bisindolyl maleimides previously disclosed as selective inhibitors of protein kinase C beta-1 and protein kinase C beta-2. Specifically, inhibition of PDK-1 by these compounds would be expected to suppress activation of the entire pathway as PDK-1 is the key kinase activating AKT. Inhibition of p70S6 kinase, a kinase effector downstream of AKT, would further suppress the enhanced ribosome biogenesis and protein translation triggered by AKT pathway activation.
[0007] Prostatic adenocarcinoma (CaP) is the most common, non-cutaneous malignancy and the second-leading cause of cancer death in men. The disease has two distinct phases: the androgen-dependent phase, which can be treated effectively with androgen ablation therapies, and the androgen-independent phase. It is estimated that over thirty thousand men will die each year from androgen-independent metastatic CaP. Efforts to understand the metastatic progression of CaP progression to androgen-independent, metastatic disease involves a dampened apoptotic response, a release from the cell cycle block that initially follows androgen withdrawal and a shift from dependence on paracrine-derived growth and survival factors to autonomous production of these key proteins. Functional loss of the tumor suppressor phosphatase and tensin homologue deleted on the chromosome ten (PTEN) and subsequent activation of the AKT pathway, have been prominently implicated in the progression of CaP to androgen-independence. Activation of the AKT pathway can suppress the apoptotic response, undermine cell cycle control and selectively enhance the production of key growth and survival factors. Though many proteins and intracellular signaling pathways can influence these biological responses, activation of the AKT pathway is a particularly potent signal involved in CaP progression to androgen-independence and therefore provides a therapy of advanced androgen-independent CaP (Graff 2002). Treatment of CWR22Rv1, LNCAP and Du145 prostate cancer cells with the compound induces apoptosis.
SUMMARY OF THE INVENTION
[0008] The present invention provides a method of treating prostate cancer comprising administering to a patient in need thereof a therapeutically effective amount of a compound of the formula (I)
wherein R 1 and R 2 are each independently hydrogen or C 1 -C 4 alkyl; or a pharmaceutically acceptable salt thereof.
[0009] In a second embodiment, the invention provides a method of treating androgen-independent prostatic adenocarcinoma comprising administering to a patient in need thereof a therapeutically effective amount of compound of formula (I) or a pharmaceutically acceptable salt thereof.
[0010] In a third embodiment, the invention provides a method of treating an AKT-mediated disease selected from the group consisting of glioblastoma, colon cancer, pancreatic cancer, ovarian cancer, endometrial cancer, and renal cell cancer, comprising administering to a patient in need thereof a therapeutically effective amount of compound of formula (I) or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0011] General terms used in the description of compounds herein described bear their usual meanings. For example, the term “C 1 -C 4 alkyl” refers to straight or branched, monovalent, saturated aliphatic chains of 1 to 4 carbon atoms and includes, but is not limited to, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, and tert-butyl.
[0012] Preferred compounds of this invention include compounds of formula I wherein R 1 is hydrogen, methyl, ethyl, n-propyl, or isopropyl. Further preferred compounds include those wherein R 2 is hydrogen or methyl. More preferred compounds are those where R 1 is hydrogen. The skilled artisan will appreciate that additional preferred embodiments may be selected by combining the preferred embodiments above, or by reference to the examples given herein.
[0013] The term “pharmaceutically-acceptable salt” as used herein, refers to a salt of a compound of the above Formula (I). It should be recognized that the particular counterion forming a part of any salt of this invention is usually not of a critical nature, so long as the salt as a whole is pharmacologically acceptable and as long as the counterion does not contribute undesired qualities to the salt as a whole.
[0014] The compounds of Formula (I) described herein form pharmaceutically-acceptable acid addition salts with a wide variety of organic and inorganic acids and include the physiologically-acceptable salts which are often used in pharmaceutical chemistry. Such salts are also part of this invention. A pharmaceutically-acceptable acid addition salt is formed from a pharmaceutically-acceptable acid, as is well known in the art. Such salts include the pharmaceutically acceptable salts listed in Journal of Pharmaceutical Science, 66, 2-19 (1977), which are known to the skilled artisan. See also, The Handbook of Pharmaceutical Salts; Properties, Selection, and Use. P. H. Stahl and C. G. Wermuth (ED.s), Verlag, Zurich (Switzerland) 2002.
[0015] Typical inorganic acids used to form such salts include hydrochloric, hydrobromic, hydriodic, nitric, sulfuric, phosphoric, hypophosphoric, metaphosphoric, pyrophosphoric, and the like. Salts derived from organic acids, such as aliphatic mono and dicarboxylic acids, phenyl substituted alkanoic acids, hydroxyalkanoic and hydroxyalkandioic acids, aromatic acids, aliphatic and aromatic sulfonic acids, may also be used. Such pharmaceutically acceptable salts thus include acetate, phenylacetate, trifluoroacetate, acrylate, ascorbate, benzoate, chlorobenzoate, dinitrobenzoate, hydroxybenzoate, methoxybenzoate, methylbenzoate, o-acetoxybenzoate, naphthalene-2-benzoate, bromide, isobutyrate, phenylbutyrate, α-hydroxybutyrate, butyne-1,4-dicarboxylate, hexyne-1,4-dicarboxylate, caprate, caprylate, cinnamate, citrate, formate, fumarate, glycollate, heptanoate, hippurate, lactate, malate, maleate, hydroxymaleate, malonate, mandelate, mesylate, nicotinate, isonicotinate, nitrate, oxalate, phthalate, teraphthalate, propiolate, propionate, phenylpropionate, salicylate, sebacate, succinate, suberate, benzenesulfonate, p-bromobenzenesulfonate, chlorobenzenesulfonate, ethylsulfonate, 2-hydroxyethylsulfonate, methylsulfonate, naphthalene-1-sulfonate, naphthalene-2-sulfonate, naphthalene-1,5-sulfonate, p-toluenesulfonate, xylenesulfonate, tartarate, and the like.
[0016] The compounds of formula (I) are described in Heath, Jr. et al., U.S. Pat. No. 5,668,152. The synthesis of the compounds of formula (I) are fully set forth as well as a disclosure that said compounds are useful as beta-1 and beta-2 isozyme selective protein kinase C (PKC) inhibitors. As isozyme selective PKC inhibitors, the compounds have previously been disclosed as useful in the treatment of conditions associated with diabetes mellitus and its complications as well ischemia, inflammation, central nervous system disorders, cardiovascular disease, dermatological disease, Alzheimer's disease and cancer. U.S. Pat. No. 5,668,152 is hereby incorporated by reference in its entirety as if fully set forth.
[0017] While U.S. Pat. No. 5,668,152 describes the treatment of cancer using PKC beta-1 and beta-2 selective inhibitors, of which the present compounds of formula (I) are included generically, there is no teaching or suggestion that the compounds of formula (I) are inhibitors of the PI3K/AKT pathway. Because the AKT pathway acts as a central regulator of the apoptotic response, inhibitors of this pathway would be expected to induce apoptosis and/or block cell cycle progression whereas inhibition of PKC, which has many disparate roles in the cell, would not necessarily be expected to do so.
[0018] As used herein, the term “patient” refers to a warm-blooded animal or mammal which is in need of treating, or at risk of developing, one or more diseases or disorders associated with AKT pathway activity (e.g. PDK-1/p70S6 kinase activity). It is understood that guinea pigs, dogs, cats, rats, mice, hamster, and primates, including humans, are examples of patients within the scope of the meaning of the term. Preferred patients include humans.
[0019] The compounds of the present invention can be administered alone or in the form of a pharmaceutical composition, that is, combined with pharmaceutically acceptable carriers, or excipients, the proportion and nature of which are determined by the solubility and chemical properties of the compound selected, the chosen route of administration, and standard pharmaceutical practice. The compounds of the present invention, while effective themselves, may be formulated and administered in the form of their pharmaceutically acceptable salts, for purposes of stability, convenience of crystallization, increased solubility, and the like.
[0020] Thus, the present invention provides pharmaceutical compositions comprising a compound of the Formula (I) and a pharmaceutically acceptable diluent.
[0021] The compounds of Formula (I) can be administered by a variety of routes. In effecting treatment of a patient afflicted with or at risk of developing the disorders described herein, a compound of Formula (I) can be administered in any form or mode that makes the compound bioavailable in an effective amount, including oral and parenteral routes. For example, compounds of Formula (I) can be administered orally, by inhalation, or by the subcutaneous, intramuscular, intravenous, transdermal, intranasal, rectal, occular, topical, sublingual, buccal, or other routes. Oral administration is generally preferred for treatment of the disorders described herein. However, oral administration is not the only preferred route. For example, the intravenous route may be preferred as a matter of convenience or to avoid potential complications related to oral administration. When the compound of Formula (I) is administered through the intravenous route, an intravenous bolus or slow infusion is preferred.
[0022] One skilled in the art of preparing formulations can readily select the proper form and mode of administration depending upon the particular characteristics of the compound selected, the disorder or condition to be treated, the stage of the disorder or condition, and other relevant circumstances. ( Remington's Pharmaceutical Sciences, 18th Edition, Mack Publishing Co. (1990)).
[0023] The pharmaceutical compositions are prepared in a manner well known in the pharmaceutical art. The carrier or excipient may be a solid, semi-solid, or liquid material that can serve as a vehicle or medium for the active ingredient. Suitable carriers or excipients are well known in the art. The pharmaceutical composition may be adapted for oral, inhalation, parenteral, or topical use and may be administered to the patient in the form of tablets, capsules, aerosols, inhalants, suppositories, solutions, suspensions, or the like.
[0024] For the purpose of oral therapeutic administration, the compounds may be incorporated with excipients and used in the form of tablets, troches, capsules, elixirs, suspensions, syrups, wafers, chewing gums and the like. These preparations should contain at least 4% of the compound of the present invention, the active ingredient, but may be varied depending upon the particular form and may conveniently be between 4% to about 70% of the weight of the unit. The amount of the compound present in compositions is such that a suitable dosage will be obtained. Preferred compositions and preparations according to the present invention may be determined by a person skilled in the art.
[0025] The tablets, pills, capsules, troches, and the like may also contain one or more of the following adjuvants: binders such as povidone, hydroxypropyl cellulose, microcrystalline cellulose, gum tragacanth or gelatin; excipients such as dicalcium phosphate, starch, or lactose; disintegrating agents such as alginic acid, Primogel, corn starch and the like; lubricants such as talc, hydrogenated vegetable oil, magnesium stearate or Sterotex; glidants such as colloidal silicon dioxide; and sweetening agents, such as sucrose, aspartame, or saccharin, or a flavoring agent, such as peppermint, methyl salicylate or orange flavoring, may be added. When the dosage unit form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier such as polyethylene glycol or a fatty oil. Other dosage unit forms may contain other various materials that modify the physical form of the dosage unit, for example, coatings. Thus, tablets or pills may be coated with sugar, shellac, or other coating agents. Syrups may contain, in addition to the present compounds, sucrose as a sweetening agent and certain preservatives, dyes and colorings and flavors. Materials used in preparing these various compositions should be pharmaceutically pure and non-toxic in the amounts used.
[0026] The compounds of Formula (I) are inhibitors of PDK1 and p70S6 kinase, two members of the PI3kinase/AKT pathway. The inhibitory activity of the compounds of Formula (I) may be demonstrated by the methods below.
[0000] Kinase Activity Assays
[0027] The assay described measures the phosphorylation of the PDK1 consensus phosphorylation site PDK-tide peptide (KTFCGTPEYLAPEVRREPRILSEEEQEMFRDFDYIADWC; cat # 14452, lot 23876U) by recombinant PDK-1 (UBI) at Km for ATP and PDKtide saturation using phosphocellulose membrane filter plates. Phosphorylation of the p70S6 kinase substrate by recombinant p70S6 kinase is also measured similarly.
[0000] Cell Culture, Drug Treatment, Apoptosis and Proliferation Assays
[0028] Both HCT116 colon carcinoma (cat#CCL-247) and U87MG glioblastoma (cat#HTB-14) cell lines were obtained from the American Type Culture Collection (ATCC). The standard growth media differed for each cell line but all were grown in 10% heat-inactivated FBS (Invitrogen cat# 10082-147), 37° C., 5% CO 2 atmosphere and in a humidified chamber. Cell passage was completed one to two times per week using 0.25% trypsin/1 mM EDTA (Invitrogen, cat# 25200-056) solution maintaining cells in log phase growth. U87MG cells were cultured in DMEM media (Invitrogen cat# 11965-092), 1 mM non-essential amino acids (NEAA), and 0.1 mM Sodium Pyruvate. HCT116 cells were grown in McCoy's 5A Modified media (Invitrogen, cat# 16600-082), 0.15% sodium bicarbonate, 0.1 mM HEPES, 25 mM D-glucose and 0.1 mM sodium Pyruvate.
[0029] Apoptosis assays were executed using the Cell Death Detection ELISAPIUS (Roche, 1774425) assay kit strictly following the enclosed protocol.
[0030] Changes in cellular proliferation resulting from treatment with LY317615, which is a compound of the formula
or a compound of formula (I) were R 1 is hydrogen and R 2 is methyl (Compound 1) were assessed by incorporation of propidium iodide (PI) (Sigma, cat# p-4864). Briefly, each cell culture plate was centrifuged 10 minutes (200 rpm), the supernatant was gently aspirated and 100 μl 0.125 mM PI in PBS was added to each well of a 96-well plate. The fluorescence intensity of each well in the culture was measured (non-viable cells) using the Vector 2 multi-channel plate reader (Wallac, model#1420) and frozen to −80° C. The plate was allowed to thaw, come to room temperature and re-analyzed for changes in fluorescence intensity (total cells) again using the Vector 2 . The proliferating cells in the culture, were determined by subtracting the non-viable fraction from the total cells. The results were then reported as a percent of the un-treated control.
[0031] Protein lysates were prepared by incubation in RIPA Buffer (50 mM Tris-HCl, 150 mM NaCl, 1 mM EDTA, 1% NP40, 0.25% Sodium deoxycholate, 1 mM sodium fluoride, 1 mM sodium orthovanadate and Complete™ protease inhibitors (Roche Cat# 10019600) for one hour with rotation. The lysate was then centrifuged (10 minutes@ 10,000 rpm), supernatant harvested and protein concentrations were determined using the Bio-Rad DC Protein Assay (cat# 500-0122). Proteins were separated by SDS-PAGE using 4-20% tris-glycine gels (Invitrogen, cat# EC6028) and transferred to Hyper™-bond PVDF membrane (Amersham, cart# rpn303F). All primary antibodies were incubated overnight at 4° C. in 5% milk/1×PBS (Gibco, cat# 70011-044) solution. Horseradish peroxidase (HRP) linked secondary antibodies (Santa Cruz, cat# sc-2055, sc-2054) were incubated for a minimum of two hours prior to detection. Specific signal was determined by the Lumi-Imager™ and Lumi-Analyst software to define changes in protein expression and phosphorylation. The primary antibodies used are as follows: GSK3b, pGSK3b ser9 (Cell Signaling, cat#9332, 9336), S6 ribosomal protein, pS6 ribosomal protein ser 240/244 (Cell Signaling, cat#2212, 2215), AKT (Transduction Labs cat#610861), pAKT ser308 , PAKT ser473 (Cell Signaling, cat#9275, 9271), PHASi (Zymed, cat#51-2900), p4EBP1 ser65 (Cell Signaling cat#9451), p70S6 kinase, phos-p70S6 kinase thr421/ser 424 (Cell Signaling cat#9202, 9204), p90RSK, phos-p90RSK thr359/ser363 (Cell Signaling cat#9347, 9344), FKHRL1, pFKHRL thr32 (Upstate Biochemicals, Inc. cat#06-951, 06952).
[0000] Experimental Protocol for In Vivo Tumor Inhibition Studies
[0032] Approximately 5×10 6 tumor cells are implanted subcutaneously into the flank of athymic nude mice (Harlan, Indianapolis, Ind.). Treatment of tumors begins when the tumors reach 100 mm 3 and continues for 21 consecutive days twice per day PO. Body weight and tumor size are monitored weekly or twice weekly.
[0000] Results
[0033] Compound 1 inhibits PDK-1 with an EC50 of 370 nM and inhibits p70S6kinase with an EC50<500 nM. Treatment with Compound 1 induces apoptosis in human cancer cell lines derived from colon, lung, and prostate (both androgen-dependent and independent cell lines) as well as from non-Hodgkin's lymphoma. Treatment with Compound 1 suppresses phosphorylation of GSK3β, the forkhead transcription factor AFX, 4EBP1, and ribosomal protein S6—all readouts of AKT pathway activity. Furthermore, treatment of human tumor xenograft-bearing mice with Compound 1 suppresses GSK3β ser9 phosphorylation in these xenograft tissues, including an androgen-independent prostate carcinoma cell line, for up to 8 hours post dosing. Anti-tumor efficacy of the compound has been demonstrated in both HCT116 colon cancer xenografts, in U87MG glioblastoma xenografts and in xenografts from the androgen-independent prostate carcinoma cell line PC3. | The present invention provides a method of treating prostate cancer comprising administering to a patient in need thereof a therapeutically effective amount of a compound of the formula (I)
wherein R 1 and R 2 are each independently hydrogen or C 1 -C 4 alkyl; or a pharmaceutically acceptable salt thereof.
In a second embodiment, the invention provides a method of treating androgen-independent prostatic adenocarcinoma comprising administering to a patient in need thereof a therapeutically effective amount of compound of formula (I) or a pharmaceutically acceptable salt thereof. In a third embodiment, the invention provides a method of treating an AKT-mediated disease selected from the group consisting of glioblastoma, colon cancer, pancreatic cancer, ovarian cancer, endometrial cancer, and renal cell cancer, comprising administering to a patient in need thereof a therapeutically effective amount of compound of formula (I) or a pharmaceutically acceptable salt thereof. | 0 |
TECHNICAL SECTOR
The present invention is related with the field of immunology and human medicine particularly with the generation and selection of a monoclonal antibody (Mab) against the N-glycolylated-galactose-glucose sialic acid olygosaccharide sequence that can be used for the diagnosis and treatment of certain neoplasic diseases.
PRIOR ART
The olygosaccharide structures can be found forming part of glycoproteins and glycolipids. They are both present in normal and pathological tissues.
The aberrant glycosilation has been described in approximately 100% of the malignant neoplasm. Frequent changes in the aberrant glycosilation are: the expression of neoantigens, variations in the composition of the olygosaccharide sequences, increase or decrease of the sialic acid molecules in the olygosaccharides and increase in the density of the molecules in the cell surface, among others (Hakomori S. H. et al. Curr. Opin. in Immunol. 1991,(3) 646-653). In addition to the changes that can be found in the mechanism of the sialyl-tranferases, there are also variations in the activated sialic acid N-acetylated dependent hydroxilases.
Gangliosides are glycoesfingolipids that contain sialic acid in their structure and are characterized by being present in most cells of the vertebrates. These molecules are found in normal tissue and can have a higher expression in the tumors, with a different organization and conformation in the surface of malignant cells (Hakomori, S H., 1985, Cancer Res. 45: 2405-2414; Miraldi, F., 1989, Seminars in Nuclear Medicine, XIX,282-294).
The humoral immune response against carbohydrate antigens is generally of the IgM isotype. The olygosaccharide sequences bound to lipids are generally less immunogenic than the glycoproteins. Thus, the use of glycolipids as immunogen requires of its binding to transporting proteins or their incorporation to liposomes or to bacteria such as Micobacterium tuberculosis or R595 de Salmonella minnesota.
The response generated against Gangliosides is thymus independent. This has been reported repeatedly by Livingston, et al., (Livingston, P. O. et al., 1982, Proc. Natl. Acad. Sci. USA 84: 2911-2915; Livingston, P. O. et al. 1989, Cancer Res. 49: 7045-7050). The main characteristics of the antibodies generated against Gangliosides when studied in the serum of different species are their low affinity, considerable cross reactivity and short life (Livingston, P.O. 1991, Immunology and Allergy Clinics of North America, 11: 401-423; Portoukalian, J. et al, 1991, Int. J. Cancer, 49: 893-899).
The expression of the N-glycolylated form in the olygosaccharides is common in normal and pathological tissues of all the species of vertebrates, except for chickens and humans in which it is only found in fetal and tumoral tissue. The normal tissues of these two last species posses only the N-acetylated variant (Nishimakit et al. 1979, J. Immunology, 122: 2314; Higashi H. et al, 1985, Cancer Res., 45: 3796).
The study of the olygosaccharide composition in some human tumors demonstrate the presence of the N-glycolylated form both in glycolipids and glycoproteins of melanoma tumoral cells (Hirabayashi, Y, et al. 1987, J. Cancer Res., 78, 614 -620; Saida T. et al. 1991 Arch. Dermatol. Res. 282(3): 179-182; Kawashima I. et al. 1993, J. Biochem (Tokio) (2) 186-193; Kawachi S. et al., 1992, J. Dermatol (11): 827-830), as well as in colon tumors, especially in glycolipids (Miyoshi, I., et al, 1986, Mol. Immunol. 23 (6): 631; Higashi H., et al, 1985, Cancer Research, 45: 3796-3802). Additionally, studies have been performed to demonstrate the presence of the N-glycolylated form of the Gangliosides in tumoral samples of liver, teratoma, lymphoma, etc, (Kawai T. et al. 1991 Cancer. Res. (51) 1242-1246). Although in the former cases the concentration of the N-glycolylated variant of glycolipids was less than 0,05% of the total sialic acid, Marquina and collaborators found in breast tumors values of approximately 10% of the sialic acid bound to lipid (Marquina, G. et al, 1996, Cancer Res. 56: 5165-).
The generation of monoclonal antibodies against the N-glycolylated variant of the gangliosides has provided until now, antibodies of the IgM isotype that generally recognize more than one gangliosides molecule, for example, the human monoclonal antibodies 2-39 M and 32-27 M (Furukawa K., et al, 1988, J. Biological Chemistry, 263: 18507) and the murine antibodies GMR8 and GMR3 (Ozawa H. et al, 1992, Biochem. Biophys., 2(294):427). Other authors have reported the generation of a specific species of anti N-glycolylated gangliosides antibodies, always of IgM isotype, among which are the monoclonal antibodies Y-2-HD1, against NGcGM 2 (Samai Y. et al, 1988, Bioch Biophys. Act., 958, 368) and MK2-34 against the same molecule (Miyake, M. et al, 1990, Cancer Res. 48, 6154).
Nevertheless, Watarai (Watarai, S. et al. 1995. J. Biochem. 117, 1062) generated the monoclonal antibody SHS-1 against the i-active N-glycolylated gangliosides and Nakumara obtained the monoclonal antibody YK-3 against the (NGc-NGc) GD1c (Nakumara et al, 1995, J. of Biolog. Chemist., 8 (270):3876). Recently Vázquez, et al., (Vázquez, A. M. et al, 1995, Hybridoma, 14, 6, 551) reported the generation of the monoclonal antibody P3, that recognizes most Ganglioside molecules containing the N-glycolylated form of the sialic acid, as well as the sulfated glycolipids.
Nagai et al., have generated the HMA1 monoclonal antibody against Gangliosides (Nagai Y. et al. U.S. Pat. No. 4,965,198). They obtained a specific monoclonal antibody against the Ganglioside NGcGM2 from mice bearing an autoimmune disease. Although, they reported several of these antibodies that additionally recognized other N-glycolylated Gangliosides designated as PyK, YH02, YH03, YH04, YH05, YH06 y YH07.
Moreover, Yamasaki, M. et al., in their U.S. Pat. No. 4,942,131 report the generation of the Mabs YH08, YH09, YH10 e YH11 against the 4-O-Acetyl-NGcGM3 Ganglioside, also in mice with an autoimmune disease.
Monoclonal antibodies against Gangliosides have also been obtained using these molecules as lactones or from cell lines containing Gangliosides (U.S. Pat. Nos. 5,308,614; 5,240,833; 5,389,530 y 5,500,215).
In the same manner, different monoclonal antibodies, both murine and human, have been obtained against GD3, GD2 y GM2 gangliosides, all of the N-acetylated form and most of them of the IgM and IgG3 subclasses (Pukel, C. S. et al. 1982, J. Exp. Med., 115: 1133-1147; Hirabayashi, Y. et al. 1985, J. Biol. Chem., 260: 13328-13333; Patent application WO 86/00909; Miyake, M. et al. 1988, Cancer Res., 48: 6154-6160; Kawashima, I. et al. 1992 , Molecular Immunology, 29, 625-632; Kotani, M. et al. 1992, Biochimica et Biophysica Acta, 1117: 97-103).
The passive immunotherapy with monoclonal antibodies against gangliosides has been used in clinical trials for the treatment of some tumors such as melanomas and neuroblastomas. Treatment of melanomas have been intra lesion or systemic and although results seem to be encouraging, only a reduced number of patients showed total or partial remissions (Houghton, A. N. et al, 1985, Proc. Natl.Acad. Sci. USA, 82: 1242; Dippold, W. G. et al, 1988, J Cancer Clin. Oncol., 24: 865; Vadhan-Raj, S. et al. 1988, J. Clin. Oncol., 6: 1636; Saleh M. N. et al. 1992, Cancer Res., 52: 4332-4347).
These antibodies showed effect in complement or cell mediated cytotoxicity studies (Ravindramath M. H. et al. 1991, Inter. Rev. Immunol., 7, 303).
Up to now, all the monoclonal antibodies obtained against N-glycolylated gangliosides are of the IgM isotype and the toxicity they provoke is mediated by complement.
IgM's generally have low antigen affinity and it is difficult to use them for diagnosis or treatment as radiolabeled Mabs. Although they fix complement well and guarantee a good cytotoxicity, the possibility of large-scale purification is much more complicated than with the IgG isotype.
Moreover, little has been reported on monoclonal antibodies against N-glycolylated glycoproteins, and most of them for diagnostic purposes.
Devine et al., described the 3E1.2 monoclonal antibody which recognizes an N-glycolylated mucin (glycoproteic) expressed in 90% of breast tumors studied by immunohistochemistry (Devine, P. L., et al. 1991, Cancer Res. 51(21): 5826-36).
It has also been published a monoclonal antibody designated JAM3, that recognizes the N-acetylated and N-glycolylated forms of a 250 kD protein present on the surface of the cysts produced by the attack of Entamoeba (Avron, B., et al. 1987, Mol Biochem Parasitol. (3): 257-266).
DISCLOSURE OF THE INVENTION
The novelty of the present invention consists in having obtained a monoclonal antibody highly specific for the N-glycolylated-galactose-glucose sialic acid olygosaccharide sequence, present in both, gangliosides and glycoproteins. Additionally the characteristic of being an IgG isotype immunoglobulin makes it more specific and thus of higher affinity for the molecules it recognizes, favoring its biological activity. Unexpectedly this antibody showed the capacity to provoke cellular death directly in the cells bearing said olygosaccharide sequence.
DETAILED DESCRIPTION OF THE INVENTION
Obtention of the NGcGM3 Ganglioside
For obtaining the NGcGM3 ganglioside a modification of Hakomori's technique is used. (Hakomori, S. et al. 1974, Methods in Enzymology, 32:, Part B, 350), using natural sources such as horse erythrocytes. The yield of NGcGM3 Ganglioside extraction was between 180 and 300 mg per liter of horse erythrocytes with a purity above 90% corroborated by high efficiency liquid chromatography according to, Gazzotti's method (Gazzotti, G. et al. 1985, J. of Chromatography, 348: 371-378).
Obtention of the Immunogen
To obtain the immunogen the NGcGM3 Ganglioside is hydrophobically bound to the human lipoproteins of very low density (VLDL) obtained according to Dumontet et al., (Dumontet, C. et al. 1994. Cancer Immunol Immunother. 38: 311-318.
Immunization Scheme
To obtain anti ganglioside IgG Mabs the following immunization method is used. Mice or other mammalian species were immunized with vaccine preparations containing between 0.03 and 0.5 mg of the NGcGM3 Ganglioside bound to VLDL per dose and an adjuvant selected from one of the following: albumin, complete or incomplete Freund's adjuvant or Montanide ISA 51.
Before and after the immunization period, blood samples are taken from the animals to obtain serum for monitoring the antibodies generated in the animals against the Ganglioside used as antigen. Any of the known immunoassay methods for detecting the antigen-antibody (Ag-Ab) reaction is used for this purpose.
The animals are immunized with various doses, between 2 and 8 at time intervals varying between 7 and 14 days. The administration is performed by subcutaneous or intramuscular route with volumes between 0.1 and 0.2 mL. Other possible immunization routes are intravenous and intraperitoneal. The animals receiving this dose range show a specific response against the Ganglioside used as immunogen. Between 70 and 100% of the immunized animals had a specific IgG response to the NGcGM3 ganglioside.
Achievement of the Monoclonal Antibodies
For the production of specific Mabs against the NGcGM3 ganglioside the mice with antibody titers in serum against this ganglioside received a new immunization with the vaccine preparation 3 days before the antibody producing cells are obtained. Spleen cells should be preferred although other cells can also be used.
These cells are fused with myeloma cells, which provide the hybrid cells or hybridomas with the capacity to expand indefinitely “in vivo” and “in vitro”. For this purpose any of the known cell fusion methods can be used. To determine the antibodies produced by the hybridomas an immunoenzymatic assay is preferentially used. Other immunoassay methods can also be used. The procedure of this assay is the recognition by hybridoma supernatans of the gangliosides, and the antigen-antibody reaction can be visualized using a second antibody labeled with an enzyme which binds to the antibody produced by the hybridoma under adequate conditions and is at the same time detected.
The hybridoma once selected is cloned at least 2 times (for example, by limiting dilution). The Mab obtained can be produced “in vitro” in an adequate culture media, such as any of the ones described in the state of the art and afterwards purified from said tissue culture supernatant. In this case, between 1 and 8% of the secreting clones were specific against the N-glycolyl Gm3 Ganglioside.
Another antibodies production method, consists in the injection of the hybridoma in animals (for example, syngenic animals). The hybridoma provokes the formation of non-solid tumors that provide a large concentration of the desired antibody in the blood stream and in the peritoneal exudate of the host animal.
Purification of the Monoclonal Antibody
The purification of the monoclonal antibodies is performed from the ascitic fluid obtained by the inoculation of 0.2×10 6 cells of the monoclonal antibody producing hybridoma in the peritoneal cavity of Balb/C mice, previously treated with incomplete Freund adjuvant as ascitogenic agent.
The ascitic fluid is diluted to one half in glycine buffer 1.5 M, NaCl, 3M, pH 8.9 and applied to a protein A-Sepharose matrix at a flow rate of 60 mL/h. The Mab elution is performed using citrate buffer 0.14 M, pH 6.
The concentration of the purified Mabs is estimated by the Lowry method (Lowry, G. H., 1951, J. Biol. Chem., 193: 256) and using the absorption coefficient of the murine IgGl at 280 nm. The specificity is confirmed by ELISA.
Between 2 and 5 mg of antibody per mL of ascitis were obtained, with purity per cent above 95%. This was corroborated by low-pressure liquid chromatography.
Specificity Studies
To determine the specificity of the monoclonal antibodies obtained, immunoenzymatic studies of the Mabs produced are performed in ELISA plates and in thin layer chromatography using the N-acetylated (GM1, GM2, GM3, GM1, GD1a, GD1b, GD3 and GT1b) and N-glycolylated (GM3, GM2, GM1a, GM1b, GD1c y GD3) Gangliosides.
To run the glycolipids in the high-resolution thin layer chromatography the solvent system is used (Chloroform:Methanol:KC1 0.25% and 2.5 M NH 3 ) (5:4:1) (v:v). Chemical developing with Orcinol performs the visualization of the bands.
The plates are plastic coated with a poliisobutilmethacrilate solution and are air dried at room temperature over night. Blocking is performed during approximately 30 minutes with a 1% bovine serum albumin solution dissolved in saline phosphate buffer (PBS), pH 74. Afterwards, the monoclonal antibodies are incubated in the blocking solution.
Next the plates are washed with PBS and the peroxidase conjugated anti mouse immunoglobulin is added during one hour. Plates are again washed and the enzyme substrate solution is added until the bands are visualized. Finally the chemical and immunological development are compared. As a result the IgG recognized only the NGcGM3 ganglioside.
Cytotoxicity Determination
To determine if the antibodies generated produce cell death directly or by some of the other cytotoxic forms, 10 7 cell/mL of the P3X63 murine myeloma containing NGcGM3 is incubated at 4° C. and 37° C. respectively with the monoclonal antibody between 0.01 and 1 mg/mL during 30 minutes. Then the Tripan blue method is used for performing the viability studies. The number of dead cells as consequence of the antibody effect can be counted using propidium iodine or any other viability marker.
To study the complement mediated cytotoxicity 10 7 cells per mL were used; monoclonal antibodies are added at concentrations between 0.01 and 0.5 mg/mL. Rabbit serum that has high concentrations of the complement proteins, is added at dilutions from {fraction (1/20)} to ½ and incubated during 1 hour at 37° C. Complement mediated cytotoxicity was determined by viability counts as described above or using the Cr 51 liberation method in which the P3X63 radiolabeled myeloma cells, liberate to the culture supernatant the isotope when they die.
The direct cytotoxicity was measured using different methods that showed values between 50 and 85% of dead cells with respect to the total number of cells studied.
Monoclonal Antibody Biodistribution Determination
The Mabs generated can be used both for diagnosis and treatment, labeled with a radioisotope such as 99mTc, Re186 and Re188. Schwarz and Steinstrasser (Schwarz A., and Steinstrasser, A. 1987, J. Nucl Med. 28: 721) have described the method of labeling monoclonal antibodies with radioisotopes which was modified by Mather y Ellison (Mather S. J. and Ellison D., 1990, J. Nucl. Med. 31: 692-697). Labeling quality control is performed by chromatography in Whatman 3MM paper. The per cent of labeling obtained was 98 and 100%.
To determine the possible use of the Mab, 10 mice were inoculated with the P3X63 tumor and another 10 mice were used as normal controls (no tumor was inoculated). The time needed for tumor to grow was waited and then the 99mTc-labeled 14F7 Mab was injected by intravenous route to the 20 mice.
Monitoring of the biodistribution of the anti- olygosaccharide sequence Mab is performed in groups of 5 animals (5 healthy and 5 with tumor) 4 and 24 hours post injection. The animals are sacrificed and the main organs and tumor are weighed and the gamma emission quantified separately at the end of the study.
The monoclonal antibodies distributed in the healthy animals mainly in the blood, liver and kidney while in the animals with tumor the Mab was localized in the former organs and preferentially in the tumor at 24 hours.
Mab's Recognition of Normal and Fetal Tissues
Radiolabeled Mabs, as described in the state of the art, can be used to detect tumors where the olygosaccharide sequence is expressed.
Whole body radioactivity can be studied with a Gamma Camera. Images acquisition is performed at 5 minutes and 1, 3, 5, 24 and 48 hours after Mab injection. Mab is localized only in the tumor and in the excretion organs.
Mabs can also be bound directly or indirectly to other therapeutic agents such as drugs, radioisotopes, immunomodulators, lectins and toxins. Among the biological response modifiers (immunomodulators) that in some way can increase the destruction of the tumor by the Mab of this invention are included lymphokines such as: Tumor Necrosis Factor, Macrophage Activator Factor, Colony Stimulating Factor, Interferons, etc.
Immunohistochemical studies were performed for diagnostic purposes. Tissue sections were fixed in 10% buffered formaline solution and dehydrated, clarified and embedded in paraffin. Histopathology was studied in Hematoxilin-Eosin stained tissue sections.
Serial sections from the paraffin blocks used for the histopathological study were immunostained by the biotin streptavidin peroxidase complex method, previously described (Hsu, S. M. y Raine, L., 1981,. J. Histochem Cytochem. 29: 1349-1353).
The deparaffinized and dehydrated sections were treated with 3% hydrogen peroxide methanol solution during 30 minutes to eliminate endogenous peroxidase activity. Tissue sections were incubated with the purified Mabs. Followed by biotinilated anti mouse antibodies and streptavidin peroxidase complex (Dakopatts) at room temperature.
Between incubations sections were washed with Tris-HCl saline buffered solution. The peroxidase reaction was developed with 30% H 2 O 2 and 3-3 diaminobencidine.
Slides were washed with tap water, stained with Mayer's Hematoxilin, mounted with balsam and coverslipped. The reaction with the enzyme produces a brown-red color.
Human breast, lung, skin and nervous system tumoral tissues were studied as well as, fetal and normal adult tissues.
Fresh biopsies of pathological tissues were obtained during the first hour after surgery. The biopsy fragments were frozen, later sectioned and the slides stored frozen until the study was performed.
The use of fetal tissues for the study is due to the fact that the association of Gangliosides with oncofetal antigens has been repeatedly reported as well as the similarity of these molecules in fetal and tumoral human (Cahan, L. et al. 1982 Proc. Natl. Acad. Sci. USA., 79:7629-7633).
The fetal tissue sections were obtained from fetus between 12 and 18 weeks old.
Adult normal tissue fragments were obtained from individuals deceased in accidents and/or encephalic death during the first hour after exitus letalis.
Among the tumors studied, lung and central nervous system tumors of different ethiology resulted negative as well as the sections of normal human tissues. While melanoma and breast tumor tissue sections were all positive as well as the fetal tissue sections of the digestive system (liver, stomach, small and large intestine) and the renal system.
Antitumoral Effect
To demonstrate the anti tumoral effect of the monoclonal antibodies against the NGcGM3 Gangliosides, animals inoculated with the tumor bearing the target Ganglioside (P3X63 myeloma) was treated with the antibodies obtained. The dose can vary from 0.01 mg/kg of weight to 200 mg/kg of weight in one or more daily administrations during one or various days. The antibodies can be administered by parentheral injection (intravenous, intraperitoneal, intramuscular, subcutaneus, intracavity or transdermic).
In a typical experiment the mice treated with the antibody have a survival rate between 30 and 80% compared to with the mice of the control group, corroborated by the Log Ram test (Cox and Oakes (1984) Analysis of survival Data edits. Chapman Hall). Significant differences (<0.05%) were found between the group treated with the Mab and the control group.
EXAMPLES
Example 1
Specific IgG Response to NGcGM3, of the Mice Immunized with the Vaccine Preparation NGcGm3/VLDL/Adyuvant Freund Complex, Measured by an Immunoenzymatic Technique
Female Balb/C mice between 6-8 weeks old were injected by intramuscular route with 0.2 mg of the vaccine preparation human NGcGM3/VLDL, with the complete Freund adjuvant in the first dose and incomplete Freund adjuvant in the following doses (produced by SIGMA) mixed in equal volumes. Each animal received 6 dose. The first 4 dose weekly and the 2 remaining dose every 14 days. Blood extractions were performed previous to the first dose and every 2 weeks.
The antibody levels were measured in the serum of the animals using an indirect ELISA in Polysorp plates (Nunc trade mark), on which the Gangliosides were immobilized following the method described below:
Gangliosides NAcGM3 and NGcGM3 were dissolved separately in methanol (4 μg/ml) and 50 μl/well were added. The plate was placed at 37° C. during one hour and a half to evaporate the methanol. Afterwards, 100 ml/well of TRIS-HCl 0.05 M, pH 7.8 buffer, containing 2% bovine serum albumin (BSA) was added and incubated during one hour at room temperature. Next, 50 μl of the serum were diluted in the same buffer and incubated over nigh at room temperature.
The wells were washed 4 times with 200 μl phosphate saline buffer solution (PBS) and 50 μl of a biotin conjugated anti mouse immunoglobulins antiserum was added at an adequate dilution during one and a half hour 37° C.
After washing again with PBS, 50 μl of an adequate dilution of alkaline phosphatase streptavidin was added. Finally the last washing was performed and 100 μl p-nitrophenylphosphate substrate was dissolved in dietanolamine buffer, pH 9.8 (1 mg/ml). Absorbance was measured in an ELISA reader at 405 nm.
FIG. 1 shows the results of O.D. at 405 nm of each animal's serum diluted {fraction (1/80)} on the day 56 of the experiment. The response against NGcGM3 and GM3 was determined by ELISA using a biotinilated mouse anti IgG conjugate and alkaline phosphatase streptavidin from Jackson.
More than 70% of the animals immunized with the vaccine preparation had values at O.D. 405 nm over 0.5 against NGcGM3. All the immunized animals showed IgG response against NGcGM3, with no response observed to NAcGM3, in spite of the minimal difference between these two molecules.
FIG. 2 shows the sustained specific response of the antibodies (IgG isotype) against the NGcGM3 Ganglioside, three months after receiving the last immunization dose, with no response shown against NAcGM3.
Example 2
Achievement of Monoclonal Antibodies Against NGcGM3
The antibodies were generated by immunizing Balb/C mice using the procedure described in Example 1.
Three days before the fusion, the animals were re-immunized with the immunogen NGcGM3/VLDL, using Freund complete adjuvant. Afterwards mice spleen were obtained and a cell suspension prepared by passing the tissue through a stainless steel sieve or by spleen perfusion. Cell fusion was performed as described by Köhler y Milstein (Nature, 1975, No. 256, 495-497) with some modifications.
The cells of the non secreting P3/X63 Ag8 6.5.3, murine myeloma were fused with the murine splenocytes in a proportion 1:10, in 0.5 mL of fusion media containing 42% of poliethilenglycol (3000-3600 Sigma)in RPMI 1640 media.
The cells were cultured in HAT (hipoxantine/aminopterine/tymidine) selective media at 37° C., with a humid atmosphere of 5% CO 2 , after cell fusion.
Between 10 and 15 days after the cell fusion was performed the assay for detecting the presence of antibodies in the supernatant of the hybridoma cell cultures was started using the ELISA technique of example 1.
Culture hybridoma cells that reacted with the ganglioside of interest were selected and cloned twice by the limiting dilution method in the presence of conditioning cells.
The specificity of the antibodies produced by the selected hybridomas was determined using the indirect ELISA technique with a battery of glycolipids.
The number of specific clones against the NGcGm3 Ganglioside was 5.5%. One of the clones obtained was denominated 14F7.
Example 3
Determination of the Subclass of the 14F7 Monoclonal Antibody
To determine the immunoglobulin subclass of the monoclonal antibody of this invention an indirect ELISA on plates coated with NGcGm3 was used as described in example 1, but substituting the serum for dilutions of the supernatant of the hybridoma or of the purified Mab.
Biotin conjugated Anti IgG1, IgG2a, IgG2b e IgG3 murine Mabs produced in rats (Pharmingen), diluted in incubation buffer were added. After one hour incubation at 37° C. the plates were washed and alkaline phosphatase conjugated streptavidin diluted in the incubation buffer was added. As controls of each subclass murine Mabs previously characterized were used.
Finally the substrate solution was added. Reading of the absorbance was performed as described before. FIG. 3 shows that the 14F7 Mab belongs to the IgG1 subclass.
Example 4
Specificity Study of the 14F7 Monoclonal Antibody Using Immunostaining on High Resolution Thin Layer Chromatography
The high-resolution thin layer chromatography was used to separate the glycolipids. The solvent system sued was Chloroform:Methanol:KCL 0.25% and 2.5 M of NH3 (5:4:1) v:v. The bands were visualized by chemical development with Orcinol (Svennerholm L. 1964, J. Lipid. Res., 5, 145). While for the immunostaining the method Kawashima Y. y col. 1993 (J. Biochem, 114, 186) was used.
The plates where the thin layer chromatographies were previously performed were plastic coated by immersion during 75 seconds in a solution of 0.1% poliisobutilmethacrilate (PIBM) in N-hexane. The plates are then dried at room temperature during 30 minutes. 1% PIBM solution is the applied on the borders of the plates keeping them over night at room temperature.
Blocking of unspecific interactions was performed by applying for 30 minutes a solution of 1% bovine serum albumin dissolved in PBS pH between 7.2 and 7.4. Immediately after plates were incubated with the 14F7 Mab at a concentration between 0.01 y 0.02 mg/ml in blocking solution.
Plates were washed PBS and incubated with horseradish peroxidase conjugated rabbit anti mouse immunoglobulins antiserum diluted in the blocking buffer.
After one hour incubation stirring at room temperature the plates were washed again and the substrate solution consisting of 0,4 mg/mL of ortophenylendiamine (C6H8N2) Sigma in citrate-phosphate 80 mM pH 5 buffer with 0,12% Hydrogen Peroxide (H2O2) (Riedel de Haen) was added. The reaction was stopped with repeated washes with phosphate buffer.
The reaction showed specificity only for the NGcGm3 Ganglioside and no reaction was observed for the other N-glycolylated gangliosides evaluated as GM1a, GM1b, GM2 and N-Acetylated (FIGS. 4 and 5 ).
Example 5
Recognition of Tumoral and Fetal Tissues by 14F7 Monoclonal Antibody
Tissue sections were fixed in 10% buffered formaline solution and dehydrated, clarified and embedded in paraffin. Histopathology was studied in Hematoxilin-Eosin stained tissue sections.
Serial sections from the paraffin blocks used for the histopathological study were immunostained by the biotin streptavidin peroxidase complex method, previously described (Hsu, S. M. y Raine, L., 1981 ,. J. Histochem Cytochem. 29: 1349-1353).
The deparaffinized and dehydrated sections were treated with 3% hydrogen peroxide methanol solution during 30 minutes to eliminate endogenous peroxidase activity. Tissue sections were incubated with the purified 14F7 Mab during one hour at room temperature. Followed by biotinilated anti mouse antibodies and streptavidin peroxidase complex (Dakopatts) at room temperature.
Between incubations sections were washed with Tris-HCl saline buffered solution. The peroxidase reaction was developed with 5 mL of a Tris buffered solution. 0.005 mL of 30% H 2 O 2 and 3 mg of 3—3 diaminobencidine.
Slides were washed with tap water, stained with Mayer's Hematoxilin, mounted with balsam and coverslipped. The reaction with the enzyme produces a brown-red color.
Adult normal tissue fragments were obtained from individuals deceased in accidents and/or encephalic death during the first hour after “exitus letalis”. Fresh biopsies of pathological tissues were obtained during the first hour after surgery. The fetal tissue sections were obtained from fetus between 12 and 18 weeks old during the first hour after induced abortion. All the biopsy fragments were washed in saline solution and immediately frozen in liquid nitrogen and stored frozen at −80° C.
Serial sections of 5 μm were obtained from the frozen fragments in a Leica cryostat at −25° C. Sections were air dried and used immediately or stored at −20° C. wrapped in aluminum foil. In an case slides were fixed at the moment of use in 4% paraformaldehyde during 20 minutes.
FIG. 6 shows the immunohistochemical study of the 14F7 Mab in normal human tissues. Reactivity of the Mab in the membrane and in the cytoplasmic region of the tissues is not observed.
FIG. 7 shows the same study for pathological tissues. All breast (33/33) and melanoma (20/20) tissues studied resulted positive. While, 70 lung tumors of different etiology resulted negative as well as 33 different tumors of the central nervous system.
FIG. 8 shows the recognition of 14F7 Mab of the digestive system and renal fetal tissues.
Example 6
Recognition of the Ganglioside NGcGm3 by the 14F7 Mab in Cell Lines Studied by Flow Cytometry
The cell lines studied were the murine myeloma P3X63 expressing the Gm3 and NGcGm3 described by J. Muthing et al (Muthing,J. et al.,1994, J. Biochem 116: 64-73) and the B16 myeloma that expresses Gm3. The cells were cultured in RPMI media with 8% bovine fetal serum. Cells were adjusted to a concentration of 10 7 cells/mL of a saline phosphate solution pH 7,4 containing 0.02% sodium azide and 1% bovine serum albumin. In each tube 0,1 mL of the cell suspension was added followed by 0.05 mL of the 14F7 Mab solution dissolved in saline phosphate buffer to obtain a final concentration of 0,1 mg/mL and incubated during 30 minutes at 4° C. The cells were then washed with the solution in which they were dissolved.
Next the cell cultures were centrifuged during 5 minutes at low speed to precipitate the cells. Then the anti mouse (IgG+IgM) biotin conjugate (Jackson) was added and washed after 30 minutes incubation at 4° C. Finally 0.002 mg of the fluorescein streptavidin (FITC) (Jackson) were added and incubated in the same conditions as before. The last washed was then performed this time with saline phosphate buffer.
Supernatant was eliminated after the last centrifugation and the cells were resuspended in 0,6 mL of the last washing solution.
An 80% of the cells of the P3X63 myeloma cell were stained positive with the 14F7 monoclonal antibody (FIG. 9 ).
Example 7
Direct Cytotoxity Study of the 14F7 Monoclonal Antibody
The P3X63 murine myeloma cell line was incubated with the 14F7 Mab as described in Example 6. washing, 0,01 mL of a propidium iodine solution in saline phosphate buffer was added to the cells to determine the cell viability using flow cytometry.
Results showed that 78% of the cells died (FIG. 10 ).
Example 8
Biodistribution Study of the 99mTcs Labeled 14F7 Monoclonal Antibody in Balb/c Mice, Healthy and Bearing P3X63 Myeloma Tumors
Twenty female Balb/C mice weighing between 20 and 22 g (10 healthy and 10 with P3X63 Myeloma tumor inoculated by intraperitoneal route) received an intravenous injection of the 99mTc labeled 14F7 Mab. The label concentration relation was 0,03 mg of the 14F7 Mab/60 μCi of 99mTc.
The results of radioactivity quantification in the different organs were performed in 5 animals of each group, at 4 and 24 hours after the injection. The animals were sacrificed and the weight of each organ measured in a Sartorius scale. The radioactivity of all the tubes at once was determined approximately 25 hours after starting the experiment, in a WALLAC gamma counter (model WIZARD 1470).
The labeling method was previously described by Schwarz and Steinstrasser (1987) and modified by Muther and Ellison in 1990.
The 14F7 labeled Mab was eliminated in the healthy mice by the kidney and liver (FIG. 11 ).
In mice bearing the P3X63 Myeloma tumor binding of the 14F7 Mab was shown at 4 hours (12% of the total injected radioactivity per gram of tissue) and at 24 hours (35% of the total injected radioactivity per gram of tissue). Mab elimination was mainly by the kidneys (FIG. 12 ).
Example 9
Antitumoral Effect of the 14F7 Monoclonal Antibody in BALB/C Mice Bearing the P3X63 Ascitic Myeloma
Balb/C female mice weighing 20-22 g, were injected by intravenous route with 6 doses of the 14F7 monoclonal antibody (one group with 0,1 and a second group with 0,2 mg) every 2 days, in saline phosphate buffer solution. Three days before the experiment, the peritoneal cavity was irritated with incomplete Freund adjuvant to favor the moment in which the tumor becomes measurable. The amount of 10 000 cells of the murine P3X63 Myeloma, were inoculated on day 0 of the experiment by the intraperitoneal route, at the same time as the passive therapy with the 14F7 monoclonal antibody began, although it was inoculated by intravenous route. While the control of good prognosis (best treatment) used for comparison was a third group treated by intravenous route with Cyclophosphamide (Shangai Hua Lian Pharmaceutical Corp.) at a dose of 20 mg/kg of corporal weight, consisting of a weekly dose during all the experiment. The intravenous treatment with saline phosphate buffer solution, pH 7,4 was used as a control of the experiment.
FIG. 13 shows the survival results in the 4 groups previously described. In the groups treated with 14F7 (0,1 and 0,2 mg) and with 20 mg/kg of weight of Cyclophosphamide no measurable tumor was observed in some animals.
The survival results favored the groups treated with the 14F7 Mab. On day 30 of the experiment, while no animal of the control group was alive, 6 animals were still alive, both of the first group (0,1 mg of the Mab) as of the group treated with Cyclophosphamide and 7 animals of the second group (0,2 mg of the Mab). At 60 days of treatment, 2 animals of the first group and 2 animals of the group treated with Cyclophosphamide survived, while from the second group 5 animals were still alive.
Example 10
Inhibition of the Tumoral Growth of the Solid P3X63 Myeloma in Athymic Mice
Ten athymic female mice, from the out bread NMRI, with a weight between 20 and 22 grams were inoculated by subcutaneous route with 10 6 cells of the P3X63 murine Myeloma tumoral line on day 0 of the experiment. The animals were divided in two groups of 5.
One group started treatment by intraperitoneal route with the purified 14F7 Mab, 0.15 mg per dose 6 doses) every 2 days. While the other group acted as control and received by the same route and the same number and dose frequency of equal volume of saline phosphate buffer.
FIG. 14 shows the inhibition of the growth of the tumors in the mice treated with the 14F7 Mab, with respect to the control group. Significant differences were observed between the two groups.
A viable culture producing the monoclonal antibody 14F7 was deposited in accordance with the Budapest Treaty with the European Collection of Cell Cultures, Centre for Applied Microbiology and Research, Salisbury, Wiltshire, SP4 OJG, United Kingdom, on Oct. 19, 1998. The accession number is for this deposit is 98101901. All restrictions and conditions by the depositors/applicants upon availability of the cell culture to the public will be irrevocably removed upon granting of a patent based on the this disclosure. The cell culture will be replaced in kind if, at any time during the required term oi deposit, viable samples cannot be dispensed therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : Shows the levels of serum antibodies obtained against NGcGm3 and not against the Gm3 on day 56 of the experiment, in mice immunized with the NGcGm3/VLDL/Complete Freund adjuvant vaccine preparation.
FIG. 2 : Determination by ELISA of the isotype of the antibody response against the NGcGm3 Ganglioside in the serum of the mice 3 months after receiving the fourth dose of 0,2 mg of NGcGm3/VLDL/Complete Freund.
FIG. 3 : Determination by ELISA of the 14F7 monoclonal antibody immunoglobulin subclass (IgG)
FIG. 4 : Recognition by immunostaining using thin layer chromatography of the N-glycolylated and N-acetylated gangliosides that were used during the study of the specificity of the 14F7 monoclonal antibody
FIG. 5 : Recognition of the NGcGm3 Ganglioside by the 14F7 monoclonal antibody by immunostaining on thin layer chromatography.
FIG. 6 : Non recognition of adult normal tissues by the 14F7 monoclonal antibody in immunohistochemical studies.
FIG. 7 : Immunohistochemical recognition of some human malignant and benign tumors by the 14F7 monoclonal antibody.
FIG. 8 : Immunohistochemical recognition of normal human fetal tissue by the 14F7 monoclonal antibody.
FIG. 9 : Recognition of P3X63 Myeloma cell line expressing the NGcGm3 Ganglioside by the 14F7 Mab using Flow Cytometry.
FIG. 10 : Complement independent cytotoxic effect of the 14F7 Mab using the P3X63 Myeloma cell line by the propidium iodine technique with flow cytometry.
FIG. 11 : Biodistribution of the 99mTc-labeled 14F7 monoclonal antibody. Results of the per cent of gamma radiation with respect to the weight in grams of the organ studied in normal Balb/c mice.
FIG. 12 : Biodistribution of the 99mTc-labeled 14F7 monoclonal antibody. Results of the per cent of gamma radiation with respect to the weight in grams of the organ studied in Balb/c mice bearing the P3X63 Myeloma tumor.
FIG. 13 : Anti tumoral effect of the passive therapy of the 14F7 monoclonal antibody in groups of Balb/c mice inoculated with the P3X63 murine ascitic Myeloma tumor, treated with 0,1 y 0,2 mg of said antibody, compared with a control group treated with Cyclophosphamide 20 mg/kg and a control group with PBS.
FIG. 14 : Tumoral growth inhibition “in vivo”of the murine P3X63 solid Myeloma tumor in athymic mice of the out bread NMRI. | The present invention is related with the field of immunology and human medicine, particularly with the generation and selection of a monoclonal antibody (Mab) that recognizes the N-glycolylated-galactose-glucose sialic acid olygosaccharide sequence presents in malignant tumors.
One of the objectives of this invention is to provide a Mab of the IgG1 type that has the characteristic of recognizing with high specificity N-glycolylated-galactose-glucose sialic acid olygosaccharide sequence presents in malignant tissues of breast, melanomas and tumors of the liver, stomach, colon, rectum and kidneys. It also has the capacity of producing direct cytolysis of the tumoral cells bearing the N-glycolylated-galactose-glucose sialic acid olygosaccharide sequence, thus can be used for the diagnosis and treatment of certain neoplasic diseases.
Another objective of the present invention is to provide the hybridoma producing the referred Mab as well as the pharmaceutical composition containing it, for the treatment of neoplasic diseases. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application Ser. No. 62/113,029, filed on Feb. 6, 2015, the entire contents of which is incorporated herein by reference.
PARTIES TO A JOINT RESEARCH AGREEMENT
[0002] The claimed invention was made by, on behalf of, and/or in connection with one or more of the following parties to a joint university corporation research agreement: Regents of the University of Michigan, Princeton University, University of Southern California, and the Universal Display Corporation. The agreement was in effect on and before the date the claimed invention was made, and the claimed invention was made as a result of activities undertaken within the scope of the agreement.
FIELD OF THE INVENTION
[0003] The present invention relates to compounds for use as host materials or electron transporting materials, and devices, such as organic light emitting diodes, including the same.
BACKGROUND
[0004] Opto-electronic devices that make use of organic materials are becoming increasingly desirable for a number of reasons. Many of the materials used to make such devices are relatively inexpensive, so organic opto-electronic devices have the potential for cost advantages over inorganic devices. In addition, the inherent properties of organic materials, such as their flexibility, may make them well suited for particular applications such as fabrication on a flexible substrate. Examples of organic opto-electronic devices include organic light emitting diodes/devices (OLEDs), organic phototransistors, organic photovoltaic cells, and organic photodetectors. For OLEDs, the organic materials may have performance advantages over conventional materials. For example, the wavelength at which an organic emissive layer emits light may generally be readily tuned with appropriate dopants.
[0005] OLEDs make use of thin organic films that emit light when voltage is applied across the device. OLEDs are becoming an increasingly interesting technology for use in applications such as flat panel displays, illumination, and backlighting. Several OLED materials and configurations are described in U.S. Pat. Nos. 5,844,363, 6,303,238, and 5,707,745, which are incorporated herein by reference in their entirety.
[0006] One application for phosphorescent emissive molecules is a full color display. Industry standards for such a display call for pixels adapted to emit particular colors, referred to as “saturated” colors. In particular, these standards call for saturated red, green, and blue pixels. Alternatively the OLED can be designed to emit white light. In conventional liquid crystal displays emission from a white backlight is filtered using absorption filters to produce red, green and blue emission. The same technique can also be used with OLEDs. The white OLED can be either a single EML device or a stack structure. Color may be measured using CIE coordinates, which are well known to the art.
[0007] One example of a green emissive molecule is tris(2-phenylpyridine) iridium, denoted Ir(ppy) 3 , which has the following structure:
[0000]
[0008] In this, and later figures herein, we depict the dative bond from nitrogen to metal (here, Ir) as a straight line.
[0009] As used herein, the term “organic” includes polymeric materials as well as small molecule organic materials that may be used to fabricate organic opto-electronic devices. “Small molecule” refers to any organic material that is not a polymer, and “small molecules” may actually be quite large Small molecules may include repeat units in some circumstances. For example, using a long chain alkyl group as a substituent does not remove a molecule from the “small molecule” class Small molecules may also be incorporated into polymers, for example as a pendent group on a polymer backbone or as a part of the backbone Small molecules may also serve as the core moiety of a dendrimer, which consists of a series of chemical shells built on the core moiety. The core moiety of a dendrimer may be a fluorescent or phosphorescent small molecule emitter. A dendrimer may be a “small molecule,” and it is believed that all dendrimers currently used in the field of OLEDs are small molecules.
[0010] As used herein, “top” means furthest away from the substrate, while “bottom” means closest to the substrate. Where a first layer is described as “disposed over” a second layer, the first layer is disposed further away from substrate. There may be other layers between the first and second layer, unless it is specified that the first layer is “in contact with” the second layer. For example, a cathode may be described as “disposed over” an anode, even though there are various organic layers in between.
[0011] As used herein, “solution processible” means capable of being dissolved, dispersed, or transported in and/or deposited from a liquid medium, either in solution or suspension form.
[0012] A ligand may be referred to as “photoactive” when it is believed that the ligand directly contributes to the photoactive properties of an emissive material. A ligand may be referred to as “ancillary” when it is believed that the ligand does not contribute to the photoactive properties of an emissive material, although an ancillary ligand may alter the properties of a photoactive ligand.
[0013] As used herein, and as would be generally understood by one skilled in the art, a first “Highest Occupied Molecular Orbital” (HOMO) or “Lowest Unoccupied Molecular Orbital” (LUMO) energy level is “greater than” or “higher than” a second HOMO or LUMO energy level if the first energy level is closer to the vacuum energy level. Since ionization potentials (IP) are measured as a negative energy relative to a vacuum level, a higher HOMO energy level corresponds to an IP having a smaller absolute value (an IP that is less negative). Similarly, a higher LUMO energy level corresponds to an electron affinity (EA) having a smaller absolute value (an EA that is less negative). On a conventional energy level diagram, with the vacuum level at the top, the LUMO energy level of a material is higher than the HOMO energy level of the same material. A “higher” HOMO or LUMO energy level appears closer to the top of such a diagram than a “lower” HOMO or LUMO energy level.
[0014] As used herein, and as would be generally understood by one skilled in the art, a first work function is “greater than” or “higher than” a second work function if the first work function has a higher absolute value. Because work functions are generally measured as negative numbers relative to vacuum level, this means that a “higher” work function is more negative. On a conventional energy level diagram, with the vacuum level at the top, a “higher” work function is illustrated as further away from the vacuum level in the downward direction. Thus, the definitions of HOMO and LUMO energy levels follow a different convention than work functions.
[0015] More details on OLEDs, and the definitions described above, can be found in U.S. Pat. No. 7,279,704, which is incorporated herein by reference in its entirety.
[0016] There is a need in the art for devices with hole-transporting host compounds exhibiting increased charge delocalization and hence improved stability of the device, i.e. lifetime of the emissive layer, as well as Tg of the materials. The present invention addresses this need in the art.
SUMMARY
[0017] According to an embodiment, a compound is provided that has the structure of Formula I shown below:
[0000]
[0018] wherein X 1 to X 8 are each a carbon or nitrogen;
[0019] wherein when any of X 1 to X 8 is nitrogen, there is no substitution on that nitrogen;
[0020] wherein R 1 represents mono, di, tri, or tetra substitution, or no substitution;
[0021] wherein R 2 represents mono, di, or tri substitution, or no substitution;
[0022] wherein G 1 is selected from the group consisting of alkyl, cycloalkyl, heteroalkyl, aryl, heteroaryl, and combinations thereof;
[0023] wherein G 1 can be further substituted by one or more substituents selected from the group consisting of deuterium, halogen, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acid, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof;
[0024] wherein G 2 is selected from the group consisting of biphenyl, and fluorene;
[0025] wherein when G 2 is fluorene, G 2 can be further substituted by one or more substituents selected from the group consisting of deuterium, halogen, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acid, ester, nitrite, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof, where two alkyl substituents together with the atom they are attached can make a cycle;
[0026] wherein L is selected from the group consisting of a direct bond, aryl, and heteroaryl;
[0027] wherein G 3 is selected from the group consisting of carbazole, dibenzothiophene, dibenzofuran, dibenzoselenophene, triphenylene, fluorene, aza variants thereof, and combinations thereof;
[0028] wherein L and G 3 each can be further substituted by one or more substituents selected from the group consisting of deuterium, halogen, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acid, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof; and
[0029] wherein R 1 and R 2 are each independently selected from the group consisting of hydrogen, deuterium, halogen, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acid, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof;
[0030] and wherein any two adjacent substituents are optionally joined to form a ring.
[0031] According to another embodiment, an organic light emitting diode/device (OLED) is also provided. The OLED can include an anode, a cathode, and an organic layer, disposed between the anode and the cathode. The organic layer can include a compound of Formula I.
[0032] According to yet another embodiment, the organic light emitting device is incorporated into a device selected from a consumer product, an electronic component module, and/or a lighting panel.
[0033] According to another embodiment, the invention provides a formulation comprising a compound of Formula I.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 shows an organic light emitting device.
[0035] FIG. 2 shows an inverted organic light emitting device that does not have a separate electron transport layer.
DETAILED DESCRIPTION
[0036] Generally, an OLED comprises at least one organic layer disposed between and electrically connected to an anode and a cathode. When a current is applied, the anode injects holes and the cathode injects electrons into the organic layer(s). The injected holes and electrons each migrate toward the oppositely charged electrode. When an electron and hole localize on the same molecule, an “exciton,” which is a localized electron-hole pair having an excited energy state, is formed. Light is emitted when the exciton relaxes via a photoemissive mechanism. In some cases, the exciton may be localized on an excimer or an exciplex. Non-radiative mechanisms, such as thermal relaxation, may also occur, but are generally considered undesirable.
[0037] The initial OLEDs used emissive molecules that emitted light from their singlet states (“fluorescence”) as disclosed, for example, in U.S. Pat. No. 4,769,292, which is incorporated by reference in its entirety. Fluorescent emission generally occurs in a time frame of less than 10 nanoseconds.
[0038] More recently, OLEDs having emissive materials that emit light from triplet states (“phosphorescence”) have been demonstrated. Baldo et al., “Highly Efficient Phosphorescent Emission from Organic Electroluminescent Devices,” Nature, vol. 395, 151-154, 1998; (“Baldo-I”) and Baldo et al., “Very high-efficiency green organic light-emitting devices based on electrophosphorescence,” Appl. Phys. Lett., vol. 75, No. 3, 4-6 (1999) (“Baldo-II”), are incorporated by reference in their entireties. Phosphorescence is described in more detail in U.S. Pat. No. 7,279,704 at cols. 5-6, which are incorporated by reference.
[0039] FIG. 1 shows an organic light emitting device 100 . The figures are not necessarily drawn to scale. Device 100 may include a substrate 110 , an anode 115 , a hole injection layer 120 , a hole transport layer 125 , an electron blocking layer 130 , an emissive layer 135 , a hole blocking layer 140 , an electron transport layer 145 , an electron injection layer 150 , a protective layer 155 , a cathode 160 , and a barrier layer 170 . Cathode 160 is a compound cathode having a first conductive layer 162 and a second conductive layer 164 . Device 100 may be fabricated by depositing the layers described, in order. The properties and functions of these various layers, as well as example materials, are described in more detail in U.S. Pat. No. 7,279,704 at cols. 6-10, which are incorporated by reference.
[0040] More examples for each of these layers are available. For example, a flexible and transparent substrate-anode combination is disclosed in U.S. Pat. No. 5,844,363, which is incorporated by reference in its entirety. An example of a p-doped hole transport layer is m-MTDATA doped with F4-TCNQ at a molar ratio of 50:1, as disclosed in U.S. Patent Application Publication No. 2003/0230980, which is incorporated by reference in its entirety. Examples of emissive and host materials are disclosed in U.S. Pat. No. 6,303,238 to Thompson et al., which is incorporated by reference in its entirety. An example of an n-doped electron transport layer is BPhen doped with Li at a molar ratio of 1:1, as disclosed in U.S. Patent Application Publication No. 2003/0230980, which is incorporated by reference in its entirety. U.S. Pat. Nos. 5,703,436 and 5,707,745, which are incorporated by reference in their entireties, disclose examples of cathodes including compound cathodes having a thin layer of metal such as Mg:Ag with an overlying transparent, electrically-conductive, sputter-deposited ITO layer. The theory and use of blocking layers is described in more detail in U.S. Pat. No. 6,097,147 and U.S. Patent Application Publication No. 2003/0230980, which are incorporated by reference in their entireties. Examples of injection layers are provided in U.S. Patent Application Publication No. 2004/0174116, which is incorporated by reference in its entirety. A description of protective layers may be found in U.S. Patent Application Publication No. 2004/0174116, which is incorporated by reference in its entirety.
[0041] FIG. 2 shows an inverted OLED 200 . The device includes a substrate 210 , a cathode 215 , an emissive layer 220 , a hole transport layer 225 , and an anode 230 . Device 200 may be fabricated by depositing the layers described, in order. Because the most common OLED configuration has a cathode disposed over the anode, and device 200 has cathode 215 disposed under anode 230 , device 200 may be referred to as an “inverted” OLED. Materials similar to those described with respect to device 100 may be used in the corresponding layers of device 200 . FIG. 2 provides one example of how some layers may be omitted from the structure of device 100 .
[0042] The simple layered structure illustrated in FIGS. 1 and 2 is provided by way of non-limiting example, and it is understood that embodiments of the invention may be used in connection with a wide variety of other structures. The specific materials and structures described are exemplary in nature, and other materials and structures may be used. Functional OLEDs may be achieved by combining the various layers described in different ways, or layers may be omitted entirely, based on design, performance, and cost factors. Other layers not specifically described may also be included. Materials other than those specifically described may be used. Although many of the examples provided herein describe various layers as comprising a single material, it is understood that combinations of materials, such as a mixture of host and dopant, or more generally a mixture, may be used. Also, the layers may have various sublayers. The names given to the various layers herein are not intended to be strictly limiting. For example, in device 200 , hole transport layer 225 transports holes and injects holes into emissive layer 220 , and may be described as a hole transport layer or a hole injection layer. In one embodiment, an OLED may be described as having an “organic layer” disposed between a cathode and an anode. This organic layer may comprise a single layer, or may further comprise multiple layers of different organic materials as described, for example, with respect to FIGS. 1 and 2 .
[0043] Structures and materials not specifically described may also be used, such as OLEDs comprised of polymeric materials (PLEDs) such as disclosed in U.S. Pat. No. 5,247,190 to Friend et al., which is incorporated by reference in its entirety. By way of further example, OLEDs having a single organic layer may be used. OLEDs may be stacked, for example as described in U.S. Pat. No. 5,707,745 to Forrest et al, which is incorporated by reference in its entirety. The OLED structure may deviate from the simple layered structure illustrated in FIGS. 1 and 2 . For example, the substrate may include an angled reflective surface to improve out-coupling, such as a mesa structure as described in U.S. Pat. No. 6,091,195 to Forrest et al., and/or a pit structure as described in U.S. Pat. No. 5,834,893 to Bulovic et al., which are incorporated by reference in their entireties.
[0044] Unless otherwise specified, any of the layers of the various embodiments may be deposited by any suitable method. For the organic layers, preferred methods include thermal evaporation, ink-jet, such as described in U.S. Pat. Nos. 6,013,982 and 6,087,196, which are incorporated by reference in their entireties, organic vapor phase deposition (OVPD), such as described in U.S. Pat. No. 6,337,102 to Forrest et al., which is incorporated by reference in its entirety, and deposition by organic vapor jet printing (OVJP), such as described in U.S. Pat. No. 7,431,968, which is incorporated by reference in its entirety. Other suitable deposition methods include spin coating and other solution based processes. Solution based processes are preferably carried out in nitrogen or an inert atmosphere. For the other layers, preferred methods include thermal evaporation. Preferred patterning methods include deposition through a mask, cold welding such as described in U.S. Pat. Nos. 6,294,398 and 6,468,819, which are incorporated by reference in their entireties, and patterning associated with some of the deposition methods such as ink jet and OVJD. Other methods may also be used. The materials to be deposited may be modified to make them compatible with a particular deposition method. For example, substituents such as alkyl and aryl groups, branched or unbranched, and preferably containing at least 3 carbons, may be used in small molecules to enhance their ability to undergo solution processing. Substituents having 20 carbons or more may be used, and 3-20 carbons is a preferred range. Materials with asymmetric structures may have better solution processibility than those having symmetric structures, because asymmetric materials may have a lower tendency to recrystallize. Dendrimer substituents may be used to enhance the ability of small molecules to undergo solution processing.
[0045] Devices fabricated in accordance with embodiments of the present invention may further optionally comprise a barrier layer. One purpose of the barrier layer is to protect the electrodes and organic layers from damaging exposure to harmful species in the environment including moisture, vapor and/or gases, etc. The barrier layer may be deposited over, under or next to a substrate, an electrode, or over any other parts of a device including an edge. The barrier layer may comprise a single layer, or multiple layers. The barrier layer may be formed by various known chemical vapor deposition techniques and may include compositions having a single phase as well as compositions having multiple phases. Any suitable material or combination of materials may be used for the barrier layer. The barrier layer may incorporate an inorganic or an organic compound or both. The preferred barrier layer comprises a mixture of a polymeric material and a non-polymeric material as described in U.S. Pat. No. 7,968,146, PCT Pat. Application Nos. PCT/US2007/023098 and PCT/US2009/042829, which are herein incorporated by reference in their entireties. To be considered a “mixture”, the aforesaid polymeric and non-polymeric materials comprising the barrier layer should be deposited under the same reaction conditions and/or at the same time. The weight ratio of polymeric to non-polymeric material may be in the range of 95:5 to 5:95. The polymeric material and the non-polymeric material may be created from the same precursor material. In one example, the mixture of a polymeric material and a non-polymeric material consists essentially of polymeric silicon and inorganic silicon.
[0046] Devices fabricated in accordance with embodiments of the invention can be incorporated into a wide variety of electronic component modules (or units) that can be incorporated into a variety of electronic products or intermediate components. Examples of such electronic products or intermediate components include display screens, lighting devices such as discrete light source devices or lighting panels, etc. that can be utilized by the end-user product manufacturers. Such electronic component modules can optionally include the driving electronics and/or power source(s). Devices fabricated in accordance with embodiments of the invention can be incorporated into a wide variety of consumer products that have one or more of the electronic component modules (or units) incorporated therein. Such consumer products would include any kind of products that include one or more light source(s) and/or one or more of some type of visual displays. Some examples of such consumer products include flat panel displays, computer monitors, medical monitors, televisions, billboards, lights for interior or exterior illumination and/or signaling, heads-up displays, fully or partially transparent displays, flexible displays, laser printers, telephones, cell phones, tablets, phablets, personal digital assistants (PDAs), wearable device, laptop computers, digital cameras, camcorders, viewfinders, micro-displays, 3-D displays, vehicles, a large area wall, theater or stadium screen, or a sign. Various control mechanisms may be used to control devices fabricated in accordance with the present invention, including passive matrix and active matrix. Many of the devices are intended for use in a temperature range comfortable to humans, such as 18 degrees C. to 30 degrees C., and more preferably at room temperature (20-25 degrees C.), but could be used outside this temperature range, for example, from −40 degree C. to +80 degree C.
[0047] The materials and structures described herein may have applications in devices other than OLEDs. For example, other optoelectronic devices such as organic solar cells and organic photodetectors may employ the materials and structures. More generally, organic devices, such as organic transistors, may employ the materials and structures.
[0048] The term “halo,” “halogen,” or “halide” as used herein includes fluorine, chlorine, bromine, and iodine.
[0049] The term “alkyl” as used herein contemplates both straight and branched chain alkyl radicals. Preferred alkyl groups are those containing from one to fifteen carbon atoms and includes methyl, ethyl, propyl, 1-methylethyl, butyl, 1-methylpropyl, 2-methylpropyl, pentyl, 1-methylbutyl, 2-methylbutyl, 3-methylbutyl, 1,1-dimethylpropyl, 1,2-dimethylpropyl, 2,2-dimethylpropyl, and the like. Additionally, the alkyl group may be optionally substituted.
[0050] The term “cycloalkyl” as used herein contemplates cyclic alkyl radicals. Preferred cycloalkyl groups are those containing 3 to 10 ring carbon atoms and includes cyclopropyl, cyclopentyl, cyclohexyl, adamantyl, and the like. Additionally, the cycloalkyl group may be optionally substituted.
[0051] The term “alkenyl” as used herein contemplates both straight and branched chain alkene radicals. Preferred alkenyl groups are those containing two to fifteen carbon atoms. Additionally, the alkenyl group may be optionally substituted.
[0052] The term “alkynyl” as used herein contemplates both straight and branched chain alkyne radicals. Preferred alkynyl groups are those containing two to fifteen carbon atoms. Additionally, the alkynyl group may be optionally substituted.
[0053] The terms “aralkyl” or “arylalkyl” as used herein are used interchangeably and contemplate an alkyl group that has as a substituent an aromatic group. Additionally, the aralkyl group may be optionally substituted.
[0054] The term “heterocyclic group” as used herein contemplates aromatic and non-aromatic cyclic radicals. Hetero-aromatic cyclic radicals also means heteroaryl. Preferred hetero-non-aromatic cyclic groups are those containing 3 or 7 ring atoms which includes at least one hetero atom, and includes cyclic amines such as morpholino, piperidino, pyrrolidino, and the like, and cyclic ethers, such as tetrahydrofuran, tetrahydropyran, and the like. Additionally, the heterocyclic group may be optionally substituted.
[0055] The term “aryl” or “aromatic group” as used herein contemplates single-ring groups and polycyclic ring systems. The polycyclic rings may have two or more rings in which two carbons are common to two adjoining rings (the rings are “fused”) wherein at least one of the rings is aromatic, e.g., the other rings can be cycloalkyls, cycloalkenyls, aryl, heterocycles, and/or heteroaryls. Preferred aryl groups are those containing six to thirty carbon atoms, preferably six to twenty carbon atoms, more preferably six to twelve carbon atoms. Especially preferred is an aryl group having six carbons, ten carbons or twelve carbons. Suitable aryl groups include phenyl, biphenyl, triphenyl, triphenylene, tetraphenylene, naphthalene, anthracene, phenalene, phenanthrene, fluorene, pyrene, chrysene, perylene, and azulene, preferably phenyl, biphenyl, triphenyl, triphenylene, fluorene, and naphthalene. Additionally, the aryl group may be optionally substituted.
[0056] The term “heteroaryl” as used herein contemplates single-ring hetero-aromatic groups that may include from one to five heteroatoms. The term heteroaryl also includes polycyclic hetero-aromatic systems having two or more rings in which two atoms are common to two adjoining rings (the rings are “fused”) wherein at least one of the rings is a heteroaryl, e.g., the other rings can be cycloalkyls, cycloalkenyls, aryl, heterocycles, and/or heteroaryls. Preferred heteroaryl groups are those containing three to thirty carbon atoms, preferably three to twenty carbon atoms, more preferably three to twelve carbon atoms. Suitable heteroaryl groups include dibenzothiophene, dibenzofuran, dibenzoselenophene, furan, thiophene, benzofuran, benzothiophene, benzoselenophene, carbazole, indolocarbazole, pyridylindole, pyrrolodipyridine, pyrazole, imidazole, triazole, oxazole, thiazole, oxadiazole, oxatriazole, dioxazole, thiadiazole, pyridine, pyridazine, pyrimidine, pyrazine, triazine, oxazine, oxathiazine, oxadiazine, indole, benzimidazole, indazole, indoxazine, benzoxazole, benzisoxazole, benzothiazole, quinoline, isoquinoline, cinnoline, quinazoline, quinoxaline, naphthyridine, phthalazine, pteridine, xanthene, acridine, phenazine, phenothiazine, phenoxazine, benzofuropyridine, furodipyridine, benzothienopyridine, thienodipyridine, benzoselenophenopyridine, and selenophenodipyridine, preferably dibenzothiophene, dibenzofuran, dibenzoselenophene, carbazole, indolocarbazole, imidazole, pyridine, triazine, benzimidazole, and aza-analogs thereof. Additionally, the heteroaryl group may be optionally substituted.
[0057] The alkyl, cycloalkyl, alkenyl, alkynyl, aralkyl, heterocyclic group, aryl, and heteroaryl may be unsubstituted or may be substituted with one or more substituents selected from the group consisting of deuterium, halogen, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, cyclic amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acid, ether, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof.
[0058] As used herein, “substituted” indicates that a substituent other than H is bonded to the relevant position, such as carbon. Thus, for example, where R 1 is mono-substituted, then one R 1 must be other than H Similarly, where R 1 is di-substituted, then two of R 1 must be other than H Similarly, where R 1 is unsubstituted, R 1 is hydrogen for all available positions.
[0059] The “aza” designation in the fragments described herein, i.e. aza-dibenzofuran, aza-dibenzothiophene, etc. means that one or more of the C—H groups in the respective fragment can be replaced by a nitrogen atom, for example, and without any limitation, azatriphenylene encompasses both dibenzo[f,h]quinoxaline and dibenzo[f,h]quinoline. One of ordinary skill in the art can readily envision other nitrogen analogs of the aza-derivatives described above, and all such analogs are intended to be encompassed by the terms as set forth herein.
[0060] It is to be understood that when a molecular fragment is described as being a substituent or otherwise attached to another moiety, its name may be written as if it were a fragment (e.g. phenyl, phenylene, naphthyl, dibenzofuryl) or as if it were the whole molecule (e.g. benzene, naphthalene, dibenzofuran). As used herein, these different ways of designating a substituent or attached fragment are considered to be equivalent.
[0061] The compounds described in this disclosure may be used as hole-transporting hosts in the emissive layer of an organic light-emitting device. In one aspect, the compounds of the invention have a central unit which contains two parts: one part is either carbazole or azacarbazole; another part can be carbazole or other dibenzo ring system such as dibenzothiophene, dibenzofuran, and dibenzoselenophene, triphenylene or fluorene unit, and these two parts are separated with terphenyl or fluorenyl substituted phenyl spacer. Such substitution may increase charge delocalization and hence improve stability of the device, i.e. lifetime of the emissive layer, as well as Tg of the materials.
Compounds of the Invention:
[0062] The compounds of the present invention may be synthesized using techniques well-known in the art of organic synthesis. The starting materials and intermediates required for the synthesis may be obtained from commercial sources or synthesized according to methods known to those skilled in the art.
[0063] In one aspect, the invention includes a compound of Formula I:
[0000]
[0064] wherein X 1 to X 8 are each a carbon or nitrogen;
[0065] wherein when any of X 1 to X 8 is nitrogen, there is no substitution on that nitrogen;
[0066] wherein R 1 represents mono, di, tri, or tetra substitution, or no substitution;
[0067] wherein R 2 represents mono, di, or tri substitution, or no substitution;
[0068] wherein G 1 is selected from the group consisting of alkyl, cycloalkyl, heteroalkyl, aryl, heteroaryl, and combinations thereof;
[0069] wherein G 1 can be further substituted by one or more substituents selected from the group consisting of deuterium, halogen, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acid, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof;
[0070] wherein G 2 is selected from the group consisting of biphenyl and fluorene;
[0071] wherein when G 2 is fluorene, G 2 can be further substituted by one or more substituents selected from the group consisting of deuterium, halogen, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acid, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof, where two alkyl substituents together with the atom they are attached can make a cycle;
[0072] wherein L is selected from the group consisting of a direct bond, aryl, and heteroaryl;
[0073] wherein G 3 is selected from the group consisting of carbazole, dibenzothiophene, dibenzofuran, dibenzoselenophene, triphenylene, fluorene, aza variants thereof, and combinations thereof;
[0074] wherein L and G 3 each can be further substituted by one or more substituents selected from the group consisting of deuterium, halogen, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acid, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof; and
[0075] wherein R 1 and R 2 are each independently selected from the group consisting of hydrogen, deuterium, halogen, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acid, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof;
[0076] and wherein any two adjacent substituents are optionally joined to form a ring.
[0077] Any combination of X 1 to X 8 is contemplated by the present invention, as long as X 1 to X 8 are each a carbon or nitrogen. In one embodiment, X 1 to X 8 are each a carbon. In another embodiment, one of X 1 to X 8 is nitrogen, and the rest of X 1 to X 8 are carbon. In another embodiment, two of X 1 to X 8 are nitrogen, and the rest of X 1 to X 8 are carbon.
[0078] In one embodiment, G 1 is selected from the group consisting of phenyl, biphenyl, terphenyl, pyridine, pyrimidine, triazine, and combinations thereof.
[0079] In one embodiment, G 2 is biphenyl. In another embodiment, G 2 is fluorine. In another embodiment, G 2 is selected from the group consisting of fluorene and substituted fluorene.
[0080] In one embodiment, the compound of the invention is selected from the group consisting of:
[0000]
[0000] wherein A 1 -A 4 are each independently selected from the group consisting of hydrogen, deuterium, aryl, heteroaryl, and combinations thereof; and
[0081] wherein E is selected from the group consisting of O, S, Se and CMe 2 .
[0082] In one embodiment, the compound of the invention is selected from the group consisting of:
[0000]
[0083] In some embodiments, the compound can be an emissive dopant. In some embodiments, the compound can produce emissions via phosphorescence, fluorescence, thermally activated delayed fluorescence, i.e., TADF (also referred to as E-type delayed fluorescence), triplet-triplet annihilation, or combinations of these processes.
[0084] According to another aspect of the present disclosure, an OLED is also provided. The OLED includes an anode, a cathode, and an organic layer disposed between the anode and the cathode. The organic layer may include a host and a phosphorescent dopant. The organic layer can include a compound according to Formula I, and its variations as described herein.
[0085] The OLED can be incorporated into one or more of a consumer product, an electronic component module and a lighting panel. The organic layer can be an emissive layer and the compound can be a host in some embodiments.
[0086] The organic layer can also include an emissive dopant. In some embodiments, two or more emissive dopants are preferred. In one embodiment, the organic layer further comprises a phosphorescent emissive dopant. In some embodiments the emissive dopant is a transition metal complex having at least one ligand or part of the ligand if the ligand is more than bidentate selected from the group consisting of:
[0000]
[0087] wherein each X 1 to X 13 are independently selected from the group consisting of carbon and nitrogen;
[0088] wherein X is selected from the group consisting of BR′, NR′, PR′, O, S, Se, C═O, S═O, SO 2 , CR′R″, SiR′R″, and GeR′R″;
[0089] wherein R 1 and R″ are optionally fused or joined to form a ring;
[0090] wherein each R a , R b , R c , and R d may represent from mono substitution to the possible maximum number of substitution, or no substitution;
[0091] wherein R′, R″, R a , R b , R c , and R d are each independently selected from the group consisting of hydrogen, deuterium, halide, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acids, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof; and
[0092] wherein any two adjacent substituents of R a , R b , R c , and R d are optionally fused or joined to form a ring or form a multidentate ligand.
[0093] In some embodiments the organic layer is a blocking layer and the compound of Formula I is a blocking material in the organic layer. In other embodiments the organic layer is a transporting layer and the compound of Formula I is a transporting material in the organic layer.
[0094] In yet another aspect of the present disclosure, a formulation that comprises a compound according to Formula I is described. The formulation can include one or more components selected from the group consisting of a solvent, a host, a hole injection material, hole transport material, and an electron transport layer material, disclosed herein.
[0095] Combination with Other Materials
[0096] The materials described herein as useful for a particular layer in an organic light emitting device may be used in combination with a wide variety of other materials present in the device. For example, emissive dopants disclosed herein may be used in conjunction with a wide variety of hosts, transport layers, blocking layers, injection layers, electrodes and other layers that may be present. The materials described or referred to below are non-limiting examples of materials that may be useful in combination with the compounds disclosed herein, and one of skill in the art can readily consult the literature to identify other materials that may be useful in combination.
[0097] Conductivity Dopants:
[0098] A charge transport layer can be doped with conductivity dopants to substantially alter its density of charge carriers, which will in turn alter its conductivity. The conductivity is increased by generating charge carriers in the matrix material, and depending on the type of dopant, a change in the Fermi level of the semiconductor may also be achieved. Hole-transporting layer can be doped by p-type conductivity dopants and n-type conductivity dopants are used in the electron-transporting layer. Non-limiting examples of the conductivity dopants that may be used in an OLED in combination with materials disclosed herein are exemplified below together with references that disclose those materials:
[0099] EP01617493, EP01968131, EP2020694, EP2684932, US20050139810, US20070160905, US20090167167, US2010288362, WO06081780, WO2009003455, WO2009008277, WO2009011327, WO2014009310, US2007252140, US2015060804 and US2012146012.
[0000]
[0100] HIL/HTL:
[0101] A hole injecting/transporting material to be used in the present invention is not particularly limited, and any compound may be used as long as the compound is typically used as a hole injecting/transporting material. Examples of the material include, but are not limited to: a phthalocyanine or porphyrin derivative; an aromatic amine derivative; an indolocarbazole derivative; a polymer containing fluorohydrocarbon; a polymer with conductivity dopants; a conducting polymer, such as PEDOT/PSS; a self-assembly monomer derived from compounds such as phosphoric acid and silane derivatives; a metal oxide derivative, such as MoO x ; a p-type semiconducting organic compound, such as 1,4,5,8,9,12-Hexaazatriphenylenehexacarbonitrile; a metal complex, and a cross-linkable compounds.
[0102] Examples of aromatic amine derivatives used in HIL or HTL include, but not limit to the following general structures:
[0000]
[0103] Each of Ar 1 to Ar 9 is selected from the group consisting of aromatic hydrocarbon cyclic compounds such as benzene, biphenyl, triphenyl, triphenylene, naphthalene, anthracene, phenalene, phenanthrene, fluorene, pyrene, chrysene, perylene, and azulene; the group consisting of aromatic heterocyclic compounds such as dibenzothiophene, dibenzofuran, dibenzoselenophene, furan, thiophene, benzofuran, benzothiophene, benzoselenophene, carbazole, indolocarbazole, pyridylindole, pyrrolodipyridine, pyrazole, imidazole, triazole, oxazole, thiazole, oxadiazole, oxatriazole, dioxazole, thiadiazole, pyridine, pyridazine, pyrimidine, pyrazine, triazine, oxazine, oxathiazine, oxadiazine, indole, benzimidazole, indazole, indoxazine, benzoxazole, benzisoxazole, benzothiazole, quinoline, isoquinoline, cinnoline, quinazoline, quinoxaline, naphthyridine, phthalazine, pteridine, xanthene, acridine, phenazine, phenothiazine, phenoxazine, benzofuropyridine, furodipyridine, benzothienopyridine, thienodipyridine, benzoselenophenopyridine, and selenophenodipyridine; and the group consisting of 2 to 10 cyclic structural units which are groups of the same type or different types selected from the aromatic hydrocarbon cyclic group and the aromatic heterocyclic group and are bonded to each other directly or via at least one of oxygen atom, nitrogen atom, sulfur atom, silicon atom, phosphorus atom, boron atom, chain structural unit and the aliphatic cyclic group. Each Ar may be unsubstituted or may be substituted by a substituent selected from the group consisting of deuterium, halide, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acids, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof.
[0104] In one aspect, Ar 1 to Ar 9 is independently selected from the group consisting of:
[0000]
[0000] wherein k is an integer from 1 to 20; X 101 to X 108 is C (including CH) or N; Z 101 is NAr 1 , O, or S; Ar 1 has the same group defined above.
[0105] Examples of metal complexes used in HIL or HTL include, but are not limited to the following general formula:
[0000]
[0000] wherein Met is a metal, which can have an atomic weight greater than 40; (Y 101 -Y 102 )) is a bidentate ligand, Y 101 and Y 102 are independently selected from C, N, O, P, and S; L 101 is an ancillary ligand; k′ is an integer value from 1 to the maximum number of ligands that may be attached to the metal; and k′+k″ is the maximum number of ligands that may be attached to the metal.
[0106] In one aspect, (Y 101 -Y 102 ) is a 2-phenylpyridine derivative. In another aspect, (Y 101 -Y 102 ) is a carbene ligand. In another aspect, Met is selected from Ir, Pt, Os, and Zn. In a further aspect, the metal complex has a smallest oxidation potential in solution vs. Fc + /Fc couple less than about 0.6 V.
[0107] Non-limiting examples of the HIL and HTL materials that may be used in an OLED in combination with materials disclosed herein are exemplified below together with references that disclose those materials: CN102702075, DE102012005215, EP01624500, EP01698613, EP01806334, EP01930964, EP01972613, EP01997799, EP02011790, EP02055700, EP02055701, EP1725079, EP2085382, EP2660300, EP650955, JP07-073529, JP2005112765, JP2007091719, JP2008021687, JP2014-009196, KR20110088898, KR20130077473, TW201139402, U.S. Ser. No. 06/517,957, US20020158242, US20030162053, US20050123751, US20060182993, US20060240279, US20070145888, US20070181874, US20070278938, US20080014464, US20080091025, US20080106190, US20080124572, US20080145707, US20080220265, US20080233434, US20080303417, US2008107919, US20090115320, US20090167161, US2009066235, US2011007385, US20110163302, US2011240968, US2011278551, US2012205642, US2013241401, US20140117329, US2014183517, U.S. Pat. No. 5,061,569, U.S. Pat. No. 5,639,914, WO05075451, WO07125714, WO08023550, WO08023759, WO2009145016, WO2010061824, WO2011075644, WO2012177006, WO2013018530, WO2013039073, WO2013087142, WO2013118812, WO2013120577, WO2013157367, WO2013175747, WO2014002873, WO2014015935, WO2014015937, WO2014030872, WO2014030921, WO2014034791, WO2014104514, WO2014157018.
[0000]
[0108] EBL:
[0109] An electron blocking layer (EBL) may be used to reduce the number of electrons and/or excitons that leave the emissive layer. The presence of such a blocking layer in a device may result in substantially higher efficiencies, and or longer lifetime, as compared to a similar device lacking a blocking layer. Also, a blocking layer may be used to confine emission to a desired region of an OLED. In some embodiments, the EBL material has a higher LUMO (closer to the vacuum level) and/or higher triplet energy than the emitter closest to the EBL interface. In some embodiments, the EBL material has a higher LUMO (closer to the vacuum level) and or higher triplet energy than one or more of the hosts closest to the EBL interface. In one aspect, the compound used in EBL contains the same molecule or the same functional groups used as one of the hosts described below.
[0110] Host:
[0111] The light emitting layer of the organic EL device of the present invention preferably contains at least a metal complex as light emitting material, and may contain a host material using the metal complex as a dopant material. Examples of the host material are not particularly limited, and any metal complexes or organic compounds may be used as long as the triplet energy of the host is larger than that of the dopant. While the Table below categorizes host materials as preferred for devices that emit various colors, any host material may be used with any dopant so long as the triplet criteria is satisfied.
[0112] Examples of metal complexes used as host are preferred to have the following general formula:
[0000]
[0000] wherein Met is a metal; (Y 103 -Y 104 )) is a bidentate ligand, Y 103 and Y 104 are independently selected from C, N, O, P, and S; L 101 is an another ligand; k′ is an integer value from 1 to the maximum number of ligands that may be attached to the metal; and k′+k″ is the maximum number of ligands that may be attached to the metal.
[0113] In one aspect, the metal complexes are:
[0000]
[0000] wherein (O—N) is a bidentate ligand, having metal coordinated to atoms O and N.
[0114] In another aspect, Met is selected from Ir and Pt. In a further aspect, (Y 103 -Y 104 ) is a carbene ligand.
[0115] Examples of organic compounds used as host are selected from the group consisting of aromatic hydrocarbon cyclic compounds such as benzene, biphenyl, triphenyl, triphenylene, tetraphenylene, naphthalene, anthracene, phenalene, phenanthrene, fluorene, pyrene, chrysene, perylene, and azulene; the group consisting of aromatic heterocyclic compounds such as dibenzothiophene, dibenzofuran, dibenzoselenophene, furan, thiophene, benzofuran, benzothiophene, benzoselenophene, carbazole, indolocarbazole, pyridylindole, pyrrolodipyridine, pyrazole, imidazole, triazole, oxazole, thiazole, oxadiazole, oxatriazole, dioxazole, thiadiazole, pyridine, pyridazine, pyrimidine, pyrazine, triazine, oxazine, oxathiazine, oxadiazine, indole, benzimidazole, indazole, indoxazine, benzoxazole, benzisoxazole, benzothiazole, quinoline, isoquinoline, cinnoline, quinazoline, quinoxaline, naphthyridine, phthalazine, pteridine, xanthene, acridine, phenazine, phenothiazine, phenoxazine, benzofuropyridine, furodipyridine, benzothienopyridine, thienodipyridine, benzoselenophenopyridine, and selenophenodipyridine; and the group consisting of 2 to 10 cyclic structural units which are groups of the same type or different types selected from the aromatic hydrocarbon cyclic group and the aromatic heterocyclic group and are bonded to each other directly or via at least one of oxygen atom, nitrogen atom, sulfur atom, silicon atom, phosphorus atom, boron atom, chain structural unit and the aliphatic cyclic group. Each option within each group may be unsubstituted or may be substituted by a substituent selected from the group consisting of deuterium, halide, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acids, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof.
[0116] In one aspect, the host compound contains at least one of the following groups in the molecule:
[0000]
[0000] wherein each of R 101 to R 107 is independently selected from the group consisting of hydrogen, deuterium, halide, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acids, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof, and when it is aryl or heteroaryl, it has the similar definition as Ar's mentioned above. k is an integer from 0 to 20 or 1 to 20; k′″ is an integer from 0 to 20. X 101 to X 108 is selected from C (including CH) or N.
Z 101 and Z 102 is selected from NR 101 , O, or S.
[0117] Non-limiting examples of the Host materials that may be used in an OLED in combination with materials disclosed herein are exemplified below together with references that disclose those materials: EP2034538, EP2034538A, EP2757608, JP2007254297, KR20100079458, KR20120088644, KR20120129733, KR20130115564, TW201329200, US20030175553, US20050238919, US20060280965, US20090017330, US20090030202, US20090167162, US20090302743, US20090309488, US20100012931, US20100084966, US20100187984, US2010187984, US2012075273, US2012126221, US2013009543, US2013105787, US2013175519, US2014001446, US20140183503, US20140225088, US2014034914, U.S. Pat. No. 7,154,114, WO2001039234, WO2004093207, WO2005014551, WO2005089025, WO2006072002, WO2006114966, WO2007063754, WO2008056746, WO2009003898, WO2009021126, WO2009063833, WO2009066778, WO2009066779, WO2009086028, WO2010056066, WO2010107244, WO2011081423, WO2011081431, WO2011086863, WO2012128298, WO2012133644, WO2012133649, WO2013024872, WO2013035275, WO2013081315, WO2013191404, WO2014142472.
[0000]
[0118] Emitter:
[0119] An emitter example is not particularly limited, and any compound may be used as long as the compound is typically used as an emitter material. Examples of suitable emitter materials include, but are not limited to, compounds which can produce emissions via phosphorescence, fluorescence, thermally activated delayed fluorescence, i.e., TADF (also referred to as E-type delayed fluorescence), triplet-triplet annihilation, or combinations of these processes.
[0120] Non-limiting examples of the emitter materials that may be used in an OLED in combination with materials disclosed herein are exemplified below together with references that disclose those materials: CN103694277, CN1696137, EB01238981, EP01239526, EP01961743, EP1239526, EP1244155, EP1642951, EP1647554, EP1841834, EP1841834B, EP2062907, EP2730583, JP2012074444, JP2013110263, JP4478555, KR1020090133652, KR20120032054, KR20130043460, TW201332980, U.S. Ser. No. 06/699,599, U.S. Ser. No. 06/916,554, US20010019782, US20020034656, US20030068526, US20030072964, US20030138657, US20050123788, US20050244673, US2005123791, US2005260449, US20060008670, US20060065890, US20060127696, US20060134459, US20060134462, US20060202194, US20060251923, US20070034863, US20070087321, US20070103060, US20070111026, US20070190359, US20070231600, US2007034863, US2007104979, US2007104980, US2007138437, US2007224450, US2007278936, US20080020237, US20080233410, US20080261076, US20080297033, US200805851, US2008161567, US2008210930, US20090039776, US20090108737, US20090115322, US20090179555, US2009085476, US2009104472, US20100090591, US20100148663, US20100244004, US20100295032, US2010102716, US2010105902, US2010244004, US2010270916, US20110057559, US20110108822, US20110204333, US2011215710, US2011227049, US2011285275, US2012292601, US20130146848, US2013033172, US2013165653, US2013181190, US2013334521, US20140246656, US2014103305, U.S. Pat. No. 6,303,238, U.S. Pat. No. 6,413,656, U.S. Pat. No. 6,653,654, U.S. Pat. No. 6,670,645, U.S. Pat. No. 6,687,266, U.S. Pat. No. 6,835,469, U.S. Pat. No. 6,921,915, U.S. Pat. No. 7,279,704, U.S. Pat. No. 7,332,232, U.S. Pat. No. 7,378,162, U.S. Pat. No. 7,534,505, U.S. Pat. No. 7,675,228, U.S. Pat. No. 7,728,137, U.S. Pat. No. 7,740,957, U.S. Pat. No. 7,759,489, U.S. Pat. No. 7,951,947, U.S. Pat. No. 8,067,099, U.S. Pat. No. 8,592,586, U.S. Pat. No. 8,871,361, WO06081973, WO06121811, WO07018067, WO07108362, WO07115970, WO07115981, WO08035571, WO2002015645, WO2003040257, WO2005019373, WO2006056418, WO2008054584, WO2008078800, WO2008096609, WO2008101842, WO2009000673, WO2009050281, WO2009100991, WO2010028151, WO2010054731, WO2010086089, WO2010118029, WO2011044988, WO2011051404, WO2011107491, WO2012020327, WO2012163471, WO2013094620, WO2013107487, WO2013174471, WO2014007565, WO2014008982, WO2014023377, WO2014024131, WO2014031977, WO2014038456, WO2014112450.
[0000]
[0121] HBL:
[0122] A hole blocking layer (HBL) may be used to reduce the number of holes and/or excitons that leave the emissive layer. The presence of such a blocking layer in a device may result in substantially higher efficiencies and/or longer lifetime as compared to a similar device lacking a blocking layer. Also, a blocking layer may be used to confine emission to a desired region of an OLED. In some embodiments, the HBL material has a lower HOMO (further from the vacuum level) and or higher triplet energy than the emitter closest to the HBL interface. In some embodiments, the HBL material has a lower HOMO (further from the vacuum level) and or higher triplet energy than one or more of the hosts closest to the HBL interface.
[0123] In one aspect, compound used in HBL contains the same molecule or the same functional groups used as host described above.
[0124] In another aspect, compound used in HBL contains at least one of the following groups in the molecule:
[0000]
[0000] wherein k is an integer from 1 to 20; L 101 is an another ligand, k′ is an integer from 1 to 3.
[0125] ETL:
[0126] Electron transport layer (ETL) may include a material capable of transporting electrons. Electron transport layer may be intrinsic (undoped), or doped. Doping may be used to enhance conductivity. Examples of the ETL material are not particularly limited, and any metal complexes or organic compounds may be used as long as they are typically used to transport electrons.
[0127] In one aspect, compound used in ETL contains at least one of the following groups in the molecule:
[0000]
[0000] wherein R 101 is selected from the group consisting of hydrogen, deuterium, halide, alkyl, cycloalkyl, heteroalkyl, arylalkyl, alkoxy, aryloxy, amino, silyl, alkenyl, cycloalkenyl, heteroalkenyl, alkynyl, aryl, heteroaryl, acyl, carbonyl, carboxylic acids, ester, nitrile, isonitrile, sulfanyl, sulfinyl, sulfonyl, phosphino, and combinations thereof, when it is aryl or heteroaryl, it has the similar definition as Ar's mentioned above. Ar 1 to Ar 3 has the similar definition as Ar's mentioned above. k is an integer from 1 to 20. X 101 to X 108 is selected from C (including CH) or N.
[0128] In another aspect, the metal complexes used in ETL contains, but not limit to the following general formula:
[0000]
[0000] wherein (O—N) or (N—N) is a bidentate ligand, having metal coordinated to atoms O, N or N, N; L 101 is another ligand; k′ is an integer value from 1 to the maximum number of ligands that may be attached to the metal.
[0129] Non-limiting examples of the ETL materials that may be used in an OLED in combination with materials disclosed herein are exemplified below together with references that disclose those materials: CN103508940, EP01602648, EP01734038, EP01956007, JP2004-022334, JP2005149918, JP2005-268199, KR0117693, KR20130108183, US20040036077, US20070104977, US2007018155, US20090101870, US20090115316, US20090140637, US20090179554, US2009218940, US2010108990,US2011156017, US2011210320, US2012193612, US2012214993, US2014014925, US2014014927, US20140284580, U.S. Pat. No. 6,656,612, U.S. Pat. No. 8,415,031, WO2003060956, WO2007111263, WO2009148269, WO2010067894, WO2010072300, WO2011074770, WO2011105373, WO2013079217, WO2013145667, WO2013180376, WO2014104499, WO2014104535.
[0000]
[0130] Charge Generation Layer (CGL):
[0131] In tandem or stacked OLEDs, the CGL plays an essential role in the performance, which is composed of an n-doped layer and a p-doped layer for injection of electrons and holes, respectively. Electrons and holes are supplied from the CGL and electrodes. The consumed electrons and holes in the CGL are refilled by the electrons and holes injected from the cathode and anode, respectively; then, the bipolar currents reach a steady state gradually. Typical CGL materials include n and p conductivity dopants used in the transport layers.
[0132] In any above-mentioned compounds used in each layer of the OLED device, the hydrogen atoms can be partially or fully deuterated. Thus, any specifically listed substituent, such as, without limitation, methyl, phenyl, pyridyl, etc. may be undeuterated, partially deuterated, and fully deuterated versions thereof. Similarly, classes of substituents such as, without limitation, alkyl, aryl, cycloalkyl, heteroaryl, etc. also may be undeuterated, partially deuterated, and fully deuterated versions thereof.
EXPERIMENTAL
[0133] Chemical abbreviations used throughout this document are as follows:
[0134] SPhos is dicyclohexyl(2′,6′-dimethoxy-[1,1′-biphenyl]-2-yl)phosphine,
[0135] Pd 2 (dba) 3 is tri(dibenzylideneacetone) dipalladium(0),
[0136] Pd(PPh 3 ) 4 is tetrakis(triphenylphosphine) palladium (0),
[0137] DCM is dichloromethane, and
[0138] DME is dimethoxyethane
[0139] Synthesis of Compound 1a-1
[0000]
[0140] 3-(5-Chloro-[1,1′:4′,1″-terphenyl]-3-yl)-9-phenyl-9H-carbazole (3.25 g, 6.42 mmol), 9H-carbazole (1.074 g, 6.42 mmol), sodium 2-methylpropan-2-olate (1.234 g, 12.84 mmol) were suspended in xylene (100 ml) under nitrogen to give a yellow suspension. Pd 2 (dba) 3 (0.088 g, 0.096 mmol) and SPhos (0.079 g, 0.193 mmol) were added to the reaction mixture in one portion, and the reaction mixture was refluxed under nitrogen for 14 h. After cooling to room temperature, the solid was removed by filtration and the solvent was evaporated. The residue was purified by column chromatography on silica gel with heptane/DCM (4/1 to 3/2, v/v) as eluent to yield compound 1a-1 (3.1 g, 76%) as a white solid.
[0141] Synthesis of Compound 2a-1
[0000]
[0142] 3,5-Dibromo-1,1′:4′,1″-terphenyl (2.90 g, 7.47 mmol), (9-phenyl-9H-carbazol-3-yl)boronic acid (4.40 g, 15.32 mmol), and potassium carbonate (3.10 g, 22.42 mmol) were dissolved in DME (100 ml)/water (20 ml) mixture under nitrogen to give a colorless suspension. Pd(PPh 3 ) 4 (0.173 g, 0.149 mmol) was added to the reaction mixture in one portion. The reaction mixture was degassed and heated to reflux under nitrogen for 18 h. After cooling to room temperature, the solid was collected by filtration, washed with ethanol, and purified by column chromatography on silica gel with heptane/DCM (1/1,v/v) as eluent and recrystallized from toluene/heptane to yield compound 2a-1 (4.5, 85%) as a white solid.
[0143] Synthesis of Compound 3a-1
[0000]
[0144] 3-(5-Chloro-[1,1′:4′,1″-terphenyl]-3-yl)-9-phenyl-9H-carbazole (4.65 g, 9.19 mmol), dibenzo[b,d]thiophen-4-ylboronic acid (2.096 g, 9.19 mmol), and potassium phosphate tribasic hydrate (4.23 g, 18.38 mmol) were suspended in DME (100 ml)/toluene (100 ml)/water (5 ml) mixture under nitrogen to give a colorless suspension. Pd 2 (dba) 3 (0.126 g, 0.138 mmol) and SPhos (0.113 g, 0.276 mmol) were added to the reaction mixture in one portion. The reaction mixture was degassed and heated to reflux under nitrogen overnight. After cooling to room temperature, the organic phase was separated and the solvent was evaporated. The residue was purified by column chromatography on silica gel with heptane/DCM (1/1,v/v) as the eluent and recrystallized from heptane to yield compound 3a-1 (3.8 g, 63%) as a white solid.
[0145] Synthesis of Comparative Compound cc-1
[0000]
[0146] In a nitrogen flushed 250 mL two-necked round-bottomed flask 3-bromo-9-phenyl-9H-carbazole (2.62 g, 8.12 mmol), 9-(3-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)phenyl)-9H-carbazole (3 g, 8.12 mmol), Pd(PPh 3 ) 4 (0.094 g, 0.081 mmol) and potassium carbonate (2.246 g, 16.25 mmol) were dissolved in a DME (100 ml)/Water (20 ml) mixture under nitrogen to give a yellow suspension. The reaction mixture was refluxed under nitrogen for 14 h. After cooling to room temperature, the organic phase was separated and the solvent was evaporated. The residue was purified by column chromatography on silica gel with heptane/DCM (1/1,v/v) as the eluent and recrystallized from heptane to yield compound cc-1 (2.5 g, 63%) as a white solid.
[0147] Application in OLED
[0148] All devices were fabricated by high vacuum (˜10 −1 Torr) thermal evaporation. The anode electrode was 80 nm of indium tin oxide (ITO). The cathode electrode consisted of 1 nm of LiF followed by 100 nm of Al. All devices were encapsulated with a glass lid sealed with an epoxy resin in a nitrogen glove box (<1 ppm of H 2 O and O 2 ) immediately after fabrication, and a moisture getter was incorporated inside the package.
Device Examples
[0149] A set of device examples have organic stacks consisting of, sequentially, from the ITO surface, 10 nm of LG101 (from LG Chem) as the hole injection layer (HIL), 45 nm of PPh-TPD as the hole-transport layer (HTL), 40 nm of emissive layer (EML), followed by 30 nm of aDBT-ADN with LiQ as the electron-transport layer (En). The EML has two components, 90 wt % of invented compounds (1a-1 or 3a-1) or comparative compound (CC-1) as the host and 10 wt % of GD as the emitter. The structures of the compounds used are shown below.
[0000]
[0150] Table D1, below, is a summary of the device data, power efficiency (PE) and lifetime (LT97), recorded at 9000 nits for the devices. Device lifetime LT97 is defined as the time it takes for devices to decay to 97% of their original luminance under a constant current density with an initial luminance of 9000 nits, and the values are normalized to that of Device C-1. All devices were fabricated twice and the average data were used in this table.
[0000]
EML
PE
LT97
Device
Host
Emitter
[lm/W]
[A.U.]
Device-1
1a-1
GD
15.3
177
Device-2
3a-1
GD
16.8
193
Device C-1
cc-1
GD
10.9
100
[0151] The data in Table D1 shows that OLEDs (Device-1 and Device-2) using inventive compounds (1a-1 and 3a-1) as the host in the EML exhibit higher efficiency and longer lifetime than their counterparts using comparative compound (cc-1) as the host. This improved performance of inventive compounds is attributable to their unique chemical structures which might have provided more balanced charge carrier fluxes that is critical for enhancing device efficiency and stability.
[0152] It is understood that the various embodiments described herein are by way of example only, and are not intended to limit the scope of the invention. For example, many of the materials and structures described herein may be substituted with other materials and structures without deviating from the spirit of the invention. The present invention as claimed may therefore include variations from the particular examples and preferred embodiments described herein, as will be apparent to one of skill in the art. It is understood that various theories as to why the invention works are not intended to be limiting. | This invention discloses novel compounds containing carbazole and (or) DBX units, separated with polyaromatic spacers. These compounds can be used as hosts for PHOLEDs. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a memory test circuit enabling a central processing unit (CPU) to test a memory having a data width greater than the data width of the data bus linking the memory to the CPU.
[0003] 2. Description of the Related Art
[0004] So-called system-on-a-chip devices, for example, are often structured to transfer data directly between memory and peripheral computational circuits on a wide data bus, without the intervention of the CPU. One example of such a device is described in Japanese Patent Application Publication No. 2000-357372. When the device is fabricated, it is tested by having the CPU execute a self-test program. As part of the self-test, the CPU must write test patterns in the memory, so a memory test circuit, which is a type of switching circuit that connects the memory to the CPU, is provided. If the width of the CPU data bus is less than the data width of the memory, the memory test circuit must also convert the data width.
[0005] [0005]FIG. 1 schematically shows a conventional memory test circuit. This memory test circuit tests a memory (MEM) 1 having an m-bit data width by using a CPU 2 having an n-bit data bus (m>n). To convert between m-bit and n-bit data, the circuit includes an m-bit register (REG) 3 , L n-bit registers 4 1 , 4 2 , . . . , 4 L (where L is the least integer equal to or greater than m/n), and a selector (SEL) 5 . Register 3 is coupled between the data input-output terminals of the memory 1 and registers 4 1 - 4 L . Registers 4 1 - 4 L are coupled in parallel to the data bus of the CPU 2 . Selector 5 selects n-bit portions of the data stored in register 3 and supplies the selected data to the CPU 2 .
[0006] In this type of memory test circuit, an m-bit word of data written into the memory 1 is first written from the CPU 2 into registers 4 1 - 4 L as separate n-bit portions of write data WDT, requiring L write cycles; then the n-bit portions of write data are transferred all at once through register 3 into the memory 1 . Similarly, m-bit data read from one word in the memory 1 are stored in register 3 temporarily, and the stored data are divided into n-bit portions in selector 5 and sequentially supplied to the CPU 2 as read data RDT. Accordingly, even though the memory 1 can input or output m bits per cycle, each reading or writing operation requires (L+1) cycles.
[0007] In, for example, a memory test using the marching cubes algorithm (a specific procedure for which will be given later), a total of ten test cycles, including six write cycles and four read cycles, are inherently necessary for each word in the memory 1 . In the memory test circuit described above, (L+1) times as many cycles are required; that is, 10(L+1) cycles are required. Even in a simpler memory test using a checker pattern or the like, that inherently requires only four cycles (two write cycles and two read cycles) per word, 4(L+1) cycles are needed, and in a memory test using a diagonal pattern, 2(L+1) cycles are required for writing and reading.
[0008] The conventional memory test circuit described above is problematic because the test data must be written from the CPU 2 into registers 4 1 - 4 L in multiple separate portions, greatly increasing the necessary number of test cycles.
SUMMARY OF THE INVENTION
[0009] An object of the present invention is to provide a memory test circuit that can test a memory having a greater data width than the width of the test processor's data bus without increasing the number of test cycles.
[0010] A memory test circuit according to the present invention is interposed between a processing unit and a memory having a greater data width than the processing unit. The memory test circuit includes a data expander and a data divider. The data expander expands write data received from the processing unit from the data width of the processing unit to the data width of the memory, for writing into the memory. The data divider divides data read from the memory into portions having the data width of the processing unit and supplies these portions sequentially to the processing unit.
[0011] The data expander may expand the write data by, for example, copying one or more specific bits of the write data to other bit positions. Some of the copied bits may be inverted to produce, for example, a checkerboard pattern. The data expander may also perform an arithmetic operation on the write address to generate additional bits of write data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the attached drawings:
[0013] [0013]FIG. 1 is a block diagram illustrating a conventional memory test circuit;
[0014] [0014]FIG. 2 is a block diagram illustrating a memory test circuit according to a first embodiment of the invention;
[0015] [0015]FIG. 3 is a block diagram illustrating a bit expander according to a second embodiment of the invention; and
[0016] [0016]FIG. 4 is a block diagram illustrating a memory test circuit according to a third embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Embodiments of the invention will now be described with reference to the attached drawings, in which like elements are indicated by like reference characters.
FIRST EMBODIMENT
[0018] Referring to FIG. 2, in the first embodiment, a memory (MEM) 1 having an m-bit data width is tested by a CPU 2 having an n-bit data width (m>n). A bit extender 11 enables the CPU 2 to write m bits of data into the memory 1 in a single operation. A selector (SEL) 12 and an address decoder 13 enable data read from the memory 1 to be supplied to the CPU 2 in n-bit portions. The selector 12 and address decoder 13 constitute the data divider, while the bit extender 11 constitutes the data expander.
[0019] The bit extender 11 expands n bits of write data WDT, which are output from the CPU 2 on its data bus, to m bits of data by outputting the n bits of write data WDT to the n low-order bit positions (bit 0 to bit n−1), and outputting the most significant of these n bits (bit n−1) to all higher-order bit positions (bit n to bit m−1). The m bits of expanded data are supplied to the data input terminals of the memory 1 .
[0020] The selector 12 divides m bits of the data output from the data output terminals of the memory 1 into L n-bit portions, and supplies the n-bit portions of data separately to the CPU 2 as read data RDT. If m is not an integer multiple of n, the m-bit data may be padded with additional ‘0’ bits, for example, at the high-order end to adjust the size of each portion of read data RDT to n bits.
[0021] The address decoder 13 decodes the high-order bits of an address signal ADR output from the CPU 2 , and generates a select signal for the selector 12 . Although the address signal ADR basically specifies a read or write access area in the memory 1 , further high-order bits are added to the address signal ADR as a signal controlling selection by the selector 12 , in addition to the bits required for specification of the memory area in the memory 1 .
[0022] Next, the operation of this memory test circuit will be described, taking as an example a memory test performed by the marching cubes algorithm.
[0023] (Step 1 ) All ‘0’ bits are written from the CPU 2 into all addresses in the memory 1 . Since all n bits of the write data WDT output from the CPU 2 are ‘0’, all m bits of the expanded data produced in the bit extender 11 are also ‘0’. These m bits of ‘0’ data are written in the memory 1 . Accordingly, the number of cycles required for step 1 is equal to the number of words in the memory 1 . This number will be denoted ‘k’ below.
[0024] (Step 2 ) The following processes (A) and (B) are repeated in order from the lowest address to the highest address in the memory 1 .
[0025] (A) One m-bit word is read from the specified address in the memory 1 and divided into n-bit portions by the selector 12 . The n-bit portions are supplied one by one to the CPU 2 , which checks that all n bits are ‘0’.
[0026] (B) As the check of each address is completed, all ‘1’ bits are written into the address.
[0027] Since for each word, the number of cycles required is L for process (A) and 1 for process (B), the number of cycles required for step 2 is (L+1)k.
[0028] (Step 3 ) The following processes (C) and (D) are repeated in order from the highest address to the lowest address.
[0029] (C) One m-bit word is read from the specified address in the memory 1 and divided into n-bit portions by the selector 12 . The n-bit portions are supplied one by one to the CPU 2 , which checks that all n bits are ‘1’.
[0030] (D) As the check of each address is completed, all ‘0’ bits are written into the address.
[0031] Since for each word, the number of cycles required is L for process (C) and the 1 for process (D), the number of cycles required for step 3 is (L+1)k.
[0032] (Step 4 ) Steps 1 - 3 are repeated, reversing the values of the data written into the memory 1 .
[0033] The total number of test cycles required for the processes in steps 1 - 4 is 2(2L+3)k. This is less than half the number of test cycles required by the conventional memory test circuit in FIG. 1. The exact ratio of the numbers or test cycles is (2L+3)/(5L+5).
[0034] As described above, the memory test circuit in the first embodiment includes a bit extender 11 that expands the write data WDT received from the CPU 2 from the n-bit data width of the CPU 2 to the m-bit data width of the memory 1 by extending the most significant bit, and supplies the expanded data to the memory 1 . The memory test circuit has the advantage of enabling a CPU to test a memory having a greater data width than the width of the CPU data bus without increasing the number of test write cycles.
SECOND EMBODIMENT
[0035] Referring to FIG. 3, in the second embodiment, the bit extender 11 in FIG. 2 is replaced with a bit expander 11 A for use in a checker pattern memory test. In this type of test, different values (‘0’ and ‘1’) are written into neighboring memory cells in the cell matrix of the memory cell array. The test is referred to as a checker pattern test because the layout of the data on the memory cell array creates a checkerboard pattern.
[0036] The bit expander 11 A expands the n-bit write data WDT supplied from the CPU 2 to m-bit data by copying the most significant bit as in the first embodiment, but inverts the copied-bits in alternate bit positions, starting with the lowest-order copied bit (bit n). The m-bit expanded data are supplied to the data input terminals of the memory 1 .
[0037] Next, the operation of a checker pattern memory test performed with the memory test circuit having the bit expander 11 A will be described. As in the first embodiment, k is the number of m-bit words in the memory 1 , and L is the least integer equal to or greater than m/n.
[0038] (Step 1 ) For all addresses, the CPU 2 outputs n-bit data alternating between ‘0’ and ‘1’ at successive bit positions. The value of each bit also alternates between ‘0’ and ‘1’ at successive addresses, to create a checkerboard pattern of data in the memory 1 . Since the bit expander 11 A continues the same alternating pattern in the higher order bit positions (bit n to bit m−1), the m bits of expanded data also create a checkerboard pattern when written in the memory 1 . The number of cycles required is k for the process in step 1 .
[0039] (Step 2 ) One m-bit word is read from a specified address in the memory 1 and divided into n-bit portions by the selector 12 . The n-bit portions are supplied one by one to the CPU 2 , which checks whether the n bits have the correct pattern. This process is repeated in order from the lowest address to the highest address in the memory 1 . The number of cycles required is Lk for the process in step 2 .
[0040] (Step 3 ) Steps 1 and 2 are repeated, reversing the values of the data written into the memory 1 .
[0041] The total number of test cycles required for the processes in steps 1 - 3 is 2(L+1)k. This is half the number of test cycles that would be required by the conventional memory test circuit in FIG. 1.
[0042] As described above, the bit expander 11 A in the second embodiment expands write data WDT received from the CPU 2 from the n-bit data width of the CPU 2 to the m-bit data width of the memory 1 by creating a pattern that alternates between ‘0’ and ‘1’ from bit n−1 to bit m−1, and supplies the expanded data to the memory 1 . The advantages of the second embodiment in the checker pattern test are similar to the advantages of the first embodiment in the marching cubes test.
[0043] In a variation of the second embodiment, bit (n−1) is copied to the odd-numbered high-order bit positions (n+1, n+3, . . . ) and bit (n−2) is copied to the even-numbered high-order bit positions (n, n+2, . . . ), eliminating the need for the inverters shown in FIG. 3.
THIRD EMBODIMENT
[0044] Referring to FIG. 4, in the third embodiment, the memory test circuit is used to expand a diagonal test pattern. The data expander includes a word address converter 14 and a diagonal pattern generator 15 instead of the bit extender 11 in FIG. 2. The diagonal pattern is a pattern of ‘1’ bits forming a plurality of diagonal lines on the memory cell array, with ‘0’ bits in other positions.
[0045] The word address converter 14 discards the low-order bits of the address signal ADR output from the CPU 2 to generate an address signal ADU designating an m-bit word line in the memory 1 . The output side of the word address converter 14 is connected to the diagonal pattern generator 15 .
[0046] The lower n(L−1) bits of each word of the expanded diagonal pattern are obtained by concatenating (L−1) copies of the n-bit write data WDT output by the CPU 2 .
[0047] The diagonal pattern generator 15 includes a divider 15 a and multiplier 15 b that generate the remaining r high-order bits of each word, where r=m-n(L−1). The divider 15 a divides the address signal ADU by r, discards the quotient, and outputs the remainder q. If m is not an integer multiple of n, the number r is equal to the remainder when m is divided by n. The multiplier 15 b (actually an exponentiator) generates r bits of data in which the q-th bit is set to ‘1’ and the other bits are ‘0’, indicating the q-th power of two.
[0048] The r high-order bits of data output from the multiplier 15 b are concatenated to the n(L−1) bits of low-order data obtained by duplicating the write data WDT output from the CPU 2 to create an m-bit word that is supplied to the data input terminals of the memory 1 . The ‘1’ bits output by the CPU 2 and multiplier 15 b shift one bit position to the left at each successive address, returning to the original bit position at every n-th address in the lower bit positions and at every r-th address in the upper bit positions, creating a diagonal pattern.
[0049] Next, the diagonal pattern memory test in this memory test circuit will be described. As in the first embodiment, k is the number of words in the memory 1 , and L is the least integer equal to or greater than m/n.
[0050] (Step 1 ) The CPU 2 generates n-bit diagonal test pattern data for all word addresses. This pattern is expanded by repetition to an n(L−1)-bit diagonal test pattern, and further expanded by the diagonal pattern generator 15 to create an m-bit diagonal test pattern, which is written a word at a time into the memory 1 . The number of cycles required is k for the process in step 1 .
[0051] (Step 2 ) One m-bit word is read from a specified address in the memory 1 and divided into n-bit portions by the selector 12 . The n-bit portions are supplied one by one to the CPU 2 , which checks whether the n bits have the correct pattern. This process is repeated in order from the lowest address to the highest address in the memory 1 . The number of cycles required is Lk for the process in step 2 .
[0052] The total number of test cycles required for the processes in steps 1 and 2 is (L+1)k. This is half the number of the test cycles that would be required by the conventional memory test circuit in FIG. 1.
[0053] As described above, the memory test circuit in the third embodiment expands the n-bit diagonal test pattern generated by the CPU 2 to n(L−1) bits by repetition, and concatenates further diagonal test pattern data of width r to create m-bit diagonal test pattern data matching the m-bit data width of the memory 1 . The advantages of the memory test circuit in the third embodiment in the diagonal test are similar to the advantages of the first embodiment in the marching cubes test.
[0054] The invention is not restricted to the embodiments described above; numerous variations are possible, three examples of which are described below.
[0055] (a) Although the write data WDT output from the CPU 2 are used for the n lower bit positions of the m-bit test patterns in FIGS. 2 and 3, if the marching cubes algorithm or a simple pattern such as a checker pattern is used, the memory test circuit can generate the entire m-bit test pattern on command from the CPU 2 .
[0056] (b) Although the diagonal pattern bits output from the CPU 2 as write data WDT in FIG. 4 were only supplemented by the diagonal pattern bits generated in the diagonal pattern generator 15 , the diagonal pattern generator can be modified to create an entire m-bit diagonal pattern.
[0057] (c) Although the memory test circuits shown in FIGS. 2, 3, and 4 are useful in memory tests performed by the marching cubes algorithm, the checker pattern, and the diagonal pattern, memory test circuits that are similarly useful for memory tests with other test patterns can be obtained by modifying the bit extender 11 , the bit expander 11 A, or the word address converter 14 and diagonal pattern generator 15 .
[0058] As described in detail above, the memory test circuit according to the invention includes a data expander that expands write data received from the processing unit from the data width of the processing unit to the data width of the memory, so that an m-bit word of test data can be written into the memory each time the CPU 2 outputs n bits of test data. The number of write cycles required for testing the memory therefore remains the same, no matter how large the data width (m) of the memory may be.
[0059] Those skilled in the art will recognize that further variations are possible within the scope of the invention, which is defined in the appended claims. | A memory test circuit receives test pattern data from a processing unit having a first data width, expands the test pattern to a second data width greater than the first data width, and writes the expanded test pattern data into a memory having the second data width, thereby avoiding the need for extra write cycles when a processing unit tests a memory having a greater data width. The test pattern data may be expanded by, for example, copying a specific bit to multiple bit positions, inverting a specific bit and copying the inverted bit to multiple bit positions, or performing arithmetic operations that generate a test pattern similar to the test pattern received from the processing unit. | 6 |
FIELD OF THE INVENTION
The present invention relates generally to a method of making a test and posting the test on-line for potential test-takers.
BACKGROUND AND SUMMARY OF THE INVENTION
Tests play a key role in everyday life around the world. In international business and education, a test is a standard vehicle for assessing proficiency, measuring aptitude or determining skill and knowledge. Virtually every profession requires proof of mastery through a licensing and certification test.
The present invention provides a method of making a test with images and sound files and posting the test on-line for potential test-takers. (In the context of the present application, “test” refers to any exam, assessment, survey, lesson plan, etc. comprising questions to be answered.) A host system and a plurality of remote terminals operatively coupled to the Internet are provided. Questions are input at one of the remote terminals by a test-maker. The questions are compiled into a test by the host system and then posted on-line for potential test-takers.
The step of posting the test on-line preferably includes placing the compiled test in a directory for access by potential test-takers. The directory preferably has a plurality of categories corresponding to different types of tests and the compiled test is placed in the appropriate category. For ease in administration, a just-made test is placed into a temporary category so that it may be later reviewed (by the proprietor of the host system) and placed in the most appropriate category. A test-maker is encouraged to provide input (e.g., via e-mail) as to the most appropriate category.
The test-taker may be charged for the taking of the test and, if so, it is desirable that the test-taker be able to preview the test that he/she selects from the directory. The test-maker and the proprietor of the host system preferably share the revenues generated by the test-taker taking the test. For example, the revenues could be split (i.e., 50/50).
The present invention additionally or alternatively provides a method of posting a test on-line for potential test-takers wherein the test is placed in a restricted directory. In this case, the test-taker is required to input a password to access the compiled test. The restricted directory may include tests made on-line and/or standardized tests directly input into the system. For example, the restricted directory could include academic practice tests and a school could enroll students at a set cost per school year. Alternatively, an institution could be charged based on each time a test is taken or each time the web site is visited.
These and other features of the invention are fully described and particularly pointed out in the claims. The following descriptive annexed drawings set forth in detail one illustrative embodiment, this embodiment being indicative of but one of the various ways in which the principles of the invention may be employed.
DRAWINGS
FIG. 1 is a block diagram of a system according to the present invention.
FIG. 2 is a block diagram of a host system.
FIG. 3 is a block diagram of the software environment for one embodiment of the present invention.
FIG. 4 is a flow chart of test-making and test-taking procedure.
FIGS. 5A-5M are web pages used during test-making.
FIGS. 6A-6F are web pages used during test-editing.
FIGS. 7A-7D are web pages used during test-taking.
FIGS. 8A-8B are web pages used during report-generating.
DETAILED DESCRIPTION
Referring now to the drawings in detail, and initially to FIG. 1, a system 10 according to the present invention is shown. In the system 10 , a host system 12 exchanges data with a plurality of remote terminals 14 and 16 through data transmission across telephone and data transmission lines 18 . Data transmission on the host end utilizes a host gateway 20 which interfaces the host system 12 to the network with a protocol understood by the remote terminals 14 and 16 (or intermediary equipment connected thereto). For example, on the Internet, transmission control protocol/Internet protocol (TCP/IP) typically is used.
In the illustrated system 10 , there are three “test-making” terminals 14 and three “test-taking” terminals 16 . This is, of course, an extremely simplified version of the present invention. In actual implementation, the system 10 would include many more terminals 14 and 16 . Specifically, for example, the preferred system 10 utilizes a network such as the Internet whereby thousands and thousands of users would access the system 10 . Moreover, the test-making terminals 14 may also be test-taking terminals, and/or the test-taking terminals 16 may also be test-making terminals, at different times. In any event, prospective test-makers and/or test-takers gain access over the telephone and data transmission lines 18 to the host system 12 by contacting the host gateway 20 . This contact can be established on a network such as the Internet by sending data packets to an electronic address associated with the host system 12 .
Referring now to FIG. 2, the host system 12 is shown in more detail in block diagram. The host system 12 includes a controller 22 having a central processing unit (CPU) and associated read only memory (ROM). The ROM provides software instructions to perform basic operations upon power up of the system 12 . Once the host system 12 receives these instructions, the CPU reads the operating system instructions stored on disk to configure the system and to permit execution of the applications programs.
The controller 22 is connected along data and address bus lines 24 to a random access memory (RAM) 26 and mass storage device 28 . These components are operatively connected to input/output interface devices 30 which control various corresponding input/output devices 32 . These I/O devices 32 include such conventional elements as a video display, a keyboard, a printer, and other input devices such as a mouse and a digitizer or scanner. The illustrated host system 12 includes a modem 34 to exchange information with remote terminals over standard voice lines, although devices could instead be used to transfer data between the host system 12 and the various remote terminals 14 and 16 of the system 10 .
Referring now to FIG. 3, the software configuration of the host system 12 is generally illustrated. The host system 12 operates under control of an operating system 36 that permits various application processes to be executed. These include a communications application 38 and a data management, storage, and retrieval application 40 (i.e., a database application). The communications application 38 permits data transfer with the remote terminals 14 and 16 whereby test-makers and test-takers may log onto the host system 12 and either make or take tests. The data base application 40 organizes the information input by test-makers and test-takers and stores this organized information in one or more mass storage devices, such as the mass storage device 28 described above. Other applications 42 may also be included in the software environment.
Referring now to FIG. 4 a flow chart of the preferred system 10 is shown. In the preferred embodiment, the host system 12 provides a home page 50 that is accessible to both potential test-makers and test-takers. This home page 50 allows the user to cast themselves as either a test-maker or test-taker. Preferably, the program loads in images and sound files associated with the web page 50 and also the other web pages discussed below.
If the user is a test-maker, he/she is required to input an identifier, such as e-mail address, password, and/or account number, on a web page 52 . The user's account is then verified and the test-maker is presented with a web page 54 whereat he/she chooses to make a new test, edit an existing test, or generate a report. If the user does not yet have an account, one is set up and the test-maker is then presented with the web page 54 .
If the test-maker decides to make a new test, he/she is then presented with a series of web pages generally indicated at 55 in FIG. 4 and individually shown in detail in FIGS. 5A-5M. After making the test, it is placed in a directory for access by potential test-takers, this directory preferably including a plurality of categories such as, for example, career, civil service, creativity, current events, educators, entertainment, etc. In the preferred and illustrated embodiment, the just-made test is temporarily placed in a “slush category” until it can be reviewed in detail to determine the most appropriate category. The test-maker is encouraged to contact the proprietor of the host system 12 by e-mail, for example, to provide suggestions for the permanent category.
If the test-maker decides to edit an existing test, he/she is presented with a series of web pages illustrated schematically at 56 in FIG. 4 and as shown in detail in FIGS. 6A-6F. Once the editing is complete, the revised or edited version of the test is placed back in the directory under its permanent category.
If the test-maker decides to generate a report, he/she is presented with a series of web pages illustrated schematically at 57 in FIG. 4 and shown in detail in FIGS. 8A-8B.
As was indicated above, the home page 50 allows the user to cast himself as either a test-maker or a test-taker. If the user is a test-taker, he/she is also required to input an identifier, such as e-mail address, password, and/or account number at 62 . If the identifier is recognized by the host system 12 , the directory of test categories is displayed on web page 64 . Otherwise, an account is set up for the user and the web page 64 is displayed.
The test-taker chooses a category and the tests contained in this category are displayed on web page 66 . The test-taker then chooses a test and he/she is presented with the web pages shown schematically at 68 and shown in detail in FIGS. 7A-7E. Once the test is taken, certain data regarding the test-taker and the test are conveyed to the report storage. This data may include, for example, the identity of the test-taker, the score on the test, the time it took to complete the test, and other relevant information.
The test-maker may provide his/her test for free to potential test-takers. Alternatively, the test-maker may decide to charge a test-taker per test. To this end, the host system 12 includes a procedure for opening an account for a test-taker. For example, the home web page 50 could include an account-opening link on which the test-taker clicks to open an account. The test-taker would then be prompted to enter his/her e-mail address and to choose a password. To activate the account, a purchase link could be used to purchase electronic credits via a credit card. For example, each credit could have a value of ten cents and a user could be required to purchase at least ten dollars worth of credits (i.e., one hundred credits). As the credits are spent on tests, they are automatically deducted from the test-taker's account. Once the account is depleted, the test-taker is preferably notified.
In the preferred system 10 , the credits are shared between the test-maker and the proprietor of the host system 12 . For example, a fifty-fifty split of the revenues could be made between the test-maker and the host system proprietor. An account is opened for a test-maker in the same manner as described above for the test-taker (except that a purchase of credits may not be necessary). Since a user may be both a test-maker and a test-taker, a single user may both earn credits (from others taking a test that he/she made) and spend credits (by taking tests that others have made).
Referring now to FIGS. 5A-5M, the test-making web pages 55 are shown in detail. For ease in explanation, a very simplified test is used to demonstrate the principles of the invention. In actual use, tests may be much more complicated and lengthy.
The test-maker is initially provided with a web page having fields for inputting a test name, a header, and a footer. (FIG. 5A.) The test name will be used to display or identify the test in the directory. Accordingly, the test name should be descriptive and interesting, but preferably relatively short. The header is typically explanatory text and will be shown on each page of the generated test. The footer is shown when the test is scored whereby it preferably includes information or ratings corresponding to different scores. This information is then entered by clicking on the “add” icon. (FIG. 5B.) Alternatively, to start over, the test-maker may click on the “reset” icon.
The test-maker is then provided with a display including the quiz name, the header and the footer. (FIG. 5C.) At this point a test number (13337) is assigned. Also, the enable function is set at “No” to prevent the test from being posted to test-takers prior to its completion. “Test Options” may be clicked on to allow the test-maker to put in certain test-taking criteria, such as time allotted for taking the test, persons authorized to take the test, and/or cost of taking the test. Once the test number is recorded by the test-maker, and the accuracy of the quiz name, header and footer are verified, the “Update Test ” icon is clicked on to update the test. The test-maker then clicks at the appropriate place (“here”) to add the question.
The test-maker is then provided with a web page for inputting questions. The web page preferably identifies the test number and provides fields for entering the question type, the question statement, the answer choices, the correct answer, the value of correct answers, and an explanation. (FIG. 5D.)
The test-maker selects the question type (multiple choice is selected for question 1 in the illustrated example), inputs the question statement, inputs the answer choices, inputs the correct answer(s), assigns a value to the various possible answers, and inputs an explanation for the correct answer. (FIG. 5E.) A display is then provided which shows the test description table and lists the question number, the type of question, and the question statement for each of the questions entered so far. (FIG. 5F.)
As shown in FIGS. 5G-5L, the process is repeated as three more questions are inputted. In question number 2 , the multiple choice question type is used to make a true/false question. (FIGS. 5G and 5H.) In question number 3 , the short answer question type is selected and the complete answer is written out in different variations, namely, “four”, “4”, “four apples” and “4 apples”. (FIGS. 5I and 5J.) In question number 4, a multiple answer question type is selected and input. (FIGS. 5K and 5L.) It may be noted that although in the illustrated embodiment the questions are added one after the other, the order may be changed by clicking on the “Add After” icon in an intermediate question row. Also, to edit an existing question, the test-maker may click on the question number. (FIGS. 5H, 5 J, and 5 L.)
Once the desired number of questions are input, the enable field is set to “YES.” (FIG. 5M.) The test is then compiled and placed into the directory whereat it is available for potential test-takers.
Referring now to FIGS. 6A-6F, the test-editing web pages 62 are shown in detail. To identify the test to be edited, the test number assigned to the test (see FIG. 5C, above) is input and the “Edit Test” icon is clicked. (FIG. 6A.) The system 10 is designed so that a test can only be edited by its test-maker and the proprietor of the host system 12 if necessary.
The test-editing web page provides a display of the current name, header, footer, question number, question type, and question statement. (FIG. 6B.) The non-question portions of the test, such as the quiz name, the header and/or the footer may then be edited. For example, in the illustrated embodiment, the first few words of the header have been edited. (FIG. 6C.)
The questions may also be edited by clicking on the desired question number. For example, if “1” is clicked on, a web page will be provided displaying the particulars of the first question. (FIG. 6D.) The question type, question statement, answer choices, correct answer and/or explanation may then be updated. For example, in the illustrated embodiment, the question statement is updated to clarify that “two apples fall out of the basket.” (FIG. 6E.) The “update” icon may then clicked to revise the question accordingly. A question may be deleted by clicking on the “delete” icon.
In the editing embodiment of the invention shown in FIGS. 6A-6E, the test is not enabled. In other words, the enable input is set at “No”. After the editing is complete, the test may then be enabled by changing the enable input to “Yes”. (FIG. 6F.) The revised test will be then replace the “unedited” version of the test in the directory.
Referring now to FIGS. 7A-7D, the test-taking web pages 68 are shown in detail. Once the test-taker selects a test from the directory, a preview of the test is provided for the test-taker. (FIG. 7A.) In the illustrated embodiment, the preview page shows the header, the question numbers and the question statements. To take the test, the test-taker clicks on the indicated icons.
The compiled test is then displayed to the test-taker. (FIG. 7B.) Each question statement is followed by either answer choices (questions 1 , 2 and 4 ) or a space for filling in the correct answer (question 3 ). The test-taker inputs his/her proposed answers to the questions and then clicks on the “Score It” icon. (FIG. 7C.)
The test is then almost instantaneously scored and the test-taker is provided with the results. (FIG. 7D) Each question is followed by a statement of the test-taker's inputted answer and the correctness thereof. If the test-taker inputted answer was incorrect, the explanation is provided (questions 1 and 4). The web page also provides a score board summarizing the number of correct answers, wrong answers, unanswered questions and the points associated therewith. The footer is provided under the score board to help the test-taker interpret his performance on the test.
Referring now to FIGS. 8A and 8B, the report-making web pages 57 are shown. Once the test-maker chooses to generate a report, an initial display is provided for the entry of data. (FIG. 8A.) The report is then automatically generated by the host system 12 and displayed to the test-maker. (FIG. 8B.)
As was explained above, the compiled test is placed in a directory under a category. In the preferred system 10 , the directory includes a plurality of tests from a plurality of different test-makers. Some or all of these tests may have been compiled by a test-maker in the manner described above. However, preferably, this directory will also include practice exams and tests conventionally provided in a paper or book form. For example, the directory may preferably include professional licensing and certification tests and graduate school practice tests (i.e., SAT, ACT, GMAT, LASAT, TOEFL,). Additionally or alternatively the directory may preferably include pre-employment and employment tests such as programming and operating system tests, Office Proficiency Assessment & Certification tests, personality profiling tests, civil service practice tests, real estate license practice tests, investment tests, IQ tests, self-diagnosis tests, and career guidance tests. The directory may further include more entertainment-geared tests such as puzzles, sports trivia quizzes, etc.
The tests in the directory may be available to anyone having, for example, Internet access. However, in certain settings, it may desirable, or necessary for security reasons, to limit access to certain tests. For example, a corporation may want to limit its screening tests only to potential candidates. An educational or academic institution may wish to limit its test to certain students. In such cases, a restricted directory may be developed that functions as an intranet and access thereto is limited by knowledge of a password. In this manner, the corporation or organization controls the content of its testing program and also the test-taking participants. Once a test has been taken by an authorized participant, the scores are immediately and automatically e-mailed to the administrator and/or they appear instantly online.
With a restricted directory, a corporation or organization may purchase tests, particular to its specific needs, from the general directory. Additionally, the test-making method described above may be used to make tests regarding new product and services of the company. Also, opinion polls may be conducted within an organization with or without anonymity. With particular reference to educational settings, teachers and professors often wish to create their own tests during each teaching session to ensure integrity and to accommodate changing curriculum. As such, the test-making method described above, in combination with a restricted directory, is believed to be very advantageous to the academic community. Also, various organizations may “buy” and “sell” tests as a fund-raising activity and as a way to eventually end the tedious task of grading papers. In any event, a job candidate, employee or student simply needs a computer with Internet access and the required password to take the test, or participate in surveys.
The restricted directory is preferably provided by the proprietor of the host system 12 by charging a set-up fee and a certain amount per user per period of time. For example, if a restricted directory included SAT/ACT and Advanced Placement practice courses and tests, a high school could enroll students at ten dollars per student per school year. The enrolled students could then practice as often as necessary or desired. Alternatively, the restricted directory may be provided by charging per time a user takes a test, or per time a user visits the website.
One may appreciate that although the invention has been shown and described with respect to a certain preferred embodiment, obvious and/or equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification. The present invention includes all equivalent alterations and modifications and is limited only by the scope of the following claims. | A method of making a tests, assessments, surveys and lesson plans with images and sound files and posting them on-line for potential users. Questions are input by a test-maker and then the questions are compiled into a test by a host system and posted on-line for potential test-takers. The compiled test may be placed in a directory for access by the test-takers, the directory preferably having a plurality of categories corresponding to different types of tests and the compiled test is placed in the appropriate category. For ease in administration, a just-made test is placed into a temporary category so that it may be later reviewed (by the proprietor of the host system) and placed in the most appropriate category. | 8 |
BACKGROUND OF INVENTION
[0001] The present invention relates to a drill bit for use in drilling a bore in a hard-rock formation; and more specifically, to a rotary drill bit having a plurality of hardened cutting elements providing a polycrystalline diamond compact (PDC) crown coating on each spaced carbide insert button for scuffing a bore hole face and providing a secondary shadowing or redundant hardened PDC crowned cutting element to assume the scuffing action at the same radial groove created by the primary cutter element, after wear removes the PDC crown from the primary button. Button drill bits have long been known to be useable for drilling in formations for percussion-type bits. Some have suggested shaped button drill bits for rotary drill bit applications having cutting edges for cutting into the rock face. Others have provided enlarged buttons for crushing engagement of the well bore face. As an example, U.S. Pat. No. 4,109,731 discloses a drill bit having a plurality of PDC cutter element disposed on a bit shank, but which does not attempt to systematically scour the face of the bore and only seeks to minimize the chipping forces experienced by the brittle PDC element. In the '731 patent, the cutters are angled and mounted on compression fit posts to maximize the support given the cutter element. The PDC elements have long been known to withstand direct engagement with the well bore face but easily chip when minimally stressed on an angle to the cutter body. References herein to PDC cutter elements shall mean polycrystalline diamond compact crowns or coverings on carbide inserts. The present arrangement seeks to maximize the scouring force while aligned with the longitudinal orientation of each PDC cutter element, thereby maximizing wear and minimizing chipping. The spacing of the elements and the generous fluid flow around them prevents chipping forces from prematurely fracturing the PDC elements.
SUMMARY OF INVENTION
[0002] This rotary drill bit comprises a body having a proximal end adapted to connect to a drill string with a longitudinal passage accommodating a fluid flow through a face on a distal end of the drill bit. The rotary drill bit is populated with PDC elements which are ballistic conical buttons providing a minimal radius point to contact a bore face with a scuffing motion, thus removing a minimal amount of hardened rock in concentric tracks around the bore. These PDC elements comprise: a central PDC element with a coating of PDC creating a composite crown on a hardened element connected on the face adjacent a longitudinal axis of the drill bit; a first plurality of evenly spaced PDC crowned elements connected on the face in concentric rings providing a single point of contact on each concentric ring; and, at least three full-gauged PDC elements peripherally and evenly spaced around the face and angled from the longitudinal axis of the drill bit for contacting a bore.
[0003] This rotary drill bit can also have a second and redundant plurality of PDC elements, here each spaced about 180° from the first plurality of spaced PDC elements but placed on the same concentric radial ring, save and except for the central cutter element directly adjacent to the longitudinal axis, which has no redundant element. Each of these redundant elements has a surface profile substantially equal to the depth of the surface thickness of the PDC crown on the hardened elements of the first plurality of spaced PDC elements and there may be one or more evenly spaced plurality of PDC elements on each concentric ring. The spacing of each redundant PDC element, from one concentric ring to the next outer concentric ring, is about 120°, in the same manner as the spacing of the first plurality of elements.
[0004] At the outer edge of the rotary drill bit, the peripherally spaced full-gauged PDC crowned elements are angled away from the longitudinal axis at about 30°. As each cutter element on a concentric ring scores the wellbore face, the hardened PDC composite crown of the first plurality of spaced elements wears down. Upon full wear of the crown of each primary PDC element, the second plurality of spaced PDC elements assumes the scuffing of the well bore in place of the first on each concentric ring. The outermost elements are placed at an angle of about 30° away from the longitudinal axis to continue scuffing the well bore face as well as to prevent excessive wear on the edge of the drill bit as drilling continues into the bore.
[0005] This disclosure also provides a method for rotary drilling of hard rock providing the steps of attaching a rotary bit having radially-spaced, longitudinally-aligned ballistic conical PDC crowned carbide elements arranged in a manner that permits only a single ballistic conical element to engage a borehole face at a radius from the central longitudinal axis of the drill bit; turning the rotary bit to engage the borehole face at a central location scouring a central groove in the borehole face; increasing the forward movement of the rotary drill bit to progressively advance the crowned carbide elements against the borehole face; and, clearing borehole cuttings from the face of the borehole utilizing the hydraulic pressure from a plurality of jetting nozzles in the face of the rotary bit. The velocity of the longitudinal movement of the drill string and bit can be increased after a desired borehole width is achieved, by increasing both the speed of rotation and increasing the weight on the bit, all in a manner well known in the drilling industry. Since each radial groove is being cut in the borehole face by a single cutter, the borehole face erodes quickly from both the deepening of the grooves formed by the PDC cutter elements and the collapse of the intervening peaks from one groove to the next outer groove.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an end or face view of an embodiment of the present invention.
[0007] FIG. 2 is cross-sectional view of a portion of the drill bit of the present invention showing the relative placement of a jetting nozzle passage of one view.
[0008] FIG. 3 is a second cross-sectional view of a portion featuring the drill bit of the present embodiment showing the relative placement of the second (and third) jetting nozzle passage.
[0009] FIG. 4 is a cross-sectional schematic view depicting the central or primary cutter element adjacent the central axis of the drill bit face.
[0010] FIG. 5 is a cross-sectional schematic view of additional spaced cutter elements in a cross-sectional plane showing redundant cutter elements providing a shortened profile which become active upon wear of the primary cutter element at the same radius.
[0011] FIG. 6 is an additional, cross-sectional schematic view showing the redundant cutter elements providing a shortened profile which becomes active upon wear of the primary cutter elements.
[0012] FIG. 7 is a cross-sectional schematic view of the outer cutter elements showing a redundant cutter element and the relative location of an outer PDC element preventing wear on the outer diameter of the drill bit.
[0013] FIG. 8 is a cross-sectional view of the drill bit and the bore hole face showing the relative scuffing action of the longitudinal PDC cutter elements creating grooves in the well bore face.
DETAILED DESCRIPTION
[0014] FIG. 1 is a detailed schematic layout of the drill bit face 10 of the present application showing the arrangement of the polycrystalline diamond compact cutters (PDC) of the present embodiment. Although applicant has described these as PDC elements, other hard faced cutter element inserts might be substituted, such as cubic boron nitride (PCBN), depending on the hardness of the rock being bored, without departing from the spirit or intent of this disclosure. Junk slots 12 and a plurality of jetting nozzle passages 14 and 14 ′ permit generous use of fluid to both cool the drill bit and flush cuttings away from the bore face.
[0015] The central cutter element 16 is affixed to the drill bit adjacent the central longitudinal axis 11 of the drill bit. Central cutter element 16 is the first to engage the face of the bore and scuffs and scores the face. Since the angle of incidence of the central cutter element 16 is virtually at 90° to the rock face, no or little chipping force is experienced by this cutter element. Upon sufficient penetration of the central cutter 16 , a second cutter element 18 begins to engage the bore face. The outer diameter of this second primary cutter element 18 is located a radial distance from the longitudinal center axis 11 of the drill bit equivalent to the central cutter 16 diameter, and rotated about 120° from the radius on which the central cutter is located. In FIG. 1 , the central cutter element 16 is located on line 4 - 4 and the secondary primary cutter element 18 is located on line 5 - 5 rotated 120° from the line 4 - 4 .
[0016] Except for the central cutter element 16 , each subsequent primary cutter element, beginning with the second, has a secondary or twin, redundant or shadow cutter element shown as broken-lined elements. Accordingly, the redundant cutter 18 ′ is located on a concentric radial ring (not shown) occupied by the primary cutter 18 and is located 180° from the primary cutter 18 at the same radial distance from the longitudinal central axis 11 of the drill bit. Each redundant cutter is attached at a distance of about 0.050″ (0.13 cm) deeper into the face of the drill bit equivalent to the depth of the PDC crown on the primary cutter, thus allowing the secondary or redundant cutter to assume and continue the scuffing action commenced by the action of the primary cutter as wear erodes the PDC crown of the prior cutter.
[0017] Accordingly, PDC element 20 is located on a radius outside element 18 and rotated as described 120°. Shadow or redundant cutter element 20 ′ is on the same radius as its primary 20 , and is placed on the same radius at 180° from the primary 20 . Similarly, PDC element 22 is located on the next radial ring further from the axis and is 120° from element 20 . Its redundant cutter element 22 ′ is on the same radius at 180° from the primary cutter element 22 . Similarly, in this embodiment, primary cutter elements 24 , 26 and 28 are placed at 120° from each other and their respective secondary shadow cutter elements 24 ′, 26 ′ and 28 ′ are placed 180° on the same radius from their respective primary cutter elements.
[0018] The concentric lines shown of FIG. 1 are flats to facilitate machining and should not be construed as equivalent to the radial concentric rings for placement of the PDC crowned elements on the bit face 10 . Each of the concentric rings of cutter elements (not shown) is arranged in the same manner disposing the primary and redundant cutters around the drill bit face until the outer periphery of the drill bit is reached. Around the periphery, at least three evenly spaced PDC hardened crown elements 30 , 32 and 34 are positioned on a 30° angle from the central longitudinal axis of the drill bit as will be more accurately shown in FIGS. 2 and 3 . Secondary or redundant cutters 36 , 38 , and 40 , angled at the same 30° angle, can be inserted to the same PDC-crown-related depth to provide backup contact with the bore wall during drilling in order to prevent wear on the outer edges of the drill bit.
[0019] FIG. 2 is a first cross-sectional view of the drill bit shank showing the relative placement of the central 16 and primary 18 - 30 PDC cutter elements and a first passage 14 for fluid jetting through the drill bit through its longitudinal passage 56 . The first cutter element 16 is the central cutter and the subsequent cutter elements are the primary elements of each successive concentric ring spaced from the longitudinal axis of the drill bit. Additional hardened buttons 42 as shown in FIGS. 2 and 3 can be inserted to center the drill bit within the bore and prevent excessive wearing as the drill bit moves through the bore. FIG. 2 also discloses a breaker slot 54 found on most drill bit shanks 50 permitting the makeup of the drill bit, all in a manner well known in the drilling industry by connecting the male threaded surface 52 to a drill bit sub (not shown).
[0020] FIG. 3 is a second cross-sectional view of the drill bit shank 50 , again showing the relative placement of the PDC cutter elements 16 - 30 and a fluid passage 14 ′ connected to the longitudinal passage 56 , identical for both the second and third nozzle passages shown in FIG. 1 directed at differing angles from the longitudinal axis of the drill bit. These three nozzles 14 and 14 ′ permit abundant fluid flow around the sparsely populated drill bit face moving cuttings through the junk slots 12 identified in FIG. 1 and thereafter up the annulus to the surface. This abundant fluid flow also allows cooling of the cutter elements; thereby allowing the use of PDC cutter elements which become unstable and deteriorate at temperatures between 600° and 800° C.
[0021] FIG. 4 is a schematic and exaggerated cross-sectional view through the line 4 - 4 of FIG. 1 showing the central cutter element and the relative placement of other cutter elements spaced on other concentric rings within the drill bit face at the forth and seventh concentric ring as shown in FIG. 1 .
[0022] FIG. 5 is a schematic and exaggerated cross-sectional view through the line 5 - 5 showing the relative placement of the other cutter elements spaced on the first and fourth concentric rings described in FIG. 1 .
[0023] FIG. 6 is a schematic and exaggerated cross-sectional view through the line 6 - 6 showing the relative placement of the other cutter elements spaced at the second and fifth concentric rings shown in FIG. 1 .
[0024] Located around the periphery of the drill bit, as more fully shown in FIGS. 1 and 7 are the at least three evenly spaced cutter elements which are angled at the 30° from the longitudinal axis previously described. Redundant secondary periphery cutters, again recessed into the drill bit to a depth approximating the height of the PDC crown on each primary angled cutter element are positioned to take over and continue serving to limit wear to the drill bit shank, at the full-gauge preventing excessive wear on the edge of the drill bit as drilling continues into the bore. PDC buttons 42 can be inserted around the full diameter of the drill bit shank to minimize wear of the bit from the bore wall. These wear buttons 42 can be placed at a variety of positions along the drill bit shank in a manner well known in the art.
[0025] FIG. 8 is a cross-sectional view of the rotary drill bit bore hole face B showing the scoured grooves G rubbed in the face of the bore by the rotary movement of the PDC cutters in each distinct groove. Here, PDC cutters of line 4 - 4 , more clearly shown in FIGS. 1 and 4 , are shown scuffing grooves in the bore face B. The peaks P and P′ formed between the successive grooves G disintegrate and crumble when the central cutter 16 and adjacent cutters 22 , 22 ′, 28 and 28 ′ score the interior surfaces of each groove allowing the rock to be swept from the bore hole by the flushing drill fluid directed at them. Similar action of grooving, peak fracture and removal occur on the alternative cross-sectional planes of cutters shown in FIGS. 5-7 . The forward motion of the drill bit into the bore B continuously deepens each groove G thereby causing crumbling and fracture of the alternative peak points P and P′ which are rapidly removed from the drill bit face by the hydraulic sweep of the jetting nozzles. The swarf examined from tests run with this bit show fines originating from each groove and a larger particulate rubble from the collapsed peaks. Removal of material is both fast and effective, and wear is minimal, in the testing performed on this new and unique rotary drill bit.
[0026] Fabricators can immediately note that as the size of the drill bit made larger, exposing a greater area cut by the drill bit, the number of PDC elements increases only linearly and not in proportion to the total area of the drill bit face. This feature makes this drill bit less expensive to scale up for use in larger diameter holes; distinguishing it from other PDC drill bit products, which require additional coverage area of the PDC cutter elements to increase the size of the drill bit. The amount of space between adjacent cutter elements is believed to minimize the chipping occurring from the swarf cut from the bore face since large pathways are provided to move the cuttings into the junk slots and up the annulus. The redundant cutter elements are believed to extend the cutting life of this bit in hard rock. Testing performed in 35 Ksi granite suggests exceptional wear characteristics might be expected in drilling hard-rock formations.
[0027] Each of the foregoing aspects of the invention may be used alone or in combination with other such aspects. The embodiments described herein are exemplary only and are not limiting of the invention, and modifications thereof can be made by one skilled in the art without departing from the spirit or teachings of this invention. Many variations and modifications of the embodiments described herein are thus possible and within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described herein. | This rotary drill bit provides a plurality of spaced polycrystalline diamond compact cutter elements arranged at spaced 120° concentric rings around the face of the drill bit and a secondary, redundant deeper set polycrystalline diamond compact cutter elements placed to commence scuffing the face of a bore upon wear of the primary cutter element, thereby providing extended continuous service in hard rock drill applications previously unattainable with conventional PDC bits. | 4 |
RELATED APPLICATIONS
[0001] This application claims priority of provisional application 60/74043 filed Nov. 29, 2005
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Propellant free foamable aqueous dentifrice system.
[0004] 2. Prior Art
[0005] The desirability of a foamable toothpaste is discussed at length in Fischer et al. U.S. Pat. No. 6,139,820. This patent discusses at length the advantage of the system with respect to prevention of fluoridosis in children because of the administration and ingestion of excess fluoride. Unfortunately children also have the mischievous habit of ejecting the content of pressurized foam containers in inappropriate locations. The present invention, by requiring a fresh pump stroke per ejection, avoids this and concomitant problems of the prior art.
SUMMARY OF THE INVENTION
[0006] The propellant free foamable aqueous dentifrice system of the present invention is capable of being delivered as a foam to a toothbrush and is stable on the brush and when placed in the mouth and used for tooth cleaning, continues to generate more foam. The dentifrice suspension itself is liquid and as such can not be used without being foamed because it is so thin that it falls beneath the bristles of the toothbrush.
[0007] There is provided a novel water based dentifrice suspension which is unusable on a toothbrush in an unfoamed state consisting essentially of
[0008] negatively charged fumed Silica, positively charged fumed Aluminum Oxide, hydrated Silica abrasive and an anionic surfactant wherein said surfactant is other than Sodium Lauryl Sulfate, Sodium Lauryl Sulfoacetate an Acylglutamate or a Betaine, this suspension is readily foamable from a non-propellant pump spray container from which the thus produced foam is usable on a toothbrush in its foamed state as a dentifrice.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] It is preferred to provide a secondary surfactant selected from the group consisting of nonionic solid block polymer surfactants. It is further desirable to include one or more of the following components an anti settling agent, a humectant as well as other usual components found in tooth pastes such as flavorants and anti cavity agents such as sodium fluoride. The composition however should not be considered as limited to the components recited.
[0010] It is particularly desirable that the composition contain from about 50 to about 85%, suitably about 60-about 65% by weight of water.
[0011] A foaming agent is added to the aqueous system so as to generate the initial foam and also the subsequent foam as the teeth are brushed. This can be used as such or can be augmented by the use of a secondary surfactant to aid in mouth feel and foam density.
[0012] We have found that the use of surfactants is very critical to the stability of the system. We have identified one anionic surfactant as particularly workable, that being Sodium Lauroyl Sarcosinate as the primary foamer or surfactant, used from about 1-about 3% by weight suitably at about preferably about 1.25-about 1.50%. We have found that Sodium Lauryl Sulfate, Sodium Lauryl Sulfoacetate, Acylglutamates and Betaines interfere with the formation of the anionic/cationic complex formed by the fumed Silica and fumed Aluminum Oxide. As a result, upon extended storage, a formulation utilizing one of these surfactants forms a gelatinous mass and is unstable.
[0013] From about 1 to about 3% by weight of fumed silica, suitably about 2% and from about 1 to about 3% by weight of fumed aluminum oxide, again suitably about 2%, are preferably used, it being especially desirable that the fumed components be provided in equal amounts.
[0014] As abrasive, from about 1 to about 10% suitably from about 3-about 6%, by weight of hydrated silica, suitably amorphous synthetic precipitated silica of about 10-about 15 microns diameter, is preferably used. The hardness of the abrasive selected will depend on proposed usage, thus Degussa Sident® grade 8 (low hardness) composition is used for a children's dentifrice while Sident® grade 10 (high hardness) is used for adults.
[0015] Where a secondary surfactant is desirable it is useful to employ from about 1-about 4% by weight, of nonionic solid block polymer surfactants suitably Poloximer 407®.
[0016] The use of additional components in the system have been found useful, there include a concentration of about 0.1-about 2.0%, preferably about 0.2-about 1.0% of an anti settling agent such as an inorganic colloidal Magnesium Aluminum Silicate, humectant materials such as sorbitol or glycerin, suitably at concentrations of about 20-about 25% by weight of the entire composition are employed.
[0017] The system can contain a fluoride such as Sodium Fluoride in amounts of about 0.243% based on the total weight of the system.
[0018] The system can also contain sweeteners flavors, colorants, preservatives, medicaments, desensitizers such as various nitrate systems, anti-tartar materials, etc.
[0019] According to the present invention, the stable foam of the present invention is produced using a propellantless mechanical pump. Such a pump precisely mixes water and air upon actuation to produce a foam. While it may be possible to use a conventional mechanical foam dispenser, such as a squeeze bottle foamer, the best results have been achieved with the finger activated pump foamer.
[0020] Preferably the foam is produced using the F-2 Finger Pump Foamer™, manufactured by Air Spray International, Inc. of Pompano Beach, Fla. Such a spring loaded valve system operates without the use of gas propellants or the like. Upon actuation, precise amounts of air and liquid are mixed and a foam capable of maintaining its structure for a substantial length of time is dispensed. In addition, the dispenser can deliver a variable amount of foam so as to just fit a variable size of toothbrush.
[0021] The F-2 Finger Pump Foamer™ is similar in design and operation to conventional propellant less finger actuated mechanical pump foamers such as described in U.S. Pat. No. 5,443,569 issued on Aug. 22, 1995 and U.S. Pat. No. 5,813,576 issued Sep. 29, 1998, the disclosure of which are incorporated by reference herein. Such propellantless finger actuated mechanical foamers can be employed to dispense the stable dentifrice foam of the present invention.
[0022] The F-2 Finger Pump Foamer™ is an easy to use dispenser with excellent performance and provides a clean single stroke action, zero VOC formulations and high quality. Shaking the container will not affect the foam quality. Precise dosage per stroke is possible and the container is refillable
EXAMPLES
Example 1
[0023] Propellant free foamable toothpaste
% 1. Fumed Silicon Dioxide (Aerosil 200 ®, Degussa) 2.000 2. Fumed Aluminum Oxide (Alum C ®, Degussa) 2.000 3. Amorphous Synthetic ppt. Silica (Sident ®, Degussa) 6.000 4. Sorbo Solution (70% Active) 12.500 5. Glycerin 12.500 6. Sodium Saccharin 0.100 7. Sodium Fluoride 0.243 8. Sodium Lauroyl Sarcosinate, 30% Active 4.000 (Hamposyl L-30 ®) 9. Poloxamer 407 ® (BASF Corp.) 2.000 10. Methyl Paraben 0.200 11. Propyl Paraben 0.050 12. Colloidal Magnesium Aluminum Silicate 0.400 (Veegum ® Regular) 13. Deionized Water 58.007 100.000
Procedure:
In a tank, add water, Sorbo solution and Glycerin. Stir well.
With high speed stirring, add the fumed Silicon Dioxide and fumed AluminumOxide C followed by the Sident abrasive. Mix well with high speed stirring and/or in tank homogenizer. Mix until smooth and uniform.
Add the Sodium Saccharin and Sodium Fluoride and continue mixing.
Add the Methyl and Propyl Parabens and continue mixing.
Add the Veegum Regular to the batch and mix until the batch is uniform.
Slow the mixing speed and add the Sodium Lauroyl Sarcosinate to the batch.
Avoid entrapping air in the batch.
Start heating the batch. Keep the mixing speed slow to avoid entrapping air.
When the temperature of the batch rises to 50 C slowly add the Poloxamer 407. Continue heating the batch to 70 C. The Poloxamer 407 should be completely dissolved in the batch. Start cooling the batch to room temperature. Add the flavor at 40° C.
Submit the batch for packaging in the F-2 Finger Pump Foamer™ manufactured by Air Spray Int., Inc. of Pompano Beach, Fla.
Example 2
[0024] Propellant free foamable toothpaste
% 1. Fumed Silicon Dioxide (Aerosil 200 ®, Degussa) 2.000 2. Fumed Aluminum Oxide (Alum C ®, Degussa) 2.000 3. Amorphous Synthetic ppt. Silica (Sident ®, Degussa) 6.000 4. Sorbo Solution (70% Active) 12.500 5. Glycerin 12.500 6. Sodium Saccharin 0.100 7. Sodium Fluoride 0.243 8. Sodium Lauroyl Sarcosinate, 30% Active 4.000 (Hamposyl L-30 ®) 9. Methyl Paraben 0.200 10. Propyl Paraben 0.050 11. Colloidal Magnesium Aluminum Silicate 0.400 (Veegum ® Regular) 12. Deionized Water 60.007 100.000
Procedure:
In a tank, add water, Sorbo solution and Glycerin. Stir well.
With high speed stirring, add the fumed Silicon Dioxide and fumed AluminumOxide C followed by the Sident abrasive. Mix well with high speed stirring and/or in tank homogenizer. Mix until smooth and uniform.
Add the Sodium Saccharin and Sodium Fluoride and continue mixing.
Add the Methyl and Propyl Parabens and continue mixing.
Add the Veegum Regular to the batch and mix until the batch is uniform.
Slow the mixing speed and add the Sodium Lauroyl Sarcosinate to the batch.
Avoid entrapping air in the batch. Add the flavor.
Submit the batch for packaging in the F-2 Finger Pump Foamer™ manufactured by Air Spray Int., Inc. of Pompano Beach, Fla. | Propellant free foamable aqueous dentifrice system which is capable of being delivered as a foam to a toothbrush and which is stable on the brush and when placed in the mouth and used for tooth cleaning, continues to generate more foam. The system is liquid and as such can not be used without being foamed because it is so thin that it falls beneath the bristles of the toothbrush. | 0 |
TECHNICAL FIELD
[0001] The present teachings are directed toward the improved cleaning and durability capabilities of steam generating surface cleaners.
BACKGROUND
[0002] A need has been recognized in the surface cleaning industry for steam generating surface cleaner that has increased longevity. A requirement for many steam generating appliances is the use of distilled water in order to prevent scale buildup within a boiler. Prior art boilers and steam generators have a single internal chamber for generating steam. Distilled water is free of any contaminates or particulates, and thus does not produce scale within the boiler. Failure to use distilled water in prior art boilers produces scale within the boiler, eventually leading to clogged outlets, and reduced efficiency and performance. Because a consumer must purchase and store distilled water in order to properly utilize a steam generating vacuum cleaner, such units have increased expense and inconvenience associated with their use. As such, there exists a need for a steam generating surface cleaner that can reduce scale buildup thereby increasing the longevity of the steam cleaning appliance while reducing the operational costs associated with use of the surface cleaner.
[0003] Other deficiencies in the prior art can be inferred by the disclosure herein.
SUMMARY
[0004] According to one embodiment, a steam generator for a surface cleaning apparatus is described. In some embodiments, the steam generator comprises a first chamber for generating steam and collecting scale, a water inlet disposed proximate a first end of the first chamber, a second chamber housed within the first chamber and in fluid communication with the first chamber, and a steam outlet for releasing steam and in fluid communication with the second chamber, wherein the steam outlet is disposed distal to the first end of the first chamber.
[0005] In some embodiments, the water inlet is substantially orthogonal to the first chamber. In some embodiments, the first chamber is substantially cylindrical in shape. In some embodiments, the second chamber is substantially cylindrical in shape. In some embodiments, the first chamber comprises a non-corrosive heat conductor. In some embodiments, the second chamber comprises a non-corrosive heat conductor.
[0006] In some embodiments, the steam generator further comprises a heating element disposed in contact with the first chamber. In some embodiments, the steam generator further comprises a temperature sensor to sense the operating temperature of the first chamber, wherein power is removed from the heating element when the operating temperature exceeds a threshold.
[0007] In some embodiments, the steam generator further comprises a water pump, and a temperature sensor to sense the operating temperature of the first chamber, wherein power is supplied to the water pump when the operating temperature exceeds a threshold.
[0008] In some embodiments, the steam generator further comprises a thermal insulator disposed around the first chamber.
[0009] According to various embodiments, a steam generator for a surface cleaning apparatus is described. In some embodiments, the steam generator comprises a first chamber for generating steam and collecting scale, a water inlet disposed proximate a first end of the first chamber, and a conduit disposed within the first chamber and including a steam inlet disposed proximate a first end of the conduit, and a steam outlet disposed proximate a second end distal from the first end, wherein the steam outlet is disposed outside the first chamber, and the first end of the conduit is disposed proximate the water inlet.
[0010] In some embodiments, the steam generator is disposed vertical to a cleaning surface. In some embodiments, the multi-chamber steam generator is horizontal to a cleaning surface. In some embodiments, the multi-chamber steam generator further comprises a water inlet and a steam outlet. In some embodiments, the steam generator further comprises a water pump, wherein a water pump outlet of the water pump is fluidly connected to a water inlet of the multi-chamber steam generator.
[0011] In some embodiments, the water pump outlet is vertically below the water inlet. In some embodiments, the cleaning apparatus further comprises a water reservoir. In some embodiments, the water reservoir is vertically above the water pump. In some embodiments, the pump is a self-priming pump. In some embodiments, the pump is a metered pump. In some embodiments, the surface cleaning apparatus further comprises a beater bar housing, a beater bar for agitating a cleaning surface, and a debris collection unit for collecting debris from the cleaning surface, wherein the debris collection unit is fluidly connected to the beater bar housing.
[0012] In some embodiments, the beater bar is driven by a motor. In some embodiments, the surface cleaning apparatus further comprises wheels, wherein the beater bar is driven by the frictional force of the wheels on the cleaning surface. In some embodiments, the surface cleaning apparatus further comprises a temperature sensor. In some embodiments, the temperature sensor turns on a pump when a minimum temperature within the multi-chamber steam generator is reached. In some embodiments, the temperature sensor shuts of power to a heating element when a maximum temperature within the multi-chamber steam generator is reached.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The same reference number represents the same element on all drawings. It should be noted that the drawings are not necessarily to scale. The foregoing and other objects, aspects, and advantages are better understood from the following detailed description of a preferred embodiment of the invention with reference to the drawings, in which:
[0014] FIG. 1 illustrates a cross section of one embodiment of a steam generator;
[0015] FIG. 2 illustrates the interior of the body of an upright vacuum cleaner having a steam generator according to one embodiment; and
[0016] FIG. 3 illustrates the interior of the base of an upright vacuum cleaner having a steam generator according to one embodiment.
DETAILED DESCRIPTION
[0017] The present teachings provide a steam generator for a surface cleaner capable of providing improved cleaning features and longevity. The structure of a steam generator can comprise an inlet, a body with an internal chamber, and an outlet. A second chamber, housed within the first chamber, prevents the accumulation of scale within the outlet, thereby increasing the longevity of the steam cleaner, reducing costs associated with use and maintenance for a consumer.
[0018] FIG. 1 illustrates an exemplary embodiment of a steam generator 100 . A steam generator housing 102 may contain a first chamber 108 and a second chamber 110 . Water may flow into steam generator 100 via water inlet 104 , where the water flows into first chamber 108 and is heated into steam. As the steam rises within chamber 108 , pressure builds in chamber 108 . Eventually the steam is forced into second chamber 110 at second chamber steam inlet 112 . Steam may exit steam generator 100 by passing through second chamber outlet passage 118 . Second chamber outlet passage 118 can include a tip that is narrow in diameter at outlet 106 . During the evaporation of water into steam within first chamber 108 , any contaminants, particulates, or mineral deposits may be released from the water to form a scale 116 . The scale 116 falls out of the water and may accumulate at the bottom and along the side walls of first chamber 108 . Thus, steam, free from any contaminants, enter second chamber steam inlet 112 and exits outlet 106 . As such, the scale 116 is generally disposed off in chamber 108 and scale 116 does not clog outlet 106 . Contaminant free steam may be delivered to a mop head or a steam nozzle where it can used to clean a surface of interest. In some embodiments, the mass or surface area of a heated surface can be increased within first chamber 108 . This can be accomplished by disposing a spring 130 around second chamber 110 , or by disposing other non-corrosive heat conductive materials shaped as spheres, rings, powders etc. within first chamber 108 . The increased surfaces, thereby allowing more efficient steam generation and increasing the efficiency of the removal of contaminants from the water.
[0019] Water, flowing into steam generator 100 , may be transformed into steam by heat generated by heater 122 embedded within a heater block 128 . Electrical power may be supplied to heater 122 . In some embodiments, heater 122 may include a resistance heating element, such as a wire, coil, ribbon, screen, foil, heat lamp or ceramic element. The heating element may comprise kanthal, nichrome, cupronickel, molybdenum dicilide, ceramic insulated metal, of PTC ceramic, or mixtures thereof.
[0020] Temperature sensors 124 may detect temperatures of first chamber 108 and second chamber 110 . Temperature sensors 124 may be connected to a monitoring circuit (not shown) such that if an internal temperature of first chamber 108 and/or second chamber 110 is exceeded, power to a heater, pump, or other component of surface cleaner is turned off. In some embodiments, temperature sensors 124 may be connected to a monitoring circuit (not shown) such that if a minimum temperature is reached, power to a pump, beater bar, or other component of the surface cleaner is turned on. Temperature sensors 124 can be in thermal contact with heater block 128 .
[0021] Housing 102 may be a single integrated unit or may contain multiple parts pieced together to form housing 102 . For example, housing 102 may include an inlet receiving portion to receive threads 126 on inlet 104 . As such, a conduit, for example, from a water reservoir, can be secured to inlet 104 . In some embodiments, outlet 106 may include threads 114 which allows second chamber 110 and second chamber outlet passage 118 to be secured into housing 102 within first chamber 108 . In some embodiments, housing 102 may comprise two halves. The two halves may be secured together via fasteners (not shown) which may be received in fastener receivers 120 . In some embodiments, fastener receivers 120 receive fasteners which secure steam generator into a surface cleaner. In some embodiments, the whole unit may be die cast. In some embodiments, housing 102 comprises a heat conducting material. For example, in some embodiments, housing 102 can comprise aluminum, steel, or other suitable materials, or combinations thereof.
[0022] In some embodiments, first chamber 108 and second chamber 110 comprise heat conductive material that is resistant to rust. In some embodiments, first chamber 108 and second chamber 110 are made from the same materials. In some embodiments, first chamber 108 is a different material than second chamber 110 . In some embodiments, first chamber 108 and/or second chamber 110 comprise brass, copper, stainless steel, polytetrafluoroethylene (i.e., Teflon), or other suitable materials, and mixtures thereof. In a preferred embodiment, second chamber 110 comprises Teflon.
[0023] FIG. 2 illustrates an embodiment of a steam generator in a surface cleaner. In this embodiment, steam generator 200 is secured within the body portion of an upright floor cleaner 202 . A water reservoir (not shown) supplies water to a pump 224 . Hose 226 may allow water to travel from pump to steam generator inlet 206 . Water enters first chamber 212 , where the water becomes steam, the steam travels to second chamber steam inlet 216 . Steam then travels through second chamber 214 , through second chamber outlet passage 210 , and out of steam generator 200 via outlet 208 . Hose 228 conducts steam from steam generator to a steam applicator, for example, a cloth mop or a nozzle. Hose 228 and/or hose 226 may be secured to various inlets or outlets via locking pins 236 or other fasteners as known in the art.
[0024] Water, flowing into steam generator 200 , may be transformed into steam by heat generated by heating elements 222 embedded within steam generator interior portion. Power may be supplied to heating elements 222 via connectors 218 . In some embodiments, heating elements 222 may include a resistance heating element, such as a wire, coil, ribbon, screen, foil, heat lamp, or ceramic element. The heating elements 222 may comprise kanthal, nichrome, cupronickel, molybdenum dicilide, ceramic insulated metal, of PTC ceramic, or mixtures thereof.
[0025] Temperature sensors 220 may detect temperatures of first chamber 212 and second chamber 214 . Temperature sensors 220 may be connected to a monitoring circuit (not shown) such that if an internal temperature of first chamber 212 and/or second chamber 214 is exceeded, power to heating element 222 is turned off. In some embodiments, temperature sensors 220 may be connected to a monitoring circuit (not shown) such that if a minimum temperature is reached, power to pump 224 is turned on.
[0026] In this embodiment, steam generator 200 is located within a floor surface cleaning machine 202 . Floor surface cleaning machine 202 may have a surface cleaner housing and a base portion 232 which are connected at pivot point 234 . Although not shown, floor surface cleaning machine may include a handle, power cords, circuit boards, a water reservoir, motors, dust collecting chambers (or bags), beater bars, brushes, hand held attachments, etc. In some embodiments, floor surface cleaning machine utilized removable cloth pads to clean the surface.
[0027] In this embodiment, pump 224 is located below steam generator 200 along axis A. In some embodiments, pump 224 is located below a water reservoir. In such embodiments, gravity may prime pump 224 with water from the water reservoir. In some embodiments, pump 224 is a self priming pump. In some embodiments, pump 224 is a metered pump. In some embodiments, first chamber 212 and/or second chamber 214 of steam generator 200 are disposed along axis A. As such, first chamber 212 and/or second chamber 214 of steam generator 200 are substantially orthogonal to the surface to be cleaned as depicted by axis B.
[0028] FIG. 3 illustrates steam generator 300 within the housing 342 of a floor cleaner base 302 . In this embodiment, water flows from a water reservoir (not shown) and into pump inlet 330 , through pump 328 , through water hose 334 , and into steam generator. Steam generated in steam generator 300 travels through a conduit and out of the floor cleaner base 302 at nipple 338 . In some embodiments, floor cleaner base includes motor assembly 324 and motor shaft 326 , which drives beater bar 320 via flexible belt 322 . In some embodiments, floor cleaner base 302 includes wheels 336 . For example, in some embodiments, the floor cleaner includes a beater bar housing, beater bar 320 for agitating a cleaning surface, and a debris collection unit for collecting debris from the cleaning surface, wherein the debris collection unit is fluidly connected to the beater bar housing.
[0029] In some embodiments, the steam generators are in any shape suitable for generating steam. In some embodiments, the steam generator may be substantially cylindrical, cuboidal, conical, rectangular, or spherical in shape. In some embodiments, the first chamber is substantially the same shape as the second chamber. In some embodiments, the first chamber has a different shape than the second chamber. For example, the first chamber may be substantially conical while the second chamber is substantially cylindrical in shape.
[0030] Combinations of different features illustratively described in connection with the embodiments are also contemplated. Although the embodiments illustrated herein relate steam generators in a floor cleaner, alternative surface cleaner configurations (e.g., hand held, canister, etc.) are also contemplated.
[0031] The various embodiments described above are provided by way of illustration only and should not be constructed to limit the invention. Those skilled in the art will readily recognize the various modifications and changes which may be made to the present invention without strictly following the exemplary embodiments illustrated and described herein, and without departing from the true spirit and scope of the present invention, which are set forth in the following claims. | A steam generator for a surface cleaning apparatus is described. The steam generator includes: a first chamber for generating steam and collecting scale; a water inlet disposed proximate a first end of the first chamber; a heater in thermal contact with the first chamber; a second chamber housed within the first chamber and in fluid communication with the first chamber; and a steam outlet for releasing steam and in fluid communication with the second chamber, wherein the steam outlet is disposed distal to the first end of the first chamber. | 1 |
RELATED APPLICATION DATA
[0001] This application is a continuation-in-part application of U.S. patent application Ser. No. 08 / 567 , 283 filed by Applicant herein on Dec. 5, 1995 and titled “Bottle and Jar Lid Opener.”
FIELD OF THE INVENTION
[0002] The present invention generally relates to devices that facilitate opening of screw-type lids from bottles, jars, jugs and other containers. More specifically the present invention relates to a bottle and jar opener suitable for removing lids using one hand.
BACKGROUND OF THE INVENTION
[0003] Various bottle and jar lid openers have been disclosed in the prior art. The prior art devices generally attempt to replicate the lid gripping and twisting motions involved in manual removal of a secured lid. Some devices known in the art also provide means to increase the torque by increasing the lever arm of the opener. Examples of openers are U.S. Pat. No. 715,226 issued Dec. 16, 1902 where a band is secured about the jar using a lever arrangement and a band wrench is disposed about the lid. The jar is placed on a platform secured by what appears to be fasteners, the platform supporting the jar banding mechanism. Smith, U.S. Pat. No. 951,203 issued Mar. 8, 1910 shows another jar opener where the jar is banded and an adjustable band wrench is disposed about the lid.
[0004] Other exemplary bottle and jar lid openers that require the jar to be held by one hand while the lid is manipulated are disclosed in the following U.S. Pat. No.: 2,698,549 to Campbell, U.S. Pat. No. 2,710,551 to Walters, U.S. Pat. No. 2,719,444 to Zeller, U.S. Pat. No. 2,749,748 to Hrebricek, U.S. Pat. No. 3,343,432 to Nagy, U.S. Pat. No. 3,453,911 to Carter, U.S. Pat. No. 3,604,289 to Steel, U.S. Pat. No. 3,724,296 to Craver, U.S. Pat. No. 3,822,614 to Kovacevic, U.S. Pat. No. 4,033,205 to Hoskins, U.S. Pat. No. 4,052,917 to Gee, U.S. Pat. No. 4,306,470 to Woloszyn, U.S. Pat. No. 4,765,207 to Yu, U.S. Pat. No. 4,932,544 to Glazer, U.S. Pat. No. 4,949,576 to Floyd, U.S. Pat. No. 4,995,295 to Floyd, U.S. Pat. No. 5,031,485 to Wu, U.S. Pat. No. 5,083,482 to Floyd and U.S. Pat. No. 5,253,552 to Brand et al.
[0005] In Weisband, U.S. Pat. No. 5,313,857 a rather elaborate bottle and jar lid opener is disclosed which includes jar and lid gripping means. U.S. Pat. No. 5,209,142 to Dickson also recognizes the problem of securing the body of a bottle or jar for removal; of a lid by a disabled or weak-handed person. The Dickson invention discloses a bottle or jar gripping device, which retains the body of the bottle or jar in a stationary position by exerting body pressure against the device which, in turn, engages the bottle or jar. Thereby both hands are free to remove the lid from the bottle or jar.
[0006] Persons who need or desire a tool to facilitate the opening of bottle or jar lids are generally persons who have arm, hand or wrist limitations. The structural and operational complexity of the prior art bottle or jar openers has limited their commercial acceptability. As previously mentioned, tightly secured lids tend to cause the body of the jar or bottle to rotate when an attempt is made to remove the lid. This problem, which has been generally overlooked by the prior art, it is particularly troublesome for disabled persons who cannot restrain the jar or bottle and simultaneously rotate the lid for removal, such as persons with a single, usable arm or hand. Many prior art devices, such as Weisband, assume that the persons can use one hand to restrain the bottle or jar and the other hand will be used to remove the lid. For other devices, it is assumed that the device will be permanently secured to a fixed substrate such as a wall or counter as suggested in Harrington discussed above.
[0007] Thus, it should be understood that there is a need for a device and method which enables a disabled person to remove a screw lid from a bottle or jar, which enables a person with a single usable hand or arm to remove a lid, which does not require permanent mounting to a kitchen counter or wall, which is portable and which is simple and easy to use.
SUMMARY OF THE INVENTION
[0008] There is, therefore, set forth according to the present invention a bottle and jar opener which is simple, easy to use, is portable and is usable by disabled persons, even those with a single usable arm or hand.
[0009] According there is set forth a one handed opener for removing the lid from a jar, which includes a base adapted to rest on a flat surface. A band support up stands from the base, the band support having a surface to engage the side of ajar. The surface may be arcuate. A flexible jar band has one end secured to the band support and extends around the body of the bottle or jar and has the other end passing though a slot defined through the band support. The jar bands other end is received through a slot in the jar band support. When jar band slides in the slot in jar band support, it causes the jar band to fit about the jar or bottle to secure jar or bottle to the base. Means are provided for imposing suction between the base and a flat surface, such as a counter top, to secure the base against movement.
[0010] Also provided is a jar top wrench including a lid band adjustably disposed on the wrench to be wrapped about the lid. The wrench includes a nose disposed to trap the lid band against the lid to forcibly grip the same as the wrench is moved to unscrew the lid.
[0011] Accordingly, the device and method of the present invention may be used by a handicapped person to remove the lid from a bottle or jar.
[0012] Further the device may be used by anyone for the same purpose. The device is adjustable, of simple construction and use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] These and other features and advantages will become appreciated, as the same becomes better understood with reference to the specification, claims and drawings wherein:
[0014] [0014]FIG. 1 is a three dimensional perspective view of the bottle and jar lid opener according to the present invention;
[0015] [0015]FIG. 2 is a top view of a jar being placed on the base within a jar band, formed as a loop of the present invention;
[0016] [0016]FIG. 3 is a top perspective view of a jar secured on the base by the jar band, formed as a loop to the present invention;
[0017] [0017]FIG. 4 is a cross-section view of the assembled platform of FIG. 3 to the present invention;
[0018] [0018]FIG. 5 is showing the rubber membrane with two metal inserts of the present invention;
[0019] [0019]FIG. 6 is a cross-section view of one of the chambers, with one of the metal inserts exposed to present invention;
[0020] [0020]FIG. 7 is a plan side view of the lid wrench;
[0021] [0021]FIG. 8 is a top plan view of the lid wrench with an exploded view of a lid band guide button;
[0022] [0022]FIG. 9 is a three dimensional breakdown of lid wrench;
[0023] [0023]FIG. 10 is an end nose view of the wrench nose;
[0024] [0024]FIG. 11 is a view of the backside of the wrench nose; and
[0025] [0025]FIG. 12 is a side view of metal insert and to left is a top view of metal insert.
DESCRIPTION
[0026] In the following description of the invention, the term “jar” should be understood to include bottles or other containers having a lid or plug which is threadably secured to the jar to define a closure therefor. “Lid” should be understood to not only embrace a lid but threaded tops and plugs as well.
[0027] [0027]FIG. 1 illustrates a jar opener 1 according to the present invention shown coupled to a jar “A” having a removable, twist off lid “B”. Opener 1 provides means to sufficiently loosen the lid B so that the lid B can thereafter be easily removed by hand.
[0028] The opener 1 includes a jar band support 29 and a gripping lid wrench 40 adapted to grip the lid B for rotation thereof. The support 29 , as shown in FIG. 1, is adapted to restrain the jar A to a fixed substrate such as counter top (not shown) so that the lid B may be loosened by one hand using the wrench 40 and, if desired, removed.
[0029] To restrain the jar A to the assembly, a jar band support 29 has a flexible jar band 21 and a base platform 30 . The wrench 40 includes a rigid wrench arm 50 and a flexible lid band 60 .
[0030] To secure jar A against jar band support 29 , the jar band 21 has a first end 21 a formed as a loop about a post 300 secured to and upstanding from the base platform 30 . Opposite the first end 21 a , the jar band 21 has a free second end 21 b . The band 21 is formed into a loop 21 disposed above the platform 30 (FIGS. 2 and 3) and is adapted to go around the jar A. The loop 21 can be adjusted to fit the size of a jar A by pulling second end 21 b to proper size. The second end passes through a slot 202 defined between the post 300 and band support 29 as shown in FIGS. 2-3. By pulling on the second end 21 b the jar band loop 21 can be fitted about the jar A. The loop 21 should be left loose enough to rotate jar A along a leading edge 200 of the band support to center of base plate 30 . As shown, the leading edge tapers or diverges away from the jar A such that rotation of the jar A along the leading edge 200 in response to the imposition of torque, tightens the jar band. When this is accomplished, jar A rotates against the jar band support 29 which secures it against jar band support leading edge 200 (FIGS. 2-3). When this takes the band loop 21 c is pulled against the jar band 21 e and then pulled against jar band support 29 a and secures the jar band 21 from slipping around the jar A (FIGS. 2 and 3) and to secure the jar A to the band support 29 .
[0031] As can be seen in FIG. 2, to fix the platform 30 of the FIG. 1 to a substrate such as a counter top, a plurality of platform suction cups 91 are disposed on the bottom surface 30 a of the base platform 30 . To secure the base platform 30 to a flat surface, suction cups 91 are preferably wetted before pressing the base platform 30 onto the flat surface.
[0032] [0032]FIGS. 6 and 4 illustrate a second embodiment of a base platform 30 for the FIG. 1. Base platform 30 has a polygonal shape and generally includes a platform support portion 80 , a platform suction portion 90 and a suction lever assembly 100 . Platform support portion 80 is substantially a cover for the base platform 30 that is receivable in the platform suction portion 90 . A vacuum is formed between the platform support portion 80 and the platform suction portion 90 .
[0033] As can best be seen in FIG. 4, platform support 80 includes a flat top wall 80 a , and a downwardly extending central wall 80 c . Suction lever assembly 100 rotatably engages opposing orifices 81 formed in the peripheral edge 80 b and a central orifice 82 formed in the central wall 80 c of platform support portion 80 . Suction lever assembly 100 interacts with the platform suction portion 90 as hereinafter described to secure the base platform 30 to a flat substrate surface such as a counter top.
[0034] As shown in FIGS. 6 and 4 platform suction portion 90 includes a peripheral slotted arm 91 and a central slotted arm 92 which respectfully receive the peripheral edge 80 b and central wall 80 c of platform support portion 80 (FIG. 4). When platform support portion 80 and platform suction portion 90 are engaged the central wall 80 c of the platform support portion 80 divided the interior of the second base platform 30 into respective first and second vacuum chambers 71 , 72 . Platform suction portion 90 is preferably formed from molded rubber or other elastic material. First and second flexible bearing plates 93 , 94 are centrally disposed on a top portion of the platform. suction portion 90 in the respective first and second vacuum chambers 71 , 72 . The vacuum formed in the respective vacuum chambers 71 , 72 of the base platform 30 causes the platform suction portion 90 to have an upwardly curving contour.
[0035] Operation of the suction lever assembly 100 selectively depresses and releases first and second bearing plates 93 , 94 to thereby adhere platform suction portion 90 to a flat surface such as a counter top. Suction lever assembly 100 includes an extended rod 101 having a crank handle 101 a formed at one end of rod 101 and disposed to an outward side of the base platform 81 . Suction lever assembly 100 further includes respective first and second lever support dogs 101 b , 101 c which align with the respective bearing plates 93 , 94 of the platform suction portion 90 . First and second bearing arms 102 , 103 are attached to the respective first and second lever support dogs 101 b , 101 c or the rod 101 . First and second bearing arms 102 , 103 include respective first and second pressure plates 102 a , 103 a and first and second pressure plate lever supports 102 b , 103 b that extend vertically upward from the respective first and second pressure plates 102 a and 103 a . First and second lever supports 102 b , 103 b include respective first and second elongated slots 104 , 105 (FIGS. 4-12) for receipt of the first and second lever support dogs 10 l b , 101 c . Crank handle portion 101 a is rotated in a first direction to move the respective pressure plates 102 a , 103 a upwardly to engage the flexible bearing plates 93 , 94 of the platform suction 90 and thereby secure base platform 30 to the flat surface. Crank handle portion 101 a is rotated in the opposite direction to release the bearing plates 93 , 94 and thereby release the platform suction portion 90 to return to its normal position. Utilizing the suction lever assembly 100 , the base platform 30 can be readily secured to a flat surface by a single hand with little physical effort. Thereby, in combination with the jar band support 29 and jar band 21 , the jar A can be restrained against rotation.
[0036] To loosen the lid B that is moderately secured to ajar A, the base platform 30 is first secured to a flat surface such as a counter top. The jar A is placed on the platform 30 and the jar band 21 is extended about the jar A and its end 21 b is threaded through the band support 29 slot 202 . Thus, a person with a single arm or hand may secure and restrain the jar A to the substrate such as a counter top for loosening the lid B. With a single hand the lid B may be loosened. However, where the lid B is tightly secured to jar A, the lever wrench 40 may be used to loosen the lid B for removal.
[0037] [0037]FIG. 1 illustrates a lever wrench according to the present invention. The lever wrench 40 includes a wrench arm 50 and a flexible lid band 60 . Wrench 50 includes an elongated wrench handle 51 having an arcuate nose 52 disposed at one end. The inner wall 52 a of the wrench nose 52 is concave and extends from a distal end of the wrench nose 52 to wrench handle 51 a . A lid band slot 53 extends longitudinally along the handle 51 from the end of the handle 51 and through the rise 51 a . Lid band slot 53 receives the lid band 60 in sliding engagement as hereinafter described.
[0038] A lid band guide 54 is receivable within the lid band slot 53 to extend over the lid band 60 . Lid band guide 54 is substantially a two-pronged fork having paired, parallel prongs 55 a , 55 b formed at the proximal end of the lid band guide 54 and lid band head 56 formed at the distal end of the band guide 54 . a guide slot 55 c is formed between the respective parallel prongs 55 a , 55 b and extends through the lid band head 56 . Lid band head 56 is formed having a rearwardly angled head extension 56 a . Lid band 61 is fixedly attached at one end thereof the head extension 56 a . The width of the guide slot 55 c is slightly larger than the width of the lid band 61 to retain the lid band within the handle 51 (FIG.9). Handle 51 includes a plurality of finger recesses 51 c formed in an outer wall 51 b of the handle 51 to facilitate manual grasping. Handle 51 further includes a stem 57 having a stem orifice 57 a formed therein for hanging storage of the lever wrench 40 . Lever wrench 40 may alternatively be stored by inserting the stem 57 in a wrench storage slot 83 formed in the platform support portion 80 of the platform 30 (FIG.1).
[0039] Referring again to FIG. 1 it can be seen that the lid band 60 is substantially a flexible strip of material 61 that extends from the head extension 56 a through the guide 53 form a closed loop. A lid band guide button 62 is disposed at the free end of the strip of material 61 to facilitate adjustment of the size of the closed loop formed by the strip of material 61 . A plurality of raised band protrusions 63 are disposed along the strip of material 61 to facilitate the adjustment of the lid band 60 using a single hand. By using the thumb to engage the button 62 or protrusions 63 the lid band material 61 may be slid though the slot 53 to expand and contract the loop.
[0040] Reference is now made to FIG. 1 which illustrates the engagement and operation of lever wrench 40 on the lid B. The closed loop formed by the strip of material 61 is first disposed about the lid B. The loop is tightened about the lid B as described above. As shown by the phantom line, the handle 51 is manipulated in a counterclockwise direction first causing the nose 52 to engage the side of the jar A and band 61 . Further rotation of the handle 51 causes the nose 52 to pivot against the side of the jar A and taking up any remaining looseness in the band to further tighten the band 61 about the lid B. Continued rotation the handle imparts torque to the lid B for loosening thereof. It should be noted that the imparted torque may tend to rotate the jar A instead of loosening the lid B. Such torque, if the jar A is not completely restrained, causes the jar A to roll along the band support leading edge 200 further tightening the jar band 21 about the jar A.
[0041] After the lid B has been loosened the handle 51 is reversely rotated in a clockwise motion. Then the lid may be removed by a single hand. The jar A may also be released in the manner described above.
[0042] While I have shown and described certain embodiments in the present invention, it should be understood that the invention is subject to many modifications and changes without departing from the spirit and scope of the present invention. For example the leading surface 200 and/or nose 52 need not be arcuate but can be flat. | A bottle and jar lid opener suitable for single hand operation. The opener includes a jar gripping assembly to restrain the jar which has a band tightened by lengthening or shortening the band to engage the band about the body to secure the jar to said band support and base. A wrench also includes a band of material forming a loop tightened about the lid. Rotation of the wrench tightens the band. Any movement of the jar in response to torque applied to the lid for opening thereof causes the jar to roll along a support leading surface to further tighten the band. | 1 |
RELATED APPLICATIONS
The present application is a Continuation-in-Part application of copending U.S. patent application Ser. No. 11/730,761 filed Apr. 4, 2007, which is a Continuation-in-Part of U.S. patent application Ser. No. 11/352,279, filed Feb. 13, 2006, now U.S. Pat. No. 7,449,381, which in turn is a Continuation-in-Part application of U.S. patent application Ser. No. 11/172,794, filed Jul. 5, 2005, now U.S. Pat. No. 7,384,856, which still further in turn is a Continuation-in-Part application of U.S. patent application Ser. No. 11/031,085, filed Jan. 10, 2005, now U.S. Pat. No. 7,541,265.
FIELD OF THE INVENTION
The invention pertains to capacitors embedded in circuit packaging structures and, more particularly, to methods of forming multilayer embedded capacitors in laminated circuit packaging structures.
RELATED PATENTS AND PATENT APPLICATIONS
In United States Patent Application Publication No. 2006/0151863, published Jul. 13, 2006 to Das et al., and entitled CAPACITOR MATERIAL FOR USE IN CIRCUITIZED SUBSTRATES, CIRCUITIZED SUBSTRATE UTILIZING SAME, METHOD OF MAKING SAID CIRCUITIZED SUBSTRATE, AND INFORMATION HANDLING SYSTEM UTILIZING SAID CIRCUITIZED SUBSTRATE and filed Jan. 10, 2005, there is defined a material for use as part of an internal capacitor within a circuitized substrate wherein the material includes a polymer (e.g., a cycloaliphatic epoxy or phenoxy based) resin and a quantity of nano-powders of ferroelectric ceramic material (e.g., barium titanate) having a particle size substantially in the range of from about 0.01 microns to about 0.90 microns and a surface area for selected ones of these particles within the range of from about 2.0 to about 20 square meters per gram. A circuitized substrate adapted for using such a material and capacitor therein and a method of making such a substrate are also described. An electrical assembly (substrate and at least one electrical component) and an information handling system (e.g., personal computer) are also described. In the examples discussed in Ser. No. 11/031,085, epoxy resin was mixed with hexahydro-4-methylphthalic anhydride, N, N dimethyl benzylamine and epoxy novolac resin. The mixed solution was stirred and barium titanate powder was added and formed into a screen printable paste. A layer of this material was screened through a 200-mesh screen onto the top surface of a copper first electrical conductor. This layer was then cured at approximately 150 degrees C. for about two hours, followed by an additional cure at approximately 190 degrees C. for about one hour. The second electrical conductor was then formed using a sputtering operation followed by a copper electroplating process and a photolithographic etch step.
In U.S. Pat. No. 7,384,856, issued on Jun. 10, 2008 to Das et al., and entitled METHOD OF MAKING AN INTERNAL CAPACITIVE SUBSTRATE FOR USE IN A CIRCUITIZED SUBSTRATE AND METHOD OF MAKING SAID CIRCUITIZED SUBSTRATE, there is defined a method of forming a capacitive substrate in which first and second conductors are formed opposite a dielectric, with one of these electrically coupled to a thru-hole connection. Each functions as an electrode for the resulting capacitor. The substrate is then adapted for being incorporated within a larger structure to form a circuitized substrate such as a printed circuit board or a chip carrier. Additional capacitors are also possible. In one of the examples (Example 5) cited in '856, epoxy novolac resin and a phenoxy resin are mixed together with barium titanate (BaTiO3) powder and propylene glycol monomethyl ether acetate and methyl ethyl ketone and ball milled for three days. A 2.5 micron thin film of this mixed composite was deposited on a copper substrate and dried at approximately 140 degrees C. for three minutes in an oven to remove residual organic solvents. This was followed by curing in an oven at 190 degrees C. for two hours. A second electrical conductor was then formed using a sputtering operation atop the cured film using a mask normally used for such sputtering operations.
In U.S. Pat. No. 7,429,510, issued Sep. 30, 2008 to Das et al., and entitled METHOD OF MAKING A CAPACITIVE SUBSTRATE USING PHOTOIMAGEABLE DIELECTRIC FOR USE AS PART OF A LARGER CIRCUITIZED SUBSTRATE, METHOD OF MAKING SAID CIRCUITIZED SUBSTRATE AND METHOD OF MAKING AN INFORMATION HANDLING SYSTEM INCLUDING SAID CIRCUITIZED SUBSTRATE, there is defined a method of forming a capacitive substrate in which at least one capacitive dielectric layer of material is screen or ink jet printed onto a conductor and the substrate is thereafter processed further, including the addition of thru-holes to couple selected elements within the substrate to form at least two capacitors as internal elements of the substrate. Photoimageable material is used to facilitate positioning of the capacitive dielectric being printed. The capacitive substrate may be incorporated within a larger circuitized substrate (e.g., to form an electrical assembly). A method of making an information handling system including such substrates is also provided.
In U.S. Pat. No. 7,449,381, issued Nov. 11, 2008 to Das et al., and entitled METHOD OF MAKING A CAPACITIVE SUBSTRATE FOR USE AS PART OF A LARGER CIRCUITIZED SUBSTRATE, METHOD OF MAKING SAID CIRCUITIZED SUBSTRATE AND METHOD OF MAKING AN INFORMATION HANDLING SYSTEM INCLUDING SAID CIRCUITIZED SUBSTRATE, there is described a method of forming a capacitive substrate in which at least one capacitive dielectric layer of material is screen or ink jet printed onto a conductor and the substrate is thereafter processed further, including forming thru-holes to couple selected elements within the substrate to form at least two capacitors as internal elements of the substrate. The capacitive substrate may be incorporated within a larger circuitized substrate (e.g., to form an electrical assembly). A method of making an information handling system including such substrates is also provided. As in Example 5 of '856, above, epoxy novolac resin and a phenoxy resin are mixed together with barium titanate (BaTiO 3 ) powder and propylene glycol monomethyl ether acetate and methyl ethyl ketone and ball milled for three days. A 2.5 micron thin film of this mixed composite is then deposited on a copper substrate and dried at approximately 140 degrees C. for three minutes in an oven to remove residual organic solvents. This is followed by curing in an oven at 190 degrees C. for two hours. A second electrical conductor was then formed using a sputtering operation atop the cured film using a mask normally used for such sputtering operations.
In United States Patent Application Publication No. 2008/0078570, published Apr. 3, 2008 to Japp et al., and entitled HALOGEN-FREE CIRCUITIZED SUBSTRATE WITH REDUCED THERMAL EXPANSION, METHOD OF MAKING SAME, MULTILAYERED SUBSTRATE STRUCTURE UTILIZING SAME, AND INFORMATION HANDLING SYSTEM UTILIZING SAME, filed Oct. 3, 2006, there is described a circuitized substrate including a composite layer comprising a first dielectric sub-layer comprising a halogen-free resin and fibers dispersed therein and a second dielectric sub-layer without fibers but also including a halogen-free resin with inorganic particulates therein. A method of making such a substrate is also provided, as is a multilayered assembly including one or more such circuitized substrates, possibly in combination with other substrates. An information handling system designed for having one or more such circuitized substrates is also provided.
In United States Patent Application Publication No. 2007/0177331, published Aug. 2, 2007 to Das et al., and entitled NON-FLAKING CAPACITOR MATERIAL HAVING AN INTERNAL CAPACITOR THEREIN INCLUDING SAID NON-FLAKING CAPACITOR MATERIAL AND METHOD OF MAKING A CAPACITOR MEMBER FOR USE IN A CAPACITIVE SUBSTRATE, filed Apr. 4, 2007, there is described a capacitor material including a thermosetting resin (e.g., epoxy resin), a high molecular mass flexibilizer (e.g., phenoxy resin), and a quantity of nano-particles of a ferroelectric ceramic material (e.g., barium titanate), the capacitor material not including continuous or semi-continuous fibers (e.g., fiberglass) as part thereof. The material is adapted for being positioned in layer form on a first conductor member and heated to a predetermined temperature whereupon the material will not possess any substantial flaking characteristics. A second conductor member may then be positioned on the material to form a capacitor member, which then may be incorporated within a substrate to form a capacitive substrate. Electrical components may be positioned on the substrate and capacitively coupled to the internal capacitor. The capacitor material as defined in this application may be used in the present invention.
All of the above pending applications are commonly assigned to the assignee of the present application and, along with the aforecited issued patents, are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
Printed circuit boards (hereinafter also referred to as PCBs), chip carriers, and the like (all referred to herein as “circuitized substrates”) are typically produced in laminate form in which several layered dielectric and conductive material members (laminates) are bonded together using conventional lamination processing involving relatively high temperatures and pressures. The conductive layers, typically of thin copper, are usually used in the formed substrate for providing electrical connections to and among various devices located on the surface of the substrate, examples of such devices being integrated circuits (semiconductor chips) and discrete passive devices, such as capacitors, resistors, inductors, and the like. Typically, these discrete passive devices occupy a high percentage of the surface area of the completed multi-layered substrate, which is obviously undesirable from a future design perspective due to the ever-present demand for miniaturization.
There have been various efforts to include multiple functions (e.g., resistors, capacitors and the like) within a single component adapted for being mounted on a substrate (e.g., PCB) in an attempt to increase the available upper substrate surface area (also often referred to as “real estate”). When passive devices are in such a configuration, these are often referred to collectively and individually as integral passive devices or the like, meaning that the functions are integrated into the singular component. Because of such external positioning, these components still utilize, albeit less than if in singular form, valuable board real estate. In response, there have been efforts to embed discrete passive components within the board. When so positioned, such components are also referred to as “embedded” passive components. A capacitor designed for disposition within (between selected layers of) a PCB substrate may thus be referred to as an embedded integral passive component, or, more simply, an embedded capacitor. Such a capacitor thus provides internal capacitance. The result of this internal positioning is that it is unnecessary to also position such devices externally on the PCB's outer surface(s), thus saving valuable PCB real estate.
For an established capacitor area, two approaches are known for increasing the planar capacitance (capacitance/area) of an internal capacitor. In one such approach, higher dielectric constant materials can be used, while in a second, the thickness of the dielectric can be reduced. These constraints are reflected in the following formula, known in the art, for capacitance per area:
C/A =(Dielectric Constant of Laminate×Dielectric Constant in Vacuum/Dielectric Thickness)
where: C is the capacitance and A is the capacitor's area. Additional formulae are provided herein with respect to defining capacitance values for the structures formed herein.
As mentioned above, there have been previous attempts to provide internal capacitance and other internal conductive structures, components or devices (one good example being internal semiconductor chips) within circuitized substrates such as PCBs, some of these including the use of nano-powders. The cited application Ser. No. 11/031,085 and U.S. Pat. No. 7,384,856 also define such approaches. Some of the patents and some pending applications cited above mention the use of various materials for providing desired capacitance levels. With respect to the following patents, some mention or suggest problems associated with the methods and resulting materials used to do so.
None of the methods of the prior art produce embedded capacitors having as high a capacitive volumetric efficiency as the method of the present invention. In other words, higher capacitance capacitors may be formed in smaller volumes within the laminated printed circuit board than has heretofore been possible.
None of the patents and published patent applications, taken singly, or in any combination are seen to teach or suggest the novel methods forming embedded, multilayer capacitors of the present invention.
SUMMARY OF THE INVENTION
In accordance with the present invention there are provided methods of forming embedded, multilayer capacitors in printed circuit boards. In each embodiment of the invention, copper or other electrically conductive channels are formed on a dielectric substrate. The copper channels may be preformed using etching or deposition techniques. For example, in at least one embodiment of the invention, an FR4 or similar copper clad laminate is etched with a desired pattern comprising substantially parallel traces. A photoimageable dielectric is vacuum bonded to the copper-bearing surface of the laminate. Exposing and etching the photoimageable dielectric exposes the space between the copper traces. These spaces are then filled with a capacitor material. Finally, copper is either laminated or deposited atop the structure. This upper copper layer is then etched to provide the necessary electrical interconnections to the capacitor elements formed by the copper traces and the capacitor material.
In other embodiments, the traces are heightened using a copper plating technique, typically an electroless plating process.
In still other embodiments, a relatively thick dielectric substrate has an opening formed in a major surface thereof, the opening being sized and configured to leave a thin dielectric layer at the bottom thereof. Copper traces are then deposited on the remaining thin dielectric layer. Traces may be formed to a height to meet a plane defining the upper surface of the dielectric substrate.
In other embodiments, thin traces are formed on the remaining dielectric surface and a secondary copper plating process is utilized to raise the height of the traces. Capacitor material is placed between the traces.
It is, therefore, an object of the invention to provide a method of forming a multilayer capacitor in a printed circuit board.
It is another object of the invention to provide a method of forming a multilayer capacitor in a printed circuit board wherein a plurality of substantially copper traces are formed on a dielectric substrate.
It is an additional object of the invention to provide a method of forming a multilayer capacitor in a printed circuit board wherein capacitor material is placed between substantially parallel copper traces.
It is a further object of the invention to provide a method of forming a multilayer capacitor in a printed circuit board wherein substantially parallel copper traces are electrically interconnect to form sections of a multilayer capacitor.
It is a still further object of the invention to provide a method of forming a multilayer capacitor in a printed circuit board that reduces manufacturing time, increases the capacitance of the formed capacitors, and facilitates control of the resulting capacitance when compared to manufacturing methods of the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
Various objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
FIG. 1 a is a side elevational view of a layer of photoimageable material;
FIGS. 1 b and 1 c are a side elevational and a top plan view, respectively, of a dielectric substrate having a pattern of electrically conductive material;
FIG. 1 d is a side elevational, cross-sectional view of the substrate of FIGS. 1 b and 1 c having the photoimageable material of FIG. 1 a laminated thereto;
FIG. 1 e is a side elevational, cross-sectional view of the laminated structure of FIG. 1 d having portions of the photoimageable material removed;
FIG. 1 f is a side elevational, cross-sectional view of the structure of FIG. 1 e having capacitor material dispensed between electrically conductive traces;
FIG. 2 a is a side elevational, cross-sectional view of a copper-clad dielectric material;
FIG. 2 b is a side elevational, cross-sectional view of the copper-clad dielectric material of FIG. 1 a with traces etched in the copper layer;
FIG. 2 c is a side elevational, cross-sectional view of the of the structure of FIG. 2 b with a photoimageable layer laminated thereto;
FIG. 2 d is a side elevational, cross-sectional view of the laminated structure of FIG. 2 c having portions of the photoimageable material removed;
FIG. 2 e is a side elevational, cross-sectional view of the structure of FIG. 2 d having additional copper plated on the existing copper traces;
FIG. 2 f is a side elevational, cross-sectional view of the structure of FIG. 2 e having capacitor material dispensed between electrically conductive traces;
FIG. 2 g is a side elevational, cross-sectional view of the structure of FIG. 2 f with an additional copper layer laminated or deposited on the top thereof;
FIG. 3 a is a side elevational, cross-sectional view of a thick, unclad dielectric material;
FIG. 3 b is a side elevational, cross-sectional view of the dielectric material of FIG. 3 a with an opening formed in the top surface thereof;
FIG. 3 c is a side elevational, cross-sectional view of the dielectric material of FIG. 3 b with full height copper traces formed within the opening;
FIG. 3 d is a side elevational, cross-sectional view of the structure of FIG. 3 c with capacitor material placed between the copper traces;
FIG. 4 a is a side elevational, cross-sectional view of a thick, unclad dielectric material;
FIG. 4 b is a side elevational, cross-sectional view of the dielectric material of FIG. 4 a with an opening formed in the top surface thereof;
FIG. 4 c is a side elevational, cross-sectional view of the dielectric material for FIG. 4 b with thin copper traces formed within the opening;
FIG. 4 d is a side elevational, cross-sectional view of the structure of FIG. 4 c with additional copper plated on the traces;
FIG. 4 e is a side elevational, cross-sectional view of the structure of FIG. 4 d with capacitor material placed between the copper traces;
FIG. 5 a is a side elevational, cross-sectional view of a copper-clad dielectric etched to form traces and having a photoimageable dielectric material laminated thereto;
FIG. 5 b is a side elevational, cross-sectional view of the structure of FIG. 5 a after a first exposure and etch of the photoimageable dielectric material to expose the copper traces;
FIG. 5 c is a side elevational, cross-sectional view of the structure of FIG. 5 b with the original copper traces plated to form full height copper traces;
FIG. 5 d is a side elevational, cross-sectional view of the structure of FIG. 5 a after a second exposure and etch of the photoimageable dielectric material to expose the substrate between the copper traces;
FIG. 5 e is a side elevational, cross-sectional view of the structure of FIG. 5 d with capacitor material placed between the copper traces; and
FIG. 6 is a schematic, vertical perspective view of an embedded capacitor formed in accordance with the method of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides several methods for forming embedded multilayer capacitors within a laminated circuit packaging structure. For convenience, the term printed circuit board (PCB) is used herein to describe any such laminated circuit packaging structure.
Several methods of forming embedded capacitors within a PCB are believed to be known to those of skill in the PCB design and manufacturing arts. These methods typically require laser ablation to form and/or trim the capacitor structures resulting in relatively time consuming and expensive manufacturing processes. The capacitor formation methods of the present invention eliminate the need for laser ablation and significantly reduce the manufacturing cost of the resulting PCBs.
Referring first to FIGS. 1 a through 1 f , there are shown schematic, cross-sectional views illustrating the steps in forming an embedded, multilayer capacitor in accordance with a first embodiment of the present invention.
FIG. 1 a is a side elevational view of a layer of photoimageable material 100 . As used herein, the term photoimageable material or photoimageable polymer is meant to be a material including three major components: a photo-active compound that undergoes cross-linking polymerization reaction on exposure to suitable radiation; a photo-packaging compound that initiates the radical polymerization; and a solvent or binder that carries both the photo-active and photo-packaging compounds either in liquid or solid form. One example of a photoimageable polymer is epoxy acrylate resin with a pendant —COOH group and 2,2′ dimethoxy-2-phenylacetophenon. It will be recognized that other suitable photoimageable materials are known to those of skill in the art and such materials may be substituted for the material chosen for purposes of disclosure. Consequently, the invention is not considered limited to the specific photoimageable material chosen for purposes of disclosure.
Referring now also to FIGS. 1 b and 1 c , there are shown a side elevational and a top plan view of a structure 120 having a dielectric substrate 122 having deposited thereupon a pattern of electrically conductive material 124 , typically copper. Electrically conductive material 124 is typically disposed in a series of substantially parallel rows, best seen in FIG. 1 c . Additional electrically conductive material 126 may be disposed perpendicular to the parallel rows to electrically connect alternate parallel traces of electrically conductive material 124 . Ideally, the thickness of photoimageable material 100 and the height 126 of the electrically conductive material 124 are similar.
First, photoimageable material 100 is laminated to structure 120 , typically using a vacuum lamination process. It will be recognized that any other suitable lamination process may be used to laminate photoimageable material 100 to structure 120 . FIG. 1 d shows the result of the laminating step.
After lamination, photoimageable material 100 is removed from the area occupied by electrically conductive material 124 leaving the electrically conductive material enclosed within remaining photoimageable material 100 as seen in FIG. 1 e.
Alternatively, material 100 can be a drilled, free-standing, partially cured dielectric or pre-preg that has exactly the same opening as a photoimageable dielectric and can be laminated directly to structure 120 to produce the article shown in FIG. 1 e . Drilled dielectric/pre-preg 100 can be completely cured or partially advanced during lamination. Drilled dielectric material does not require an expose and etching process as is required with a photoimageable dielectric.
The next process step is dispensing capacitor material 130 into the spaces between electrically conductive traces 124 as shown in FIG. 1 f . Capacitor material 130 typically comprises a polymer resin and a quantity of nano or micro powders or a mixture of nano, micro powders of ferroelectric ceramic material having average particle size substantially in the range of between about 0.005 microns and about 10 microns and a surface area for selected ones of said particles within the range of from about 0.5 to about 100 square meters per gram. Ferroelectric ceramic loading in the polymeric resin is in the range of 5 Vol % to 95 Vol %. It is also possible to use organic or polymer coated ferroelectric ceramic particles where organic/polymer coating helps to disperse particles in the solution. Furthermore, the capacitor material 130 can be a pure ferroelectric polymer such as polyvinylidene fluoride (PVDF) or it can be combination of ferroelectric polymer and ceramics.
By the term “ferroelectric ceramic” as used herein, is meant ceramics that possess ferroelectric properties. These include barium titanate, substituted barium titanate, strontium titanate, lead titanate, lead zirconate titanate, substituted lead zirconate titanate, lead magnesium niobate, lead zinc niobate, lead iron niobate, solid solutions of lead magnesium niobate and lead titanate, solid solutions of lead zinc niobate and lead titanate, lead iron tantalite, other ferroelectric tantalates, and combinations or mixtures thereof.
Capacitor material 130 is typically placed on substrate 122 between traces of electrically conductive material 124 by screen printing, ink jet deposition, stencil printing or dispensing. Capacitor material 130 can be liquid, paste or semi-solid. It is also possible to use resin coated copper capacitive type materials where capacitor material 130 flows on substrate 122 between traces of electrically conductive material 124 by a lamination process using a standard Cu mask. It will be recognized by those of skill in the art that other suitable methods for depositing of capacitor material 130 may be used; the invention is not limited to one of the particular methods disclosed for purposes of disclosure.
Following deposition of capacitor material 130 , the resulting assembly is typically given a B-stage cure at a suitable temperature and for a suitable duration depending upon the specific capacitor material 130 used. For the preferred capacitor material 130 , a temperature of approximately 130° and a duration of approximately 3 minutes has been found satisfactory. Finishing operations, including laminating and etching a copper layer are described in detail hereinbelow.
An alternate embodiment of the method of the invention is shown in FIGS. 2 a through 2 g . Referring first to FIG. 2 a , a copper clad dielectric substrate 200 has a dielectric layer 202 and a copper layer 204 . Copper layer 204 is first etched to provide a pattern (see FIG. 1 c ) of parallel, electrically conductive traces 206 as shown in FIG. 2 b.
Next, a layer of photoimageable material 100 is laminated to the etched copper clad dielectric of FIG. 2 b to form the structure shown in FIG. 2 c.
Photoimageable dielectric material is exposed and etched to expose conductive traces 206 using processes well known to those of skill in the art to expose conductive traces 206 . The resulting structure is shown in FIG. 2 d.
Next, copper 208 is grown on conductive traces 206 to raise conductive traces 206 to the height of photoimageable dielectric 100 . The resulting structure is shown in FIG. 2 e . Typically, an electroless or immersion copper deposition process is used. Such processes are believed to be well known to those of skill in the art and are not described in further detail herein. It will further be recognized that other copper deposition techniques known to those of skill in the art may be substituted.
The next process step is dispensing capacitor material 130 into the spaces between electrically conductive traces 206 / 208 as shown in FIG. 2 f . Capacitor material 130 typically comprises a polymer resin and a quantity of nano or micro powders or a mixture of nano, micro powders of ferroelectric ceramic material having average particle size substantially in the range of between about 0.005 microns and about 10 microns and a surface area for selected ones of said particles within the range of from about 0.5 to about 100 square meters per gram. Ferroelectric ceramic loading in the polymeric resin are in the range of 5 Vol % to 95 Vol %. It is also possible to use organic or polymer coated ferroelectric ceramic particles where organic/polymer coating helps to disperse particles in the solution. Furthermore, the capacitor material 130 can be a pure ferroelectric polymer such as PVDF or it can be a combination of ferroelectric polymer and ceramics.
Capacitor material 130 is typically placed on substrate 202 between traces 206 / 208 by screen printing, ink jet deposition, or stencil printing. It will be recognized by those of skill in the art that other suitable methods of capacitor material 130 deposition may be used and the invention is not limited to one of the particular methods disclosed for purposes of disclosure.
Following deposition of capacitor material 130 , the resulting assembly is typically given a B-stage cure at a suitable temperature and for a suitable duration depending upon the specific capacitor material 130 used. For the preferred capacitor material 130 , a temperature of approximately 130° and a duration of approximately 3 minutes has been found satisfactory.
Finishing operations for the method of FIGS. 1 a through 1 f and 2 a through 2 f include laminating a copper layer 210 over the top of the structure of FIG. 1 f or 2 f . A thin copper sheet, not shown, may be laminated or copper may be sputtered or otherwise deposited using any of the well-known techniques are described in detail hereinbelow.
After copper layer 210 is in place, copper layer 210 may be etched to provide a desired pattern of electrically conductive traces using any known etching technique.
A second alternate embodiment of the method of the invention for forming multilayer embedded capacitors is shown in FIGS. 3 a through 3 d.
As shown in FIG. 3 a , a relatively thick dielectric substrate 300 is provided. Typically, substrate 300 may be in the range of approximately 20-30 mils think. However, it will be recognized that other thicknesses may be utilized to meet a particular operating circumstance or environment.
A wide groove 302 is formed in substrate 300 using a drill, milling machine, laser, or any other suitable instrument or tool. A thin portion 304 of substrate 300 is left to serve as a deposition surface as shown in FIG. 3 b.
As seen in FIG. 3 c , a pattern of substantially parallel conductive traces 306 is next formed on thin substrate portion 304 using an ink jet or other suitable deposition process. Such deposition processes are well known to those of skill in the art and are not further described herein. Following deposition, the conductors are typically cured. In the embodiment chosen for purposes of disclosure, curing is accomplished at approximately 200° C. for approximately two hours.
Finally, capacitor material 130 is deposited in the spaces between conductors 306 using ink jet printing or any other suitable dispensing technique. Typical B-stage curing is performed at 130° C. for approximately 3-10 minutes. The B-stage curing is typically followed by further curing. In the embodiment chosen for purposes of disclosure, curing is accomplished at approximately 200° C. for a duration of approximately 2 hours. Although B-stage curing and a final curing process is preferred, the process is not limited to any particular curing process. This process can be a single step curing, or a B-stage lamination and curing, or a B-stage curing and lamination curing, etc.
It will be recognized that curing times and temperatures may be modified depending upon the choice of material, the printing or deposition techniques and the invention, therefore, is not considered limited to a particular material, time or temperature.
Another alternate embodiment of the method of the invention for forming multilayer embedded capacitors is shown in FIGS. 4 a - 4 e.
As shown in FIG. 4 a , a relatively thick dielectric substrate 300 is provided. Typically, substrate 300 may be in the range of approximately 20-30 mils think. However, it will be recognized that other thicknesses may be utilized to meet a particular operating circumstance or environment.
A wide groove 302 is formed in substrate 300 using a drill, milling machine, laser, or any other suitable instrument or tool. A thin portion 304 of substrate 300 is left to serve as a deposition surface as shown in FIG. 4 b.
As seen in FIG. 4 c , a pattern of substantially parallel conductive traces 400 is next formed on thin substrate portion 304 using an ink jet or other suitable deposition process. Such deposition processes are well known to those of skill in the art and are not further described herein. It should be noted that unlike the embodiment of FIGS. 3 a - 3 d , the thickness of traces 400 is significantly less than that of traces 306 ( FIG. 3 c ). Following deposition, the conductors are typically cured. In the embodiment chosen for purposes of disclosure, curing is accomplished at approximately 200° C. for a duration of approximately 2 hours.
Next, electroless or immersion copper 402 is plated on traces 400 to bring the total height of the conductive trace 400 , 402 to be substantially even with a top surface of dielectric 300 .
Finally, capacitor material 130 is deposited in the spaces between conductors 400 , 402 using ink jet printing or any other suitable dispensing technique. Typical B-stage curing is performed at 130° C. for approximately 3-10 minutes. The B-stage curing is typically followed by further curing. In the embodiment chosen for purposes of disclosure, curing is accomplished at approximately 200° C. for a duration of approximately 2 hours.
It will be recognized that curing times and temperatures may be modified depending upon the choice of material. The printing or deposition techniques and the invention is, therefore, not considered limited to a particular material, time or temperature.
Yet another alternate embodiment of the method of the invention for forming multilayer embedded capacitors is shown in FIGS. 5 a - 5 e.
As shown in FIG. 5 a , an assembly comprising a thin dielectric substrate (typically FR4 or the like) has copper traces on an upper surface thereof. Copper traces 502 may be formed in any known conventional manner including, but not limited to, etching or deposition. A photoimageable dielectric 504 is bonded to the upper surface of dielectric 550 and copper traces 502 .
Photoimageable dielectric 504 is subjected to a first exposure and etching to reveal copper traces 502 through openings 506 in photoimageable dielectric 504 as seen in FIG. 5 b.
Next, copper 508 is plated on copper traces 502 through openings 506 . Copper 508 is typically deposited using an electroless plating process. It will be recognized, however, that other suitable plating or depositions process may be utilized. The resulting structure is shown in FIG. 5 c.
Photoimageable dielectric 504 is next subjected to a second exposure and etching process to create openings 510 between copper traces 502 , 508 as seen in FIG. 5 d.
Finally, capacitor material 130 is deposited in the spaces between conductors 502 , 508 using ink jet printing or any other suitable dispensing technique. Typical B-stage curing is performed at 130° C. for approximately 3-10 minutes. The B-stage curing is typically followed by further curing. In the embodiment chosen for purposes of disclosure, curing is accomplished at approximately 200° C. for a duration of approximately 2 hours. The resulting structure is shown in FIG. 5 e . Although all capacitance layers are shown perpendicular to the photoimageable dielectric surface 504 , it is also possible to use any capacitance layer just above the photoimageable dielectric surface 504 with any angle ranging from 10 degrees to 170 degrees.
Referring now to FIG. 6 , there is shown a schematic, vertical, cross-sectional, perspective view of an embedded multilayer capacitor formed using one of the foregoing methods of the present invention, generally at reference number 600 . As may readily be seen, capacitor 600 consists of an alternating series of electrodes 602 (i.e., capacitor “plates”), and dielectric layers 604 . Each pair of dielectric-separated plates 602 forms a section C x or layer of the multilayer capacitor 600 . The total capacitance of C t capacitor 600 may be expressed as:
C t =C 1 +C 2 +C 3 + . . . +C n
where: C t is the total capacitance of the multilayer capacitor; and C 1 , C 2 , C 3 , . . . , C n are the respective capacitance of individual capacitor sections or layers. Dielectric layers 604 have thickness ranges from about 0.1 micron to 100 microns.
Table 1 compares volumetric efficiency (i.e., the capacitance per unit volume). A dielectric constant of approximately 30 is assumed.
TABLE 1
Vertical Multilayer Embedded Capacitors
Capacitance
Normal
1 mil line,
0.5 mil line,
0.25 mil line,
Layer Thickness
Capacitance
1 mil space
0.5 mil space
0.25 mil space
1 mil
6.74 nF/inch 3
3.37 nF/inch 3
13.49 nF/inch 3
53.98 nF/inch 3
2 mils
3.37 nF/inch 3
6.74 nF/inch 3
26.98 nF/inch 3
107.96 nF/inch 3
4 mils
1.68 nF/inch 3
13.48 nF/inch 3
53.96 nF/inch 3
215.92 nF/inch 3
The values of Table 1 are calculated using the formula:
C= 0 A/d
Where:
C=capacitance in farads
=dielectric constant
0 =8.854×10 −12 F/m 2
A=area in m 2
d=coating thickness in meters
The values of Table 1 show that vertical, multilayer capacitors in accordance with the methods of the present invention provide enhanced capacitance per unit volume compared to capacitors formed using methods of the prior art.
The following examples represent various combinations of capacitor dielectric materials and processes used to form capacitors according to various aspects of the invention. These should be understood to be examples only and do not limit the scope of this invention.
Example One
Fifty grams (gm) of cycloaliphatic epoxy resin (e.g., one sold under product designation “ERL-4211” by the Union Carbide Corporation, Danbury, Conn.) was mixed with about fifty gm of hexahydro-4-methylphthalic anhydride and 0.4 gm N, N dimethyl benzylamine. The mixed solution was stirred for ten minutes to assure uniform mixing. Sixty gm of barium titanate (BaTiO 3 ) powder was added to 17.5 gm of the mixed solution and formed into a screen printable paste. The average (mean) particle size for the added powder was about 0.5 micron, the surface area about 2.65 square meters/gm, and the specific gravity about 5.30.
Example Two
As in Example One, fifty gm of “ERL-4211” cycloaliphatic epoxy resin was mixed with about fifty gm of hexahydro-4-methylphthalic anhydride and 0.4 gm N, N dimethyl benzylamine. The mixed solution was stirred for ten minutes to assure uniform mixing. 150 gm of a combination of barium titanate, calcium titanate and zirconium powders was mixed thoroughly with 100 gm of the mixed solution and formed into a screen printable paste. The average (mean) particle size for the added powder was about 0.2 micron, the surface area about 8.25 square meters/gm, and the specific gravity about 5.15.
Example Three
As in Examples One and Two, above, fifty gm of “ERL-4211” cycloaliphatic epoxy resin was mixed with about fifty gm of hexahydro-4-methylphthalic anhydride and 0.4 gm N, N dimethyl benzylamine. The mixed solution was stirred for ten minutes to assure uniform mixing. 150 gm barium titanate powder was mixed thoroughly with 100 gm of the mixed solution and made into a screen printable paste. The average (mean) particle size for the added powder was about 0.1 micron, the surface area about 15.08 square meters/gm, and the specific gravity about 5.52.
Example Four
38.5 gm of an epoxy novolac resin sold under the product name “LZ 8213” from Huntsman, Salt Lake City, Utah, containing about 35 wt % methyl ethyl ketone and 6.5 gm of a phenoxy resin sold under the product name “PKHC” from Phenoxy Associates, Rock Hill, S.C., containing 50 wt % methyl ethyl ketone were mixed together with 100 gm of barium titanate (BaTiO 3 ) powder available from Cabot Corporation, Boyertown, Pa. ((50 gm BaTiO 3 with a mean particle size=0.065 micron, surface area=16 m 2 /gm) and (50 gm BaTiO 3 with mean particle size=0.12 micron, surface area=8.2 m 2 /gm)), thirteen gm propylene glycol methyl ether acetate) and twelve gm methyl ethyl ketone) and ball milled for three days until a homogeneous slurry was obtained. Here PKHC (organic) coating helped the barium titanate nano particles to disperse in solution.
This invention describes vertical multilayer capacitors. In general, horizontal multilayer capacitors can be prepared by laminating multiple capacitance layers which requires individual capacitance layer formation and subsequent lamination of next capacitance layer. Vertical multilayer capacitors can be generated from one horizontal dielectric layer. This does not require multiple laminations such as needed with multiple horizontal capacitance layers. Here, vertical multilayer capacitors can be generated within a specific volume of one dielectric layer.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims. | Methods of forming embedded, multilayer capacitors in printed circuit boards wherein copper or other electrically conductive channels are formed on a dielectric substrate. The channels may be preformed using etching or deposition techniques. A photoimageable dielectric is an upper surface of the laminate. Exposing and etching the photoimageable dielectric exposes the space between the copper traces. These spaces are then filled with a capacitor material. Finally, copper is either laminated or deposited atop the structure. This upper copper layer is then etched to provide electrical interconnections to the capacitor elements. Traces may be formed to a height to meet a plane defining the upper surface of the dielectric substrate or thin traces may be formed on the remaining dielectric surface and a secondary copper plating process is utilized to raise the height of the traces. | 7 |
This is a continuation of application Ser. No. 780,876, filed Mar. 24, 1977 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a fiber collection system. More particularly, the present invention relates to a method and apparatus for collecting fibrous material, e.g. glass microfibers.
2. Description of the Prior Art
One conventional method of forming glass fibers utilizes hot, high velocity gaseous blasts to attenuate the fibers during formation. The gaseous blasts with entrained fibers and a large volume of inspirated process air are contained and conducted by a forming tube and discharged into a collection chamber and onto a moving perforated collection surface upon which the fibers are collected. A sucton means draws spent gas and air through the collection surface.
Emission control problems arise with such a known method, particularly with the production of small diameter or microfibers (e.g. 0.05-2.60 micron diameter fibers and typically 0.1 to 0.7 micron diameter fibers) due to the difficulty of efficiently handling a large volume of moving gases. Furthermore, the gas entrained fibers tend to escape into the ambient surroundings, especially in the regions adjacent the moving collection surface and the collection chamber. The collection surface often becomes clogged with fibers which causes fibers to be blown around the production area since a fiber clogged collection surface prevents efficient exhausting of the gases. This clogging problem necessitates replacing the collection surface, e.g. screen material, frequently. This substantially diminishes the efficiency of the system due to interrupted production and excessive down-time. In addition, it is often necessary to install expensive emission control systems to avoid discharging fibers into the atmosphere.
BRIEF DESCRIPTION OF THE INVENTION
In view of the foregoing it is an object of the present invention to provide an apparatus for the efficient and effective collection of fibers, particularly microfibers.
Another object of the invention is to provide a microfiber collection apparatus which minimizes emission of fibers to the environment thereby reducing the need for supplemental emission control systems.
A further object of the present invention is to provide an efficient method of collecting fibers.
Another object of the invention is to eliminate or substantially reduce the need to preheat process air.
Accordingly, the present invention provides a method and apparatus for collecting fibrous material which includes a collection chamber and a rotating fluid pervious collection drum preferably having a fine mesh screen positioned around its peripheral surface. The collection drum is rotated along a path, a major portion, i.e. at least half, of which is within the collection chamber, and a minor portion of which is located outside the collection chamber. Fibrous material is drawn onto the peripheral surface of the collection drum moving along the portion of the path within the collection chamber. The portion of the path outside the collection chamber is sealed from the interior of the collection chamber. The collected fibrous material is removed from the path while the collection drum moves through the portion of the path outside the collection chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a collection chamber of an apparatus for the formation and collection of fibers according to the present invention partially cut away to illustrate the interior and detail of a collection drum;
FIG. 2 is an end view of the collection drum shown as FIG. 1 with associated equipment;
FIG. 3 is an end view of the drum and associated equipment taken from the same position as FIG. 2 but with the chamber wall and drum end removed;
FIG. 4 is an enlarged, fragmentary sectional view of an air knife;
FIG. 5 is a sectional view of a baffle plate and the collection drum taken along line 5--5 of FIG. 3 with their associated seals;
FIG. 6 is a schematic view and side elevation illustrating a modification of the present invention;
FIG. 7 is a fragmentary sectional view taken along line 7--7 of FIG. 3; and
FIG. 8 is a schematic view and side elevation illustrating a modification of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, in a collection apparatus 10, filaments of glass F are continuously advanced transversely into hot, high velocity gaseous blasts B produced by a plurality of burners 14. The burners 14 are preferably arranged so as to discharge substantially horizontal blasts. The gaseous blasts B attenuate the filaments F into fine staple fibers. The gaseous blasts, the fibers entrained therein and inspirated process air, generally indicated by arrows A, are contained and directed via a forming tube 15 and are discharged into a collection chamber 16 including a rotatable collection drum 17.
The inspirated air is preferably drawn in along the path indicated by the arrows A in FIG. 1 through a set of louvers 12 which can be adjusted so as to control the amount of air inspirated into the forming tube 15. A wall 11 helps contain and channel the process air through the louvers 12 where the air is then inspirated into the forming tube. With such a system, process air need not be drawn from the area behind the burners 14 where operators monitoring the process are typically located. Consequently, any air drawn through the area behind the burners needs to be heated so as to maintain comfortable working conditions for the operators. Thus, with the louvers of the present invention whereby air is inspirated into the forming tube 15 along the path indicated by the arrows A, there is no need to heat the process air.
The collection drum 17 is adapted to be rotated in the direction indicated by the arrows in FIGS. 1 and 3 and may be driven by any suitable means. The collection drum 17 has a peripheral collection surface 25 which rotates along a path, a major portion of which path is within the collection chamber 16 and a minor portion of which is outside the collection chamber 16.
In the embodiment illustrated in FIG. 1, the forming tube 15 is comprised of one section having a relatively small cross-section at the end adjacent the burners 14. The cross-section of the end of the forming tube 15 adjacent the collection chamber 16 is comparatively large and results in the discharge of the fibers over a substantial portion of the collection surface within the collection chamber 16.
Other configurations for the forming tube 15 would be suitable for use with the collection apparatus 10 of the present invention. For example as shown in FIG. 8, a forming tube 15a can have multiple sections. In such a modification, a first section 110, positioned adjacent the burners 14, is arranged substantially horizontally. This first section may be constructed of any suitable refractory material, e.g. panels of asbestos fibers and diatomaceous silica marketed under the registered Trademark MARINITE by Johns-Manville Corporation. A refractory material is necessary since the temperature at the burners 14 is approximately 3000° F.
A second section, or mid-section 112 of the forming tube 15a is positioned intermediate the first section 110 and a third section 114. The mid-section 112 of the forming tube 15a is constructed of any suitable material, e.g. stainless steel and is oriented in such a manner that the end of the mid-section attached to the third section 114 is substantially lower than the end of the mid-section attached to the first section. In this modification of the present invention, such an orientation serves to lower the fiber path in such a manner that the fibers enter a collection chamber 16a at a point beneath collection drum 17a. Any other suitable method of achieving this end, that is entry of the fibers from a point beneath the collection drum, would also be suitable. For example, the collection drum 17a can be positioned relatively higher than the burners 14 and the forming tube 15a could then be oriented in a substantially horizontal position.
The end of the mid-section 112 attached to the third section 114 typically has a greater cross-sectional area than the end of the mid-section attached to the first section 110. The increased cross-sectional area of the downstream end of the mid-section serves to slow down the velocity of the gaseous stream and entrained fibers.
The third section 114 of the forming tube 15a is attached at one end to the mid-section and its other end is open to the collection chamber 16a. The third section is of substantially constant cross-section and, like the mid-section, can be constructed of stainless steel. The third section 114 is oriented in a substantially horizontal position and opens into the collection chamber 16a at a point beneath the collection drum thereby preventing direct impingement of the fibers onto the collection screen of the collection drum. This minimizes fiber penetration into and through the collection screen mesh, thereby minimizing emission problems and clogging of the collection screen surface.
Other orientations of the forming tube in this embodiment are suitable, e.g. the forming tube 15a can open into the collection chamber at a point above the collection drum or the forming tube can also be oriented to open in such a manner that the axis of the forming tube, that is the major directional line of travel for the fibers, is at some angle other than perpendicular to the rotational axis of the collection drum. With such systems, although the suction force still draws the fibers onto the collection screen, the fibers are not directly impelled onto the collection screen by the force of the gaseous blasts B and the inspirated process air.
In the illustrated embodiment (see FIGS. 2 and 7), a sprocket 18 is connected by a tubular stub shaft 19 (FIG. 7) to a rotatable end plate 22, and is chain driven by an electric motor 23 or other suitable source of power. The tubular stub shaft 19 is supported for rotation by bearings housed in a journal box 20. The journal box 20 and the electric motor 23 are supported by a beam 24 which is attached to a suitable framing structure 11. The end of the drum opposite the drive end, that is, the end adjacent an exhaust duct 33 (FIG. 1) is similarly supported; i.e. a spider 27 (FIG. 3) is supported by a tubular stub shaft 28 which rotates in a journal box 29 (FIG. 7). The journal box 29 is mounted on a beam 32, also supported by the framing structure 11.
The peripheral surface 25, of the collection drum 17 is made of a perforated metal sheet. Hot rolled steel 5/16 inch thick and having 2 1/16 inch square holes punched on 23/8 inch centers in staggered rows, is suitable. Other types of perforated metal can be used for the collection drum surface, e.g. round holes, oblong holes, etc. or flattened expanded sheet metal. A fine mesh collection screen 26, e.g. a stainless-steel wire cloth is attached to the peripheral surface 25. The collection screen 26 can be attached to the periphery of the collection drum 17 with a high temperature epoxy adhesive and joined to itself at its overlapping edges by epoxy and silver solder. Other suitable means of attaching the screen to the collection drum surface can be used, e.g. "snap-in" sections which decrease replacement time. The size of the screen mesh is dependent on the size of the fibers to be collected. Finer mesh size is utilized for small diameter fibers and larger screen is used for coarser fiber collection. A 32 mesh screen (0.0238 inch wide openings) has been found to be quite suitable for the collection of microfibers.
Finer mesh screens, e.g. 46 mesh (with 0.0172 inch wide openings) allow lower fiber emission rates into the exhaust but tend to have a shorter operating life. Such shorter operating life is due to the smaller diameter wire in such finer mesh screens which wears through more rapidly than the wire in coarser screens and which tends to flex more in place causing the wire to break more rapidly.
The finer mesh screen operating life problem can be satisfactorily handled by improved fastening methods for attaching the screen to the collection drum. For example, multiple discrete snap-in segments can be used which have less of a flex tendency than a continuous sheet of screen and are easier to replace when the screen does wear.
For a given rate of the production, the collection drum is rotated faster for the collection of fine diameter fibers than for the collection of coarse fibers since finer fibers tend to block the screen holes more rapidly.
In an actual working embodiment of the present invention, the speed of the rotation of the collection drum is set so as to maintain a collection screen loading of 2.63 grams of fibers per square foot. However, slower rotational speeds can be used, e.g. 3.31 gms/sq. ft. loading, but slower rotational speed results in a high pressure drop across the fibers and collection screen which forces the fibers into and through the interstices of the screen resulting in fiber emission through the exhaust duct 33.
The spiders 27 at the end of the drum 17 adjacent the exhaust duct 33 provide openings so that the interior of the collection drum 17 communicates (as indicated by arrow E in FIG. 7) via the exhaust duct 33 with a suitable large-capacity exhaust or suction blower (not shown). The exhaust duct 33 may also be equipped with conventional dampers to control the amount of air drawn through the collection drum.
As shown in FIG. 3, an approximately 80° segment of the peripheral wall of the collection drum 17 is separated from the suction effect of the exhaust blower by an arcuate baffle plate 34. This section of the collection drum 17 is exposed to the atmosphere on the outside of the collection chamber 16. The baffle plate 34 is positioned on the interior wall of the peripheral surface 25 by a support member 35 (FIGS. 1 and 3) which in turn is secured to a stationary tubular shaft 30. As shown in FIG. 7, the tubular shaft 30 is mounted in a block 37 which is fastened to a base plate 38 mounted on the beam 32. A key 41 locks the tubular shaft 30 against rotation. The tubular shaft 30 extends axially through the interior of the collection drum 17 and is supported at the drive end of the collection drum 17 by bearings 40 located at the hub of the tubular stub shaft 19 on which the sprocket 18 rotates relative to the stationary shaft 30. The baffle plate 34 is sealed against the interior surface of the collection drum 17 along its upper and lower edges by longitudinally extending flexible seals 44 and 45 (FIG. 3), and, as shown in FIG. 5, along its side edges by seals 46.
The flexible seals 44 and 45 and the two seals 46 are held in position in a sealing relationship by metal angles which press the seals against the peripheral surface 25 of the collection drum. The seals 44, 45 and 46 are preferably made of a polytetrafluoroethylene impregnated asbestos fabric, e.g. ASBESTAN material produced by Johns-Manville Corporation which is a Teflon (trademark of E. I. du Pont de Nemours Co.) impregnated asbestos fabric.
As shown in FIG. 7, two additional seals 43 and 47 are provided and are preferably comprised of a polytetrafluoroethylene impregnated fabric such as ASBESTAN fabric. The seal 47 is disposed between the end plate 22 of the collection drum 17 and the collection chamber 16. The seal 47 is positioned in such a manner that air adjacent the exterior of the collection chamber is not inspirated into the collection chamber. The seal 43 is positioned between the collection chamber 16 and the exhaust duct 33. The seal 43 prevents fibrous material from bypassing the collection screen and entering directly into the exhaust duct 33.
A baffle plate 34a (FIG. 8) is smilarly sealed as the baffle plate 34 and serves a similar function, i.e. it inhibits the suction force within the collection drum 17a from acting on that portion of the path of the collection drum outside the collection chamber 16a.
As shown in FIGS. 1, 2 and 3, an air knife 48 is attached along the longitudinal lower edge of the baffle plate 34 and includes longitudinally extending fluid nozzles positioned to clean residual fibers from the collection screen 26 and the peripheral surface 25 of the collection drum 17 after the fibers have been removed from the collection screen at a point of the path outside the collection chamber 16. Due to the longitudinally extending seal 45, the air knife 48 operates without influence from the low pressure zone within the collection drum. Compressed air or other fluid under low pressure and high volume (e.g. approximately 5.5 psi and 635 cfm) is fed to the air knife 48 from a source 50 external of the apparatus framing structure 11 and via a plurality of pipes 49, which are connected through the center of the stationary shaft 30 at nipples 100.
In operation, the gaseous blasts B, the inspirated air drawn along the path indicated by the arrows A, and the entrained fibers are discharged into the collection chamber 16 via the forming tube 15. A major portion, e.g. approximately 280° of the screen-covered collection drum surface, serves as a wall within the collection chamber and thereby intercepts the fibers. As shown in FIG. 3, a longitudinally extending outer seal 51 and a longitudinally extending upper outer seal 52 which cooperates with an idler roll 53 also help confine the gaseous stream of fibers within the collection chamber. The idler roll 53 serves as a moving seal that is adjustable to varying collection thicknesses while still maintaining an effective seal between the atmosphere and the collection chamber 16.
The suction established within the drum interior by the exhaust blower through the exhaust duct 33, continously draws spent gases and process air through the screen-covered collection drum surface. The fibers entrained in the gaseous blasts are collected on the collection screen 26 and are held on the screen by suction force until the collection drum rotates to a point beyond the idler roll 53 i.e. to a point along the path which is outside the collection chamber 16. The baffle plate 34, appropriately sealed as described above, confines the suction effect to the major portion of the screen, e.g. the 280° portion, that is moving within the collection chamber at any given moment. The baffled portion of the drum, e.g. the approximately 80° which is exposed to the atmosphere, is utilized for removing the collected fibers from the path.
In the embodiment of the present invention illustrated in FIG. 8 the baffle plate 34a is attached to an air knife 48a in a similar manner as that discussed above with regard to baffle plate 34 and the air knife 48. The air knife 48a cleans any residual fibers from the collection drum 17a and its collection screen after collected fibers 102 are removed from the path at a point outside the collection chamber 16a.
In another embodiment of the invention, fibers are collected by a conveyor belt 101 as shown in FIG. 6. In this embodiment, the collection screen 26 lies against the peripheral surface 25 of the collection drum while it is within the collection chamber 16, preferably, for example approximately 250° of the circumference of the collection drum 17. The conveyor belt 101 is mounted on a roller 21 and travels from a position adjacent the collection drum to a material take-off position outside the collection chamber 16. As FIG. 6 further illustrates, an air knife 48b, which is similar in construction to the air knife 48, discharges a high volume fluid jet through the collection screen 26 and conveyor belt 101 thereby cleaning residual fibers from the collection screen and conveyor belt and into the collection chamber 16.
The collected fibers can be taken off the collection screen in several ways. FIG. 6 illustrates one method wherein a lightweight gathering mandrel 56, controlled by appropriate guides 57, is laid against a layer of collected fibers 102 and an initial wrap is manually performed so as to form a first layer around the mandrel. Thereafter the gathering mandrel 56 is frictionally rotated and wind-up of the collected fibers 102 continues until a predetermined roll size is achieved. The mandrel is then replaced by an empty one. The wrapped material can then be stripped from the completed mandrel and packaged for shipment.
The gathering mandrel is preferably changed frequently, e.g. approximately every 10 minutes for an operation producing 60 pounds of fiber per hour. This produces a package of approximately 10 pounds when collecting 0.5-0.7 micron diameter fiber. Since the collection screen 26 gradually retains more fibers as the mandrel package is building, the amount of air passing through the screen is reduced which thereby reduces the static pressure within the forming tube. A small mandrel, e.g. an empty gathering mandrel, removes the fibers from the collection screen more efficiently which thereby presents more open area for air passage thus increasing the forming static pressure and reducing the temperature in the exhaust gas since more air can be inspirated into the forming tube.
A second method of winding the collected fibers 102 utilizes a multi-position turret which is adapted to receive three rotatable gathering mandrels aligned such that the rotational axis of each mandrel is parallel to the rotational axis of the collection drum. After one of the gathering mandrels is fully wrapped, the turret is rotated to bring an empty gathering mandrel into position against the collection screen for winding the collected fibers 102.
A third method of winding the collected fibers is illustrated in FIG. 2 and involves a "flip-flop" arrangement 58. First and second mandrels 56a and 56b are rotably mounted on either end of a bar 103 having a counterweight 105 acting on its center. The first mandrel 56a begins winding the collected fibers 102. Upon reaching a predetermined package size and weight on the first mandrel 56a, the second mandrel 56b is swung over to a point on the collection drum surface between the idler roll 53 and the wind-up position, indicated at reference numeral 107. The first mandrel 56a is then pulled outwardly away from the collection screen 26 and the second mandrel 56b drops into the proper wind-up position at 107. The second mandrel 56b is pre-wetted which causes the collected fibers 102 to gegin winding around the second mandrel 56b. During the winding opertion on the second mandrel, the fibers can be stripped from the first mandrel 56a so that upon completion of the wrapping process on the second mandrel 56b, the process can be repeated.
Other methods of collecting the fibers from the screen can be utilized. For example the fibers can be vacuumed from the screen rather than frictionally winding them onto a rotating mandrel. In an embodiment wherein the collection apparatus utilizes 30,000 cubic feet of air per minute, fibers can be vacuumed off the collection screen and recollected with a vacuum force of approximately 600-700 cfm. In another method the collection screen can be supplied with a pervious paper or felt upon which the fibers can be collected. The collected fibers and the felt or paper can then be removed together by, for example, one of the winding operations discussed above.
Any fibers that may remain upon the screen after such removal are cleaned by a high volume fluid jet e.g. by the air knife 48, 48a or 48b. Clogging of the collection screen 26 with residual fibers is thereby prevented, and since the air knife is positioned so as to discharge the fibers into the collection chamber 16, the screen is not only efficiently cleaned but atmospheric emissions of fibers is also mimimized.
Furthermore, since the fibers are discharged into the collection chamber 16 they can be recollected on the collection drum. This minimizes operator exposure to the fibers and also eliminates scrap from the process which results in more efficient and economical collection system than that of the prior art.
It is apparent that, within the scope of the invention, modifications and different arrangements may be made other than herein disclosed, and the present disclosure is illustrative merely, the invention comprehending all variations thereof. | A method and apparatus for collecting fibrous material, particularly small diameter glass fibers, i.e. within the range of 0.05 to 2.60 microns, from a gaseous medium in an efficient, environmentally sound manner is disclosed herein. The apparatus includes a collection chamber which partially encloses a rotating drum having a perforated peripheral surface and having a fine mesh collection screen superimposed thereover. The drum is positioned in such a manner that the screen intercepts a gaseous stream of fibers, e.g. glass microfibers. A suction force established interiorly of the peripheral surface of the drum draws the gaseous stream through the collection screen in order to thereby continuously collect a layer of fibers upon a portion of the rotating screen. The layer of fibers is removed from the drum and wound on a mandrel at a point outside the collection chamber. In a preferred embodiment of the present invention the drum surface is cleaned of any residual fibers. | 3 |
BACKGROUND OF THE INVENTION
This invention concerns blast hole drill bits and is especially concerned with a bit for forming longitudinal grooves in already drilled blast holes.
A study conducted for the United States Department of Transportation has concluded that longitudinal V-notches or grooves formed along the peripheral surfaces of predrilled blast holes aids in the control of crack propagation during blasting of the bore hole.
The study, entitled "Field Evaluation of Fracture Control in Tunnel Blasting," (Report No. UMTA-MA-06-0100-79-14) determined the effect of groove geometry on the crack initiation phase of controlled fracture. The study indicates that grooved blast holes may be a more efficient alternative to conventional drill and blast procedures. The notched holes require significantly less explosives to achieve the same results as fully charged conventional holes. This results in lower blast noise levels and less vibration. This is very beneficial, particularly in highly populated areas.
Conventional drill bits for drilling blast holes usually are comprised of a bit body having a forward working face. The forward working face has wear resistant compacts of the button, log cabin or other configuration, embedded therein and protruding out of the working face.
Tools for forming grooves in roof bolt holes are also known, such as shown and described in U.S. Pat. No. 3,960,222, granted to applicant corporation. Such tools do not readily lend themselves to forming longitudinal grooves in rock formations in which blast holes are drilled.
The cutting elements used in the referenced patent and in U.S. Pat. No. 2,879,973, also granted to applicant corporation, which discloses a percussion drill bit, are not designed to form a V-notch in the wall of a blast hole. U.S. Pat. No. 3,191,700, granted to applicant corporation, discloses a rotary percussion drill bit having cemented carbide cutting inserts with a V-shaped cutting edge. However, the included angle formed by the V-shaped cutting edge is too large and, therefore, would not lend itself to use in forming a sharp notch in a blast hole.
BRIEF SUMMARY OF THE INVENTION
According to the present invention, a blast hole drill bit comprises an elongate body with opposing ends. One end is adapted to be attached to and driven by a blast hole drill and the other end has a face that extends foremost into the blast hole. This extension acts as a pilot to aid in starting the broach in the hole. The pilot also minimizes side to side drift within the hole.
This extension has a pilot diameter which extends rearwardly from said face to one or more grooving wings that extend radially outwardly from the pilot diameter on the bit.
Preferably, each grooving wing is formed by end milling a longitudinal recess along the outer periphery of the body so as to form a forwardly facing seat portion rearwardly of the pilot diameter. A wear resistant compact is then mounted in said seat and extends radially outwardly from said pilot diameter.
The seat portion is formed, preferably, on an enlarged section of the body so as to substantially support said wear resistant compact.
Preferably, a clearance angle is provided between the rearmost part of the grooving wing and the side of the grooved bore hole by tapering the wing radially inwardly as it extends from the pilot diameter. When viewed in side, preferably, that taper will be approximately 3 degrees when compared to the longitudinal axis of the body.
Preferably, when viewed in plan, the sides of the grooving wings converge in a radially outward direction so as to be V-shaped with the V-opening in the direction of the body.
According to the present invention, a hard wear resistant compact is provided for mounting on the wing of the grooving bit. The compact comprises a forward impact face and a side clearance face angularly related to, and extending rearwardly from, the forward clearance face. The side clearance face has a V-shaped configuration as viewed from the forward direction. It joins the forward impact face along a V-shaped cutting edge whose shape determines the shape of the notch formed in the blast hole. A side mounting face joins and extends rearwardly of said forward impact face and joins the side clearance face. The side clearance face and side mounting face terminate at a rear mounting face.
Preferably, the forward impact face has a V-shaped configuration which widens as it extends rearwardly.
Preferably, the side clearance face slopes inwardly of the compact as it extends rearwardly.
Preferably, the side clearance face forms an included angle of 2 to 10 degrees with a line extending parallel to the forward direction and, more preferably, 3 degrees.
Preferably, the V-shaped cutting edge forms an included angle of 45 to 100 degrees and, more preferably, 75 to 90 degrees.
Preferably, the compacts are made from a material having greater wear resistance than the body of the drill bit. Preferably, this material is a cemented hard metal carbide, such as tungsten carbide.
It is an object of the present invention to provide a drill bit that can efficiently drill longitudinal grooves in blast holes.
It is a further object of the present invention to provide a grooving bit for blast hole that is long lasting and resists wear.
It is a further object of the present invention to provide a rugged cutter bit with carbide compacts for the drilling of longitudinal grooves in blast holes.
It is also an object of this invention to provide hard wear resistant compacts for forming V-notches in blast holes.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects of this invention, and the exact nature of the present invention, will become more clearly apparent upon reference to the following detailed specification taken in connection with the accompanying drawings in which:
FIG. 1 is a view of a grooving bit according to the present invention.
FIG. 2 is a top plan view of the bit shown in FIG. 1 without the wear resistant compacts.
FIG. 3 is a top plan view of an alternate embodiment of the grooving bit according to the present invention.
FIG. 4 is a longitudinal section through a grooving bit taken along line III--III shown in FIG. 2.
FIG. 5 is a wear resistant compact according to the present invention.
FIG. 6 is a top view of the wear resistant compact shown in FIG. 5.
FIG. 7 is an alternative embodiment of a wear resistant compact according to the present invention.
FIG. 8 is another alternative embodiment of the present invention.
FIG. 9 shows a partial side view of a drill according to the present invention having a wear compact as shown in FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings somewhat more in detail, shown in FIG. 1 is a blast hole drill bit 1 according to the present invention. It has an elongate body with a rear end 3 and an opposing forward end 5. The rear end 3 is adapted to be attached to a drill rod (not shown) and nonrotatably driven into a predrilled blast hole. The forward face 5 extends foremost into the blast hole and has a pilot diameter 9 which extends rearwardly from forward face 5. At the end of this pilot diameter is located one or more grooving wings 7 which extend radially outwardly from the pilot diameter 9. The grooving wings 7 are formed by longitudinal recesses 11 extending from the forward face 5 down the side of the pilot diameter 9 and radially extending seat 13 on which is located a hard and wear resistant compact 50.
The seat 13 extends transversely to the longitudinal axis of the drill bit 1. Mounted on the seat 13 and in the bottom of recess 11 is a compact 50 which extends radially outwardly from the pilot diameter 9.
Referring now to FIG. 2, which is a forward or top view of the drill bit shown in FIG. 1, except that the hard wear resistant compacts have been removed, it can be seen that two openings 17 are located in the forward face 5 of the pilot diameter 9. These openings communicate with a chamber in the lower portion of the drill bit 1 from which flushing fluid is driven under pressure out of the openings 17. The flushing fluid used may be a liquid or a gas, and is typically air.
As can be seen in FIG. 2, the seat portions 13 taper inwardly as they extend radially outwardly and are shown as being V-shaped in this figure with the V opening in the direction of the body of the drill bit. This V-shaped seat or grooving wing 13 forms an included angle A' which should have a value between 45 to 100 degrees and, more preferably, a value between 75 to 90 degrees.
The actual value of the angle A' used will depend upon the type of material which is being drilled through. The purpose of these seats 13 is to support the hard wear resistant compacts 50. The angle A' should match the included angle on the clearance face of the compact where the clearance face meets the rear face of the compact.
Shown in FIG. 3 is another top view of the drill bit 1. In this embodiment, there are three grooving wing seats 13. It is within the scope of this invention that one or more grooving wings may be placed on the drill bit. The number of grooving wings 7 used would be determined by the type of fracture pattern that is desired when blasting in the grooved hole. Each groove formed by the drill bit 1 acts as a stress riser such that when the pressure is suddenly increased in the hole due to the detonation of the blasting material, cracks will initiate at the tip of the V-notches that have been formed by the drill.
Shown in FIG. 4 is a longitudinal cross section of the drill bit shown in FIG. 2 taken along arrows III--III. It can be seen in FIG. 4 that the orifice 17 communicates between the forward face 5 of the drill bit 1 to a chamber 21 in the interior of the drill bit and located toward the rear end of the drill bit. The chamber communicates with the rear face 3 of the bit. The internal surface 22 of the chamber is threaded for attachment to a drill rod, not shown. Any of the other means known in the art for attaching a drill bit to a drill rod may be substituted for the threaded means shown.
Pressurized fluid is pumped up the hollow drill rod into the chamber 21 through passageway 23 and out the orifice 17 on the forward face. The pressurized fluid then flushes chips produced by the grooving action out the bottom of the blast hole.
It can also be seen in FIG. 4 that the grooving wing 7 extends farthest from the pilot diameter at its foremost end, that is, where the compact seat 13 is located. It then tapers inwardly and rearwardly at an angle B which should be between 2 to 10 degrees, preferably, approximately 3 degrees. The actual value used should be equivalent to or greater than the clearance angle on the hard wear resistant compact that is mounted on the seat 13 of the bit.
Shown in FIG. 5 is a hard wear resistant compact that is designed to be mounted by brazing or other means on the periphery of a grooving bit such as those shown in the preceding figures. The compact 50 has a forward impact face 52, a side clearance face 54, which is angularly related to and extends rearwardly from the forward clearance face 52. This side clearance face has a V-shaped configuration, as viewed from the forward direction. This is most clearly shown in FIG. 6. There is a V-shaped cutting edge 56 which forms the juncture between the forward impact face 52 and the side clearance face 54. A side mounting face 58 joins and extends rearwardly from the forward impact face 52 and also joins the side clearance face 54. Rearmost on the compact 50 is a rear mounting face 60 which joins the side clearance face and the side mounting face.
As can be seen in FIG. 5, the side clearance face 54 slopes inwardly as the compact extends rearwardly, the arrow F showing the direction of forward movement when the compact is appropriately mounted on the grooving bit seat 13. This clearance face 54 forms an included angle with the forward direction or longitudinal axis of the bit, shown in the FIG. 5 as angle D. It is preferred that this angle be between 2 to 10 degrees, and most preferably, it should be 3 degrees. This clearance angle serves to allow chips to be flushed out of the hole and also serves to reduce jam ups as the bit is being withdrawn from the grooved hole.
Shown in FIG. 6 is a top view of the compact shown in FIG. 5. The impact face 52 is shown and the cutting edge 56 is also shown. It can be seen that the cutting edge is V-shaped and it forms an included angle A which should be between 45 to 100 degrees, and most preferably, 75 to 90 degrees.
While it is desirable that this angle A be as sharp and acute as possible, the greater the sharpness of the angle, the faster and more prone the cutting edge will be to wearing out by chipping. However, the angle should not be so large so as to produce a notch which will not act as a crack initiation cite. In addition, chipping may also be alleviated by placing a radiused peak 62 rather than a sharp peak on the cutting edge; but, again, the radius should not be so large as to cause the root of the notch produced to fail in its function as a crack initiation site.
As shown in both FIGS. 5 and 6, the forward impact face 52 has a V-shaped configuration which widens as it extends rearwardly. However, other configurations are possible for this face and some are shown in FIGS. 7 and 8.
FIG. 7 shows a compact 80 having a forward impact face 82 which is convex.
FIG. 8 shows a compact 90 which has a flat forward impact face 92. This impact face 92 slopes rearwardly as it extends inwardly of the grooving bit body 1, as shown in FIGS. 8 and 9.
The depth N of the V of the compacts shown in FIGS. 5, 6, 7 and 8 is most preferably approximately one-fourth inch. Grooves of this depth with the values of the angle A which have been previously mentioned should produce adequate stress risers in most blasting hole applications.
Modifications may be made within the scope of the appended claims. | A blast hole drill bit is disclosed for forming longitudinally extending grooves in already drilled blast holes, having a body with a forward face and a rearwardly extending pilot diameter. One or more radially extending wings are located at the rearmost part of the pilot diameter and are V-shaped when viewed in plan. Wear resistant compacts form a part of the wings and have a V-shaped cutting edge. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for directing air against a surface to dislodge material thereon. More particularly, the present invention relates to a blower or fan assembly for mounting on the ceiling of a textile processing area for dislodging dust, lint and other textile by-products that have accumulated on such ceilings over time.
The ceilings of textile work processing rooms often become the resting place of lint, dust and other generally lighter than air by-products created during textile processing. The accumulation of these by-products tends to encourage the further accumulation of by-products thereon, and becomes detrimental to the working environment for the textile processing machines. By far the greatest harm of such by-product accumulation, however, is the creation of a harmful environment for the textile workers who are beset by various respiratory ailments aggravated by the presence of minute airborne lint and other textile by-products.
Accordingly, several types of apparatus have been proposed to deal with these by-product accumulations and one type thereof operates to dislodge such textile by-products from the ceiling and thereby set these by-products with the surrounding air into circulation to eventually be removed by conventional lint-removal devices, such as special filters and the like positioned adjacent the textile processing machines. For example, a universally mounted ceiling cleaner disclosed in U.S. Pat. No. 3,072,321 to King, Jr., includes a high velocity fan and its motor mounted in a fan casing having horizontal trunnions which are mounted in the lower ends of an inverted U-shaped yoke. The fan and its motor oscillate through a vertical swing path relative to the U-shaped yoke. The yoke is rotatably mounted on a hollow vertical shaft which is fixed to the ceiling of a textile processing room. A gear motor unit mounted on the U-shaped yoke drives both the rotation of the yoke and the oscillating motion of the fan and its motor.
However, the ceiling cleaner disclosed in the King, Jr. patent suffers from a number of disadvantages. For example, both the rotational movement the U-shaped yoke and the simultaneous oscillating motion of the fan's motor are ultimately transmitted to the assembly which mounts the ceiling cleaner to the ceiling, thereby subjecting the assembly mounting means to the type of relatively significant torsional forces which occur when a moving object of relatively significant mass, such as the oscillating fan motor, is mounted at a distance from the support means. Additionally, the gear motor must be of sufficient size to rotate the U-shaped yoke with the moving fan and motor supporter thereon as well as to drive the oscillation of the fan and its motor with respect to the yoke and the mass of the gear motor contributes to the strain on the assembly mounting means.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for directing air in a predetermine pattern to clean surfaces in the vicinity of textile machines by dislodging accumulated textile fibers, lint and other textile by-products therefrom, the apparatus including a blower for generating a stream of air, a support for supporting the blower in a substantially fixed disposition relative to the surfaces to be cleaned, a first air directing assembly movable about an axis and communicated with the blower for directing the air stream in a direction parallel to a plane during movement of the first air directing assembly about the axis, a device for moving the first air directing assembly about the axis and a second air directing assembly for selectively changing the direction of the air stream relative to the plane, the second air directing assembly being movable in response to movement of the first air directing assembly about the axis, whereby the air stream is directed in a predetermined pattern to dislodge accumulated fibers, lint and other textile by-products from the surfaces in the vicinity of the textile machines.
The apparatus preferably includes a stationary duct portion communicated with the blower and the first air directing assembly includes a rotating duct portion rotatably mounted on the stationary duct portion and the device for moving the first air directing assembly includes a drive assembly for rotating the rotating duct portion relative to the stationary duct portion about the axis. Additionally, the second air directing assembly preferably includes a vane having an air directing surface and a pivot assembly for pivotably mounting the vane on the rotating duct portion.
According to one aspect of the present invention, the apparatus further includes a cam having a predetermined varying contour connected to the stationary duct portion and a cam follower connected to the vane, the cam follower being adapted to selectively follow the cam during rotation of the rotating duct portion whereby the vane pivots in correspondence to the following action of the cam follower along the cam and the air directing surface of the vane changes the direction of the air stream relative to the plane.
According to one aspect of the present invention, the apparatus includes an air filter mounted to the inlet portion of the blower for selectively permitting the inletting of air and particles beneath a predetermined size into the blower. The air filter preferably has a surface area greater than the cross-sectional area of the inlet portion at which it is mounted and the air filter is movable from a rest position outward of the inlet opening to a position inward of the inlet opening in response to the intake of air into the blower.
Accordingly, the present invention provides an apparatus for dislodging lint and other textile by-products from selected surfaces in a textile processing area which minimizes the torsional and other strain forces exerted upon its mounting assembly. Additionally, the apparatus of the present invention allows the direction and duration of the air stream directed against each surface to be selectively controlled so that those surfaces on which the relatively greatest accumulations of lint and other textile by-products characteristically occur can be subjected to an air stream of sufficient duration to reliably dislodge the by-products therefrom. Moreover, since the blower of the apparatus of the present invention remains stationary with respect to the ceiling to which the apparatus is mounted, the undesirable torsional forces which develop in the prior art devices due to movement of the blower relative to the mounting assembly is eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one preferred embodiment of the apparatus of the present invention, showing the apparatus installed on the ceiling of a textile processing area and showing the rotating elbow of the apparatus and its associated damper in their respective positions at one point during the operation of the apparatus;
FIG. 2 is a view similar to FIG. 1, showing the respective positions of the rotating elbow and its associated damper of the apparatus at another point during the operation of the apparatus; and
FIG. 3 is a side elevational view in vertical cross-section of the vertical channel, the rotating elbow, the damper and the drive assembly for rotating the rotating elbow of the apparatus shown in FIGS. 1 and 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
During the operation of a textile processing machine, small pieces of the textile material being processed are set free, and they tend to ultimately accumulate together to form lint. Some of the lint, and the by-products of the processing operation, are removed from the air almost immediately by traveling cleaners which operate along paths closely adjacent the textile machines, examples of these traveling cleaners being disclosed in U.S. Pat. No. 4,333,772 to Mulligan, et al; U.S. Pat. No. 4,258,450 to Sohler and U.S. Pat. No. 3,342,130 to Clark, Jr. et al. However, even with the use of the traveling cleaners, and other conventional filtering equipment, some lint eventually accumulates on the ceiling under the influence of various air currents within the textile processing area. As can be understood, some areas of the ceilings tend to accumulate more lint, and other by-products, than other areas of the ceiling.
As can be appreciated, it is desirable to dislodge the accumulated lint on the ceiling and again return the lint to circulation so that it may eventually be engaged and removed by apparatus such as the traveling cleaner apparatus. In fact, practical experience with the considerable volume of lint which in practice accumulates on all surfaces of textile processing areas including the ceiling has shown that such lint is best dislodged by the application of a removal medium, such as blasts of air, on a repeating basis of fairly short duration, for example, at intervals of approximately one minute.
In FIG. 1, one preferred embodiment of the directional air apparatus 10 of present invention is illustrated and includes an air generating blower 12, a connecting subassembly 14, an air directing subassembly 16 and a filter subassembly 18. The directional air apparatus 10 is designed to radially direct a stream of air while continuously changing the axial inclination of the airstream to dislodge lint and other fabric by-products which have accumulated on the ceiling 20 of a textile processing area in which a yarn spinning machine 22 is located.
Referring now in more detail to the construction of the directional air apparatus 10, as seen in FIGS. 1, 2 and 3, the air generating subassembly 12 includes an impeller 24 rotatably mounted in a housing 26 and driven by an electric motor 28. The impeller 24, the housing 26 and the electric motor 28 are all of conventional construction and are available commercially as a single unit. A plurality of rigid mounting legs 30, preferably composed of metal or some other durable, rigid material, have flanges which are mounted to the housing 26 and coplanar end portions adapted to be flush mounted to the ceiling 20 so that the directional air apparatus 10 is supported in a suspended disposition from the ceiling. A motor mounting flange 32 is attached to the housing 26 for supporting the motor 28 of the impeller 24. The orientation of the coplanar end portions of the mounting legs 30 relative to the housing 26 is such that, when the directional air apparatus 10 is mounted to the ceiling 20, the impeller 24 rotates in a plane generally parallel to the ceiling 20.
An intake conduit 34 of the housing 26 communicates with the filter subassembly 18 and an outlet conduit 36 of the housing 26 communicates with the connecting subassembly 14. The rotation of the impeller 24 draws air through the filter subassembly 18 into the housing 26, and the drawn in air is propelled as an air stream 38 through the connecting subassembly 14 to the air directing subassembly 16 from which it is selectively directed against the ceiling 20 as described in greater detail below.
The filter subassembly 18 includes an elongate cylindrical portion 40 preferably of larger diameter than the diameter of the impeller 24 and sealingly coupled at one end to the inlet opening of the inlet conduit 34. The other end 42 of the elongate portion 40 is open and includes an annular lip 44. A filter 46, which is preferably of lightweight porous fabric made as a filter medium, is drawn over the annular lip 44 and secured to the elongate portion 40, such as by cinching of a drawstring 48, so that the annular lip 44 resists the pulling of the filter 46 thereover. The filter 46 completely encloses the open end 42 and has a greater surface area than the cross-sectional area of the opening end 42. With the aid of a weight 50 secured to its midpoint, the filter 46 normally extends to some extent axially below the open end 42 when the apparatus 10 is not in operation as shown in FIG. 1. However, the filter 46 is composed of a durable material of sufficient flexibility and lightweightedness to move, under the influence of the air being drawn therethrough during the intake of air by the impeller 24, in the direction of the interior of the elongate portion 40. The permeability of the filter 46 is such that lint and other textile by-product pieces larger than a predetermined size cannot pass therethrough yet sufficient air can pass therethrough to satisfy the intake requirements of the impeller 24.
The communicating subassembly 14 includes an elbow 52 communicating the outlet conduit 36 of the housing 26 with a longitudinal duct 54. The elbow 52 and the longitudinal duct 54 are mounted to the outlet conduit 36 of the housing 26 and can be composed of any conventional duct material such as sheet metal having sufficient rigidity to be both self supporting with respect to the housing 26 and capable of supporting the air directing subassembly 16 thereon.
The air directing subassembly 16 includes a fixed cam track 56 mounted by a plurality of support arms 58 mounted to the periphery of the longitudinal duct 54, a rotating elbow 60, a vane 62 and a drive assembly 64. The rotating elbow 60 includes an annular shoulder 66 compatibly configured with the cylindrical top edge 68 of the longitudinal duct 54 such that the radially extending surface of the shoulder is rotatably supported on the longitudinal duct and the circumferential, axially extending surface of the shoulder has a diameter slightly larger than the outer diameter of the longitudinal duct and extends axially along the longitudinal duct. The rotating elbow 60 includes a channel 70 through which the air stream 38 is discharged from the apparatus 10 in a direction generally parallel to, and slightly below, the ceiling 20.
The elbow drive assembly 64 includes an electric motor 72 mounted to, and laterally of, the longitudinal duct 54 by a bracket 74. A pulley 76 fixedly mounted to the shaft of the motor 72 has a belt 78 trained around it which transmits rotation of the pulley to a driven pulley 80 fixedly mounted to the bottom of a shaft 82. The shaft 82 is rotatably supported in a bearing 84 mounted in the wall of the longitudinal duct 54 and extends generally axially centrally through the longitudinal duct 54 and through a portion of the rotating elbow 60 and extends outside the elbow through an opening 86, which may be sealed if desired. A generally L-shaped flange 88 fixedly mounted to the rotating elbow 60 and overlying the opening 86 includes a bore through which the upper axial end portion of the shaft 82 is received. A nut 90 threaded onto the upper axial portion of the shaft 82 cooperates with a second nut 92 which is threaded onto the shaft 82 on the other side of the L-shaped flange 88 to secure the shaft to the L-shaped flange. A bearing 84' disposed interiorly of the longitudinal duct 54 and at approximately the same axial position as the cam track 56 rotatably supports the shaft 82 and centers it with respect to the longitudinal duct. Accordingly, rotation of the shaft 82 by the motor 72 causes the elbow 60 to rotate about a vertical axis and longitudinal duct 54.
The vane 62 is of generally cylindrical configuration and has a diameter slightly less than the diameter of the channel 70 of the rotating elbow 60. A pivot shaft 94 fixedly mounted to the vane along its diameter is rotatably carried in a pair of diametrically opposite bores 96 (see FIG. 1) in the channel 70 so that the vane 62 can pivot on pivot shaft 94 with respect to the elbow 60. One end of the pivot shaft 94 projects outwardly beyond its respective bearings 96 and has a cam follower member 98 fixedly mounted thereto. The cam follower 98, which includes an engaging portion 100 and a connecting portion 102, is adapted to contact and follow the cam track 56 during the rotation of the rotating elbow 60 on the longitudinal duct 54. The cam track 56 includes a surface having a predetermined contour for controlling the operation of the vane 62 in a manner described shortly below. The bores 96 are disposed in a plane perpendicular to the shaft 82 so that the vane 62 pivots within the channel 70 during the oscillation of the pivot shaft 94 in the bearings 96.
In operation, and in no particular sequence, the electric motor 28 is activated to rotate the impeller 24 and the electric motor 72 is activated to rotate the rotating elbow 60. The rotation of the impeller 24 in the direction indicated by the arrow A in FIG. 2 causes air to be drawn through the filter subassembly 18 into the housing 26. The air being drawn into the filter assembly 18 passes through the filter 46 and the filter 46 moves, under the influence of this incoming air, from the position illustrated in FIG. 1 to the position illustrated by the dashed lines in FIG. 2. Pieces of lint, fabric and other matter entrained in the air entering the elongate cylindrical portion 40 are prevented by the filter 46 from continuing to move with the air toward the impeller 24.
The air drawn into the housing 26 is propelled by the impeller 24 along the airstream 38 into the air directing subassembly 16. The airstream 38 passes through the rotating elbow 60, including its channel 70, and is directed in a direction generally parallel to a plane P which is parallel to the ceiling 20. Simultaneously with the passage of the air stream 38 through the rotating elbow 60, the elbow 60 rotates with respect to the longitudinal duct 54 and thereby causes the cam follower 98 to slide along the cam track 56. Since the cam follower 98 is fixedly connected to the pivot shaft 94, the vane 62 pivots within the channel 70 as the radial spacing of the cam track engaging portion 100 of the cam follower 98 from the shaft 82 varies during its travel along the cam track 56. As seen in FIG. 1, the vane 62 and the cam follower 98 can be set in a predetermined relationship to one another such that, when the engaging portion 100 of the cam follower 98 is at a predetermined radial distance from the axis of the shaft 82, the vane 62 is oriented in the position shown in FIG. 1 at an intersecting orientation to the plane P. Continued rotation of the rotating elbow 60 relative to the longitudinal duct 54 causes the cam follower 98 to slide along the cam track 56 to subsequently reach the position illustrated in FIG. 2 at which the cam track engaging portion 100 of the cam follower 98 has a different radial spacing from the shaft 82 than in FIG. 1. Further rotation of the rotating elbow 60 eventually brings the vane 62 into the position illustrated in FIG. 3 in which it is inclined downwardly with respect to the plane P. Since the cam follower 98 continuously contacts the cam track 56, the radial spacing of the cam track 56 from the shaft 82 at each circumferential position of the cam track determines the radial spacing of the cam follower 98 and, thus, the extent to which the pivot shaft 94 pivots. Since the vane 62 and the pivot shaft 94 are connected in a predetermined orientation to one another, pivoting of the pivot shaft 94 causes a change in the orientation of the vane 62 with respect to the plane P. A s shown in the dotted lines designated A in FIG. 3, the vane 62 is oriented generally parallel to the plane P, and thus the ceiling 20, in its orientation shown in FIG. 1. Additionally, as shown by the dotted lines designated B in FIG. 3, the vane 62 is upwardly inclined with respect to the plane P in its orientation shown in FIG. 2. The solid line position of the vane 62 in FIG. 3 is representative of a downwardly inclined orientation of the vane with respect to the plane P.
Each respective orientation of the vane 62 with respect to the plane P causes the air exiting the channel 70 to be directed against those portions of the ceiling 20 at a selected radial distance from the apparatus 10 and/or a selected vertical distance from the ceiling itself. For example, when the vane 62 is in its generally parallel orientation with respect to the ceiling 20 as shown in FIG. 1, the air exiting the apparatus 10 travels parallel to the ceiling until contacting a surface, such as a ceiling duct, extending from the ceiling or until the air stream dissipates. With the vane 62 in its upwardly inclined orientation with respect to the ceiling 20 as shown in FIG. 2, the air stream 38 is directed against those portions of the ceiling relatively near to the apparatus 10. Contrastingly, with the vane 62 in its downwardly inclined orientation shown in FIG. 3 in solid lines, the air stream 38 is directed downwardly and away from the ceiling 20; this orientation of the vane 62 is useful, for example, for dislodging by-products from the tops of machines or other surfaces disposed at a spacing from the ceiling 20.
The rate of rotation of the rotating elbow 60 and, correspondingly, the rate of change of the orientation of the vane 62 relative to the plane P, is determined by the rate of rotation of the shaft 82 and the contour of the cam track 56. To adjust the rate of rotation of the shaft 82, a number of variables affecting the rate of rotation can be changed such as, for example, by replacing the pulley 76 with a pulley of a different diameter.
As described above, lint and other by-products too large to pass through the filter 46 tend to collect on the filter 46 during suction of air into the filter subassembly 18. Once the electric motor 28 of the impeller 24 is deactivated, the rotation of the impeller decreases and gradually stops and the suction which pulls the filter 46 inside the elongate cylindrical portion 40 also ceases, whereupon the filter 46 is returned to its initial position illustrated in FIG. 1 by the action of the weight 50. If desired, a container can be placed under the filter 46 to collect the lint and other by-products collected on the filter 46 during the operation of the impeller 24 which fall away from the filter upon cessation of the suction or during the downward movement of the filter.
The conical surface of the filter 46 presents a relatively large surface against which the lint and other by-products can be drawn during suction of air through the filter. Moreover, the conical shape insures that there is sufficient clearance between the filter when it is drawn into the filter subassembly 18 and the inner walls of the filter subassembly so that air is drawn through the entire extent of the filter. The conical shape of the filter 46 also beneficially aids in the dislodging of relatively large accumulations of lint or other accumulation, such as cakes of by-products thereon, so that the filter assembly 46 is substantially self cleaning in that the lint accumulations and cakes on its surface are dislodged as the filter changes its configuration during its downward movement out of the filter subassembly 18 under the action of the weight 50. Specifically, the conical shape of the filter 46 is basically inverted as the filter moves from the drawn in position shown in FIG. 2 to its initial position shown in FIG. 1 and this inverting action tends to dislodge the accumulated by-products, such as cakes of by-products, from the filter surface.
The apparatus of the present invention can be adapted with cam tracks of different predetermined contours in accordance with the various cleaning situations which it is desired for the apparatus to handle. Thus, the apparatus offers virtually infinite versatility in the cleaning operations for which it is adapted and this versatility offers particular advantages in view of the wide variety of layouts of textile processing areas, each of which presents its own unique arrangement of surfaces as well as surface portions which particularly tend to accumulate relatively significant accumulations of by-products and which, accordingly, must be subjected to correspondingly longer applications of air to dislodge the by-products therefrom.
The present invention has been described in detail above for purposes of illustration only and is not intended to be limited by this description or otherwise to exclude any variation or equivalent arrangement that would be apparent from, or reasonably suggested by, the foregoing disclosure to one skilled in the art. | An apparatus for selectively directing air against surfaces adjacent textile machines to dislodge dust, lint and other textile by-products from such surfaces. The apparatus includes a blower, a support for supporting the blower in a fixed relation to the ceiling above the textile machines, a first air directing assembly for directing the blower air stream in a plane while the assembly is rotated and a second air directing assembly movable in response to rotation of the first air directing assembly to vary the direction of the air stream. Preferably, the first air directing assembly includes a rotating duct portion rotatably mounted in a stationary duct portion of the blower and the second air directing assembly includes a vane pivotally mounted on the rotating duct portion. | 3 |
BACKGROUND OF THE INVENTION
[0001] (1) Technical Field
[0002] This invention relates to a DC/DC converter for carrying out a step-up or a step-down operation upon transferring an electric energy and, in particular, to a symmetrical DC/DC converter.
[0003] (2) Background Art
[0004] For example, an electric double layer capacitor is known as an energy storage device having a voltage variable in dependence upon the amount of energy stored therein. When the electric double layer capacitor is used, a step-up or a step-down operation by a DC/DC converter is required when energy transfer is carried out upon charging or discharging.
[0005] In case where a motor of an electric automobile is used as a load to consume an electric energy of the electric double layer capacitor, the motor may conversely generate an electric energy, for example, upon braking to act as a power generator. If the electric energy produced by the motor is recovered, it is possible to considerably improve an energy efficiency of a whole system including the electric double layer capacitor and the motor as a power supply and a load, respectively.
[0006] Therefore, it is important that the DC/DC converter for carrying out the step-up or the step-down operation has a function of transferring the electric energy in one direction from one terminal portion to the other terminal portion and in the other direction from the other terminal portion to the one terminal portion, whichever terminal portion acts as an input terminal portion to be supplied with the electric energy. To this end, it is proposed to provide a pair of DC/DC converters for the respective directions and a switch for selecting one of the DC/DC converters. However, this structure is not practical because the size of the whole system is increased. In view of the above, it is indispensable to provide a DC/DC converter which, as a single circuit, is operable even if an input terminal portion and an output terminal portion are exchanged.
[0007] As the DC/DC converter of the type described, proposal has already been made of a so-called bidirectional converter.
[0008] A first existing bidirectional DC/DC converter is a circuit device connected between a battery or a power supply (such as an electric double layer capacitor) and a load (such as a motor) and has a plurality of switching circuits and four terminals.
[0009] The first existing bidirectional DC/DC converter is operable in the following manner. In case where the electric double layer capacitor supplies the electric energy to the motor to drive the motor, one of the switching circuits is put into an opened state while the other switching circuit is operated under PWM (Pulse Width Modulation) control or the like. In this event, the DC/DC converter is operated as a forward converter circuit. On the other hand, in case where the electric energy generated by the motor is supplied to the electric double layer capacitor to charge the electric double layer capacitor, the other switching circuit is put into an opened state while the one switching circuit is operated under the PWM control or the like. In this case, the DC/DC converter is operated as the forward converter circuit.
[0010] Japanese Unexamined Patent Publication No. 2000-33445 (JP 2000-33445 A) discloses a second existing bidirectional DC/DC converter connected between a d.c. power supply and a load including a capacitor. The second existing bidirectional DC/DC converter uses FETs (Field Effect Transistors) as switching devices. Specifically, the second existing bidirectional DC/DC converter comprises a first series circuit, a second series circuit, an inductor, and a control unit. The first series circuit comprises first and second FETs connected in parallel to the d.c. power supply. The second series circuit comprises third and fourth FETs connected in parallel to the load. The inductor is connected between a junction of the first and the second FETs and another junction of the third and the fourth FETs. The control unit controls respective gates of the first, the second, the third, and the fourth FETs so that the electric energy is supplied from the d.c. power supply to the load and that the electric energy stored in the capacitor is recovered and fed back to the d.c. power supply.
[0011] The above-mentioned first existing bidirectional capacitor comprises a plurality of inductors and has a complicated circuit structure.
[0012] In case where the energy storage device, such as the electric double layer capacitor, having a variable voltage is used or in case where the motor is driven as the load and conversely produces the electric energy to be recovered, the system includes voltage variation corresponding to the amount of energy. Therefore, it is necessary not only to transfer the energy in two directions but also to desiredly carry out the step-up or the step-down operation in correspondence to the status of energy at the electric double layer capacitor (power supply) and the motor (load).
[0013] In case where the system is constructed by a combination of a plurality of energy storage devices, a plurality of power generators, and a plurality of loads, it is necessary to set an appropriate step-up ratio or an appropriate step-down ratio of the DC/DC converter connected to these components. Thus, each of the existing bidirectional DC/DC converters is not applicable to such system.
SUMMARY OF THE INVENTION
[0014] It is therefore an object of this invention to provide a symmetrical DC/DC converter which is operable in a variable direction corresponding to an energy transfer direction at a step-up or a step-down ratio corresponding to an input/output voltage ratio.
[0015] According to this invention, there is provided a symmetrical DC/DC converter comprising a single inductor with a pair of switching means connected to its terminals in a symmetrical arrangement with respect to the inductor, the converter being operable as a step-up (boost) converter and a step-down (buck) converter in a manner such that one and the other of the switching means are used as an input switch and an output switch, respectively, and that one and the other of the switching means are conversely used as an output switch and an input switch, respectively.
BRIEF DESCRIPTION OF THE DRAWING
[0016] [0016]FIG. 1 is a circuit diagram showing the structure of a first existing bidirectional DC/DC converter;
[0017] [0017]FIG. 2 is a circuit diagram showing the structure of a second existing bidirectional DC/DC converter;
[0018] [0018]FIG. 3 is a circuit diagram of a symmetrical DC/DC converter according to a first embodiment of this invention;
[0019] [0019]FIG. 4 is a circuit diagram of a symmetrical DC/DC converter according to a second embodiment of this invention;
[0020] [0020]FIG. 5 shows the symmetrical DC/DC converter in FIG. 4 during a step-up operation using third and fourth terminals as input terminals;
[0021] [0021]FIG. 6 shows the symmetrical DC/DC converter in FIG. 4 during a step-down operation using third and fourth terminals as input terminals;
[0022] [0022]FIG. 7 is a circuit diagram of a symmetrical DC/DC converter according to a third embodiment of this invention;
[0023] [0023]FIG. 8 is a circuit diagram of a symmetrical DC/DC converter according to a fourth embodiment of this invention;
[0024] [0024]FIG. 9 is a circuit diagram of a symmetrical DC/DC converter according to a fifth embodiment of this invention;
[0025] [0025]FIG. 10 is a circuit diagram of a symmetrical DC/DC converter according to a sixth embodiment of this invention;
[0026] [0026]FIG. 11 is a flow chart for describing an operation of the symmetrical DC/DC converter illustrated in FIG. 10;
[0027] [0027]FIG. 12 is a circuit diagram of a symmetrical DC/DC converter according to a seventh embodiment of this invention; and
[0028] [0028]FIG. 13 is a flow chart for describing an operation of the symmetrical DC/DC converter illustrated in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] For a better understanding of this invention, description will at first be made of existing DC/DC converters.
[0030] Referring to FIG. 1, a first existing bidirectional DC/DC converter is connected between an electric double layer capacitor 17 as a power supply and a motor 19 as a load and comprises a transformer 25 and a pair of switching circuits 27 and 29 .
[0031] In case where an electric energy is supplied from the electric double layer capacitor 17 to the motor 19 to drive the motor 19 , the switching circuit 29 is put into an opened state while the switching circuit 27 is operated under PWM control or the like. In this event, the DC/DC converter is operated as a forward converter circuit.
[0032] In case where an electric energy generated by the motor 19 is supplied to the electric double layer capacitor 17 to charge the electric double layer capacitor 17 , the switching circuit 27 is put into an opened state while the switching circuit 29 is operated under the PWM control or the like. In this case, the DC/DC converter is operated as the forward converter circuit.
[0033] Referring to FIG. 2, a second existing bidirectional DC/DC converter 31 is connected between a d.c. power supply 33 and a load 37 including a capacitor 35 . The second existing bidirectional DC/DC converter 31 uses FETs as switching devices. Specifically, the second existing bidirectional DC/DC converter 31 comprises a first series circuit 43 , a second series circuit 49 , an inductor 23 , and a control unit (not shown). The first series circuit 43 comprises first and second FETs 39 and 41 connected in parallel to the d.c. power supply 33 . The second series circuit 49 comprises third and fourth FETs 45 and 47 connected in parallel to the load 37 . The inductor 23 is connected between a junction of the first and the second FETs 39 and 41 and another junction of the third and the fourth FETs 45 and 47 . The control unit controls respective gates of the first, the second, the third, and the fourth FETs 39 , 41 , 45 , and 47 so that the electric energy is supplied from the d.c. power supply 33 to the load 37 and that the electric energy stored in the capacitor 35 is recovered and fed back to the d.c. power supply 33 .
[0034] Now, description will be made of several preferred embodiments of this invention with reference to the drawing.
[0035] Referring to FIG. 3, a symmetrical DC/DC converter 51 according to a first embodiment of this invention comprises an inductor 23 and a pair of switching portions 53 , 53 . By individually controlling the switching portions 53 , 53 , selection is made of an input/output direction (i.e., an energy transfer direction) and a step-up or a step-down operation.
[0036] Referring to FIG. 4, a symmetrical DC/DC converter 55 according to a second embodiment of this invention comprises the inductor 23 , first and second switching portions 57 and 59 having one ends connected to one end of the inductor 23 , third and fourth switching portions 61 and 63 having one ends connected to the other end of the inductor 23 , first through fourth terminals 65 , 67 , 69 , and 71 connected to the other ends of the first through the fourth switching portions 57 , 59 , 61 , and 63 , respectively, and a pair of capacitors 73 , 73 connected between the first and the second switching portions 57 and 59 and between the third and the fourth switching portions 69 and 71 , respectively. The second and the fourth terminals 67 and 71 are connected to each other.
[0037] Table 1 shows the states of the first through the fourth switching portions 57 , 59 , 61 , and 63 in case where the first and the second terminals 65 and 67 are used as input terminals while the third and the fourth terminals 69 and 71 are used as output terminals and in case where the first and the second terminals 65 and 67 are used as output terminals while the third and the fourth terminals 69 and 71 are used as input terminals. For each case, the step-up operation and the step-down operation are shown.
TABLE 1 1st, 2nd 3rd, 4th Terminals Terminals 57 59 61 63 Input Output Step-up ON OFF D SW Step-down SW D ON OFF Output Input Step-up D SW ON OFF Step-down ON OFF SW D
[0038] In Table 1, “ON” and “OFF” represent a short-circuited or a closed state and an opened state, respectively. “SW” is a controlled state where ON/OFF is intermittently switched under PWM control or the like so that an appropriate step-up or a step-down ratio is obtained. “D” represents a rectifying state of performing a rectifying operation.
[0039] Referring to FIG. 5, the symmetrical DC/DC converter 55 is operated as a step-up converter with the first and the second terminals 67 and 67 used as input terminals and the third and the fourth terminals 69 and 71 used as output terminals.
[0040] The first switching portion 57 is in the ON state, i.e., in the closed state while the second switching portion 59 is in the OFF state, i.e., in the opened state. The third switching portion 61 is in the D state, i.e., acts as a diode 75 to perform the rectifying operation. The fourth switching portion 63 is in the SW state, i.e., acts as a switching circuit 77 to controllably set an appropriate step-up ratio.
[0041] Referring to FIG. 6, the symmetrical DC/DC converter 55 according to the second embodiment of this invention is operated as a step-down converter with the first and the second terminals 65 and 67 used as input terminals and the third and the fourth terminals 69 and 71 used as output terminals, like in case of FIG. 5.
[0042] The first switching portion 57 is in the SW state, i.e., acts as the switching circuit 77 to controllably set an appropriate step-down ratio. The second switching portion 59 is in the D state, i.e., acts as the diode 75 to perform the rectifying operation. The third switching portion 61 is in the ON state, i.e., in the closed state while the fourth switching portion 63 is in the OFF state, i.e., in the opened state.
[0043] On the contrary, in case where the first and the second terminals 65 and 67 are used as output terminals while the third and the fourth terminals 69 and 71 are used as input terminals, the similar operation is realized by changing the states of the switching portions between a pair of the first and the second switching portions 57 and 59 and another pair of the third and the fourth switching portions 61 and 63 .
[0044] Referring to FIG. 7, a symmetrical DC/DC converter according to a third embodiment of this invention is similar in structure to the second embodiment. In the third embodiment, each of the first through the fourth switching portions 57 , 59 , 61 , and 63 comprises a switching circuit 77 ( 77 a - 77 d ) and a rectifier 75 connected in parallel to each other.
[0045] Table 2 shows the states of the first through the fourth switching portions 57 , 59 , 61 , and 63 in case where the first and the second terminals 65 and 67 are used as input terminals while the third and the fourth terminals 69 and 71 are used as output terminals and in case where the first and the second terminals 65 and 67 are used as output terminals while the third and the fourth terminals 69 and 71 are used as input terminals. For each case, the step-up operation and the step-down operation are shown.
TABLE 2 1st, 2nd 3rd, 4th Terminals Terminals 57 59 61 63 Input Output Step-up ON D D SW Step-down SW D ON D Output Input Step-up D SW ON D Step-down ON D SW D
[0046] In Table 2, if the switching circuit 77 is put in the OFF state, i.e., in the opened state, the switching portion performs the rectifying operation in the D state because the diode 75 is connected in parallel to the switching circuit 77 . Therefore, the OFF state or the opened state in each part of Table 1 is changed into the D state of the rectifying operation.
[0047] However, at the part where the opened state is changed into the D state of the rectifying operation, the diode in the switching portion is not applied with a forward voltage. This means that this D state is equivalent to the opened state. Therefore, the operation similar to that shown in Table 1 is achieved.
[0048] Thus, in the symmetrical DC/DC converter in FIG. 7, the operation similar to that shown in Table 1 can be realized simply by turning ON/OFF of the switching circuit 77 .
[0049] Referring to FIG. 8, a symmetrical DC/DC converter 79 according to a fourth embodiment of this invention uses FETs 81 as the switching circuits 77 ( 77 a - 77 d ) illustrated in FIG. 7. Each of the FETs 81 has a body diode 83 which can be used as a rectifier.
[0050] As illustrated in FIG. 8, the diode 75 as a high-performance diode which is low in forward voltage Vf than the body diode 83 and short in recovery time is connected in parallel to the body diode 83 of each FET 81 to be oriented in the same direction. With this structure, the symmetrical DC/DC converter 79 is operable irrespective of the body diode 83 .
[0051] Referring to FIG. 9, a symmetrical DC/DC converter 85 according to a fifth embodiment of this invention has a structure in which the diode operation in the DC/DC converter in FIG. 8 is realized by synchronous rectification so as to improve the efficiency.
[0052] Specifically, in the fifth embodiment, a diode 21 is connected to one end of each FET 81 through a resistor 87 so as to perform analog control in a manner such that the output of an operational amplifier 89 is not saturated on a minus side.
[0053] As described above, according to the first through the fifth embodiments of this invention, it is possible to provide a symmetrical DC/DC converter operable in a desired energy transfer direction and at a desired step-up or a desired step-down ratio.
[0054] Referring to FIG. 10, a symmetrical DC/DC converter 91 according to a sixth embodiment of this invention is used in a similar energy transfer system to that mentioned in conjunction with the second embodiment. The converter 91 is connected to the electric double layer capacitor 17 , a solar cell 93 , and a light emitting device 95 as an energy storage device, a power generator, and a load among which the electric energy is transferred. A control unit 97 is supplied from voltage monitors 99 and 101 with voltage information of each terminal and from current sensors 103 and 105 with current information of each terminal. The control unit 97 has a function of judging the state of energy with reference to the voltage information and the current information. The control unit 97 is connected to the first through the fourth switching portions 57 , 59 , 61 , and 63 so that each of the switching portion is controllably put into one of a switching state (SW state) of switching the opened state and the closed state at a high speed, the closed state (ON state), the opened state (OFF state), and the rectifying state (D state) of the rectifying operation or flowing an electric current only in one direction.
[0055] Referring to FIG. 11, in the symmetrical DC/DC converter 91 according to the sixth embodiment of this invention, the state of each of the first through the fourth switching portions 57 , 59 , 61 , and 63 is controlled by the control unit 97 . The control unit 97 acquires and judges the voltage information from the voltage monitors 99 and 101 (steps SA 1 and SA 2 ) and the current information from the current sensors 103 and 105 and determines which terminals are to be used as input and output terminals (i.e., the energy transfer direction) and whether the DC/DC converter is to be operated as a step-up converter and a step-down converter (step SA 3 ).
[0056] Once the energy transfer direction and one of the step-up and the step-down operations are determined, the switching portions 57 , 59 , 61 , and 63 are controllably put into the states shown in Table 3 to perform the corresponding operations. In addition, for each of the switching portions in the SW state, time intervals between opening and closing operations are controllably set to appropriate lengths in correspondence to the input/output voltage ratio (step SA 4 ). After energy transfer is performed (step SA 5 ), the control unit 97 again judges the voltage information from the voltage monitors 99 and 101 and the current information from the current sensors 103 and 105 and determines how to operate the switching portions next (step SA 6 ). Generally, the above-mentioned operation is repeated unless an end instruction is supplied.
TABLE 3 1st, 2nd 3rd, 4th Terminals Terminals 77a 77b 77c 77d Input Output Step-up ON OFF OFF SW Step-down SW OFF ON OFF Output Input Step-up OFF SW ON OFF Step-down ON OFF SW OFF
[0057] The sixth embodiment has a structure such that not only the electric energy generated by the solar cell 93 is consumed by the light emitting device 95 but also excess electric energy is charged to the electric double layer capacitor 17 . When the solar cell 93 generates an electric energy sufficient to make the light emitting device 95 fully emit light, the control unit 97 judges that the operation of charging the electric double layer capacitor 17 is to be carried out. At this time, irrespective of the state of energy, i.e., the voltage of the electric double layer capacitor 17 , the control unit 97 judges the input and the output voltages of the converter 91 and determines the step-up or the step-down operation to charge the electric double layer capacitor 17 . Furthermore, it is assumed that the light emitting device 95 is desired to emit light even when the solar cell 93 does not generate the electric energy. In this event, if the voltage of the electric double layer capacitor 17 is higher or lower than a particular voltage required to light emission of the light emitting device 95 , the voltage is adjusted to an appropriate level and is then supplied to the light emitting device 95 . Thus, the light emitting device 95 emits light at a desired luminance.
[0058] Referring to FIG. 12, a symmetrical DC/DC converter according to a seventh embodiment of this invention is used in an energy transfer system similar to that described in conjunction with the third embodiment. The DC/DC converter is connected to the electrical double layer capacitor 17 and the motor 19 as an energy storage device, a power generator, and a load among which the electric energy is transferred. The control unit 97 is supplied from the voltage monitors 99 and 101 with voltage information of each terminal and from the current sensors 103 and 105 with current information of each terminal.
[0059] The control unit 97 is also supplied from a torque setting unit 107 with torque information representative of a desired torque of the motor 19 as desired by a user. The control unit 97 has a function of judging the status of energy from these information supplied thereto. The control unit 97 is connected to the switching circuits 77 so that each switching circuit can be controllably put into one of the switching state (SW state) of switching the opened state (OFF state) and the closed state (ON state) at a high speed, the closed state, and the opened state.
[0060] Referring to FIG. 13, in the symmetrical DC/DC converter according to the seventh embodiment of this invention, the state of the switching circuit 77 is controlled by the control unit 97 . The control unit 97 is supplied with external input information, i.e., the torque information from the torque setting unit 107 in the illustrated example (step SB 1 ). The control unit 97 is also supplied from the voltage monitors 99 and 101 with the voltage information and from the current sensors 103 and 105 with the current information (step SB 2 ). The control unit 97 judges these information supplied thereto (step SB 3 ) and determines which terminals are to be used as the input and the output terminals (i.e., the energy transfer direction) (step SB 4 ) and whether the DC/DC converter is to be operated as the step-up converter or the step-down converter (step SB 5 ).
[0061] Once the energy transfer direction and one of the step-up and the step-down operations are determined, the switching circuits 77 are controllably put into the states shown in Table 4 so that the switching portions 57 , 59 , 61 , and 63 perform the corresponding operations. For each of the switching portions in the SW state, time intervals between the opening and the closing operations of the switching circuit is controllably set to appropriate lengths in correspondence to the input/output voltage ratio (step SB 6 ). After energy transfer is performed (step SB 7 ), the control unit 97 again judges the voltage information from the voltage monitors 99 and 101 and the current information from the current sensors 103 and 105 and determines how to operate the switching circuits 77 next (step SB 8 ).
TABLE 4 1st, 2nd 3rd, 4th Terminals Terminals 57 59 61 63 Input Output Step-up ON D D SW Step-down SW D ON D Output Input Step-up D SW ON D Step-down ON D SW D
[0062] In the seventh embodiment of this invention, the desired torque of the motor 19 is used as the external information or signal. If the desired torque is smaller than an actual torque of the motor 19 in operation, for example, if the stop of rotation is desired while the motor 19 is rotated, the motor 19 acts as the power generator. At this time, irrespective of the state of energy, i.e., the voltage level of the electric double layer capacitor 17 , and irrespective of the voltage level produced by the motor 19 , the control unit 97 judges the input and the output voltages and determines the step-up or the step-down operation to charge the electric double layer capacitor 17 . If the desired torque is greater than the actual torque of the motor 19 in operation, for example, if the rotation at a certain speed is desired while the motor 19 is stopped, the motor 19 serves as the load. In this event, if the voltage of the electric double layer capacitor 17 is higher or lower than a particular voltage required to operate the motor 19 , the voltage is adjusted to an appropriate level to drive the motor 19 . | A symmetrical DC/DC converter is adapted to desirably select an energy transferring direction and a step-up or a step-down operation as well as a desired step-up or a step-down ratio. The converter comprising a single inductor with a pair of switching means connected to its terminals in a symmetrical arrangement with respect to the inductor. The converter is operable as a step-up converter and a step-down converter in a manner such that one and the other of the switching means are used as an input switch and an output switch, respectively, and that one and the other of the switching means are conversely used as an output switch and an input switch, respectively. | 7 |
BACKGROUND OF THE INVENTION
[0001] A. Field of the Invention
[0002] The present invention relates to an apparatus and method for initializing an optical recording media. The present invention also relates to an initializing apparatus for changing an amorphous recording layer of an optical disc into a crystal recording layer. The invention may be used to manufacture phase-change optical recording media. The present invention also relates to a system for verifying uniform crystallization of phase-change optical recording media.
[0003] B. Description of the Related Art
[0004] In optical recording discs with rewrite capability, such as a CD-RW phase-change optical recording disc, a first dielectric layer, a recording layer, a second dielectric layer and a metal layer are formed on a disc substrate. The substrate is generally made of polycarbonate. A UV hardening layer may be provided on the metal layer.
[0005] The phase-change recording material of the CD-RW optical disc transitions into either ( 1 ) a crystal condition by lengthening the cooling time after it has been heated, or ( 2 ) an amorphous condition by shortening the cooling time after it has been melted. Phase-change recording media can record information in the form of marks by reversibly changing between the crystal condition and the amorphous condition. A recording signal can be used to change the intensity of the optical beam that is radiated on the recording layer to change the recording layer from a crystal condition to an amorphous condition, or vice versa. When forming marks, the optical beam intensity may be set at the amorphous level. On non-mark portions, the intensity of the optical beam intensity is set at the crystal level, and the recording layer is crystallized. Since non-mark portions are not heated as much and cool slowly, they transition into the crystal condition regardless of whether they were in an amorphous condition or in a crystal condition.
[0006] On the other hand, when manufacturing phase-change recording media, the recording layer is left in an amorphous condition after spattering. Therefore, it is necessary to crystallize all of the recording layer. This crystallization process is called the initialing process. As mentioned above, the length of the cooling time effects the transition to either the crystal condition or the amorphous condition. When the cooling time is longer, the recording layer transitions into the crystal condition. When the cooling time is shorter, the recording layer transitions into the amorphous condition. Therefore, in the initializing process of the recording layer, an optical beam is radiated on the recording layer and the cooling time is made longer after raising the temperature of the recording layer.
[0007] Because the substrate is generally made from polycarbonate, it is possible to exceed the heat-resisting properties of the material if the entire surface is initialized simultaneously. The initializing process is generally carried out by radiating an optical beam on the optical recording media while rotating the optical recording media. Successive portions of the recording layer are crystallized as the radiating position is moved in the radial direction.
[0008] One problem with the above-described scanning system is that any instability in the optical beam can result in incomplete crystal portions on the recording layer. If there are incomplete crystal portions, problems with recording and reproducing signals are caused, and it is impossible to record and reproduce information accurately.
SUMMARY OF THE INVENTION
[0009] It is therefore an object of the present invention to provide an initializing method and apparatus for determining if a recording layer of a phase-change optical recording disc is uniformly crystallized.
[0010] It is another object of the present invention to provide an initializing method and apparatus that can uniformly crystallize a recording layer of a phase-change optical recording disc.
[0011] In one aspect of the invention, the intensity of light reflected off of the optical recording media is detected. Based on the intensity of the reflected light, a judgement is made as to whether the initializing condition is acceptable or not. According to this aspect of the invention, the light used for initializing may be radiated on a rotating phase-change optical recording medium. The radiating position of the light may be moved radially relative to the optical recording medium
[0012] In another aspect of the invention, the intensity of the reflective light of the optical recording media is detected and the driving power of an initializing light source is adaptively adjusted. The initializing light radiated by the light source may be based on the intensity of the reflective light.
[0013] In another aspect of the invention, the intensity of the reflective light off of the optical recording media is detected and the rotation speed of the optical recording media and the relative moving speed of the initializing light in the radial direction of the optical recording process is adjusted as a function of the intensity of the reflective light. The intensity detection and speed adjustment steps may occur during the initialization process.
[0014] In another aspect of the invention, an initializing apparatus comprises: a driving means that drives an initalizing light source for radiating the initializing light on optical recording media; a rotating means for rotating the optical recording media; a moving means for moving the radiating position from the initializing light source against the optical recording media in a radial direction; a detecting means for detecting the intensity of the reflective light of the optical recording media in initializing action of the optical recording media; and an analyzing means for determining if initializing conditions are acceptable or not based on the detected intensity of the reflective light.
[0015] In another embodiment of the invention, an initializing apparatus comprises: a driving means which drives an initializing light source for radiating the initializing light on optical recording media; a rotating means for rotating the optical recording media; a moving means for moving the radiating position from the initializing light source against the optical recording media in a radial direction; a detecting means for detecting intensity of the reflective light of the optical recording media in initializing action of the optical recording media; and an adjusting means for adjusting the driving power of the initializing light source based on the detected intensity of the reflective light of the optical recording media.
[0016] In another embodiment, an initializing apparatus comprises: a driving means which drives an initializing light source for radiating the initializing light on optical recording media; a rotating means for rotating the optical recording media; a moving means for moving relatively the radiating position from the initializing light source against the optical recording media in a radial direction; a detecting means for detecting the intensity of the reflective light of the optical recording media in initializing action of the optical recording media; and an adjusting means for adjusting a rotating speed of the optical recording media and the relative moving speed between the radiating position of the initializing light source and the optical recording media based on the detected intensity of the light reflected by the optical recording media.
[0017] In another aspect of the invention, the intensity of the reflective light is detected based on the reflection of the light radiated on the optical recording media.
[0018] In another aspect of the invention, the intensity of the reflective light is detected based on the reflection of the light radiated on the optical recording media by a second light source different from the light source used for initializing.
[0019] In another aspect of the invention, the intensity of the reflected light is determined and analyzed, the system responds accordingly, and the initialization process is repeated.
[0020] In another aspect of the invention, a determination is made as to whether the optical recording medium was inadequately initialized. The determination may be made during or after the initialization process.
[0021] In another aspect of the invention, the driving power of the initializing light source is monitored and actively adjusted to prevent poor initializing conditions.
[0022] In another aspect of the invention, the rotation speed of the optical recording media and the relative moving speed of the initializing light in the radial direction of the optical recording media are actively adjusted to prevent poor initializing conditions.
[0023] In another aspect of the invention, optical focusing servo and tracking servo systems may be employed.
[0024] In another aspect of the invention, information on the reflective light intensity is obtained by an exclusive optical arrangement independent of the reflective optical arrangement for the focusing servo and the tracking servo. This feature may be used to improve the reliability of the reflective light intensity information.
[0025] In another aspect of the invention, to carry out an initializing process, an initializing light source radiates an initialization light on the rotating phase-change optical recording media, and the radiation position is moved relatively in the radial direction of the optical recording media. The intensity of the reflective light of the optical recording media is detected. Based on the detected result, a determination is made as to whether the initializing condition is acceptable or not. The intensity of the reflective light may be detected during or after the initializing process.
[0026] In another aspect of the invention, to carry out an initializing process, an initializing light from the initializing light source is radiated on the rotating phase-change optical recording media, and the radiation position is relatively moved in the radial direction of the optical recording media. The intensity of the reflective light of the optical recording media is detected, and the driving power of the initializing light source is adaptively adjusted based on the detected result to prevent poor initializing conditions.
[0027] In another aspect of the invention, an initializing light from the initializing light source is radiated on the rotating phase-change optical recording media, and the radiation position is relatively moved in the radial direction of the optical recording media. The intensity of the reflective light of the optical recording media is detected, and the rotating speed of the optical recording media and the relative moving speed of the initializing light in the radial direction of the optical recording media are adaptively adjusted based on the detected result to prevent poor initializing conditions.
[0028] With these and other objectives, advantages and features of the invention that may become apparent, the nature of the invention may be more clearly understood by reference to the following detailed description, the appended claims, and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] [0029]FIG. 1 is a diagram of a laminate structure of an optical recording media constructed in accordance with the invention;
[0030] [0030]FIG. 2 is a diagram of an initializing apparatus;
[0031] [0031]FIG. 3 is a graph based on experimental results showing the error rate of an optical recording media after initializing by a conventional method;
[0032] [0032]FIG. 4 is a graph based on experimental results showing the error rate of an optical recording media after re-initializing using changed parameters; and
[0033] [0033]FIG. 5 is a graph based on experimental results showing the error rate of an optical recording media initialized in accordance with the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] Preferred embodiments of the present invention are described in detail with reference to the accompanying drawings.
[0035] [0035]FIG. 1 shows the laminate structure of a phase-change optical disc 1 . The optical disc 1 is formed from a first protective layer 3 , a recording layer 4 , a second protective layer 5 , a reflective layer 6 , an overcoat layer 7 , and a printing layer on the surface of the substrate 2 . A hard coat layer 9 is coated on the opposite surface of the substrate 2 . The substrate 2 may be composed of polycarbonate or acrylic resin. The desired material may be selected based on optical characteristics, forming characteristics and cost considerations. The desirable thickness is 1.2 mm or 0.6 mm.
[0036] The substrate 2 is not limited to a disc shape and may be a card form, sheet or other form. In addition, it is expressly contemplated that other phase-change products may be used. The present invention is not limited to the particular optical disc described herein but may be used with other phase-change optical recording media.
[0037] The first protective layer 3 , the recording layer 4 , the second protective layer 5 and the radiation reflective layer 6 can be formed as films by spattering techniques. These films may have thicknesses of 65-130 nm, 15-35 nm, 15-45 nm and 7-180 nm, respectively. The recording layer 4 is composed of a phase-change recording material, and transitions into a crystal condition when it is slowly cooled after it is melted, and transitions into an amorphous condition when cooled immediately after heating. After spattering, the recording layer 4 is in an amorphous condition.
[0038] The over coat layer 7 has a 7-15 micro-meter (um) thickness and is formed on the reflective layer 6 . The printing layer 8 may be formed after initializing the recording layer 4 .
[0039] The recording layer 4 is heated by light radiated onto the substrate 2 from the side of the hard coat layer 9 . When the cooling time of the recording layer 4 is made longer after it has been heated, the recording layer 4 transitions into a crystal condition. When the cooling time of the recording layer 4 is made shorter after it has been heated, the recording layer 4 transitions into an amorphous condition.
[0040] [0040]FIG. 2 shows an initializing apparatus 10 . The initializing apparatus 10 may use a laser diode 11 as an optical resource for the initialization process. A rotating mechanism 12 is provided that includes a driving resource and a moving mechanism 13 . The laser diode may be substituted with another suitable source including, but not limited to, an electron beam, X-rays, ultraviolet rays, visible rays, infrared rays, or microwaves.
[0041] A laser diode 11 is advantageous because it is compact and its power can be controlled easily. The rotating mechanism 12 drives and rotates the optical disc 1 based on commands from the control circuit 14 of the microcomputer. The moving mechanism 13 makes the optical disc 1 move in a perpendicular direction against the rotating shaft based on commands from the control circuit 14 , and makes the focusing position of the laser beam from the laser diode 11 move in a radial direction relative to the disc 1 .
[0042] The laser diode 11 may be driven by a laser diode power supplier 15 , which is controlled by the control circuit 14 . Laser rays from the laser diode 11 are made parallel by the collimator lens 16 , polarized by the polarizing beam split means 17 , and focused on the optical disc 1 by the objective lens 18 . Reflective rays from the optical disc 1 are deflected at a right angle by the polarizing beam split means 17 , deflected at a right angle again by a filter 19 , pass through a quarter-wave plate 20 , pass through a polarizing beam split means 21 , and then are radiated into element 22 for controlling the focus servo signal. An actuator 23 adjusts the objective lens 18 in the direction of the ray axis and adjusts the servo focus.
[0043] The initializing apparatus 10 has a beam split means 24 which deflects the polarized laser beam going straight to the polarizing beam split means 21 at right angles. The laser beam polarized at right angles by the beam split means 24 is received by a photo sensor 25 . An electromotive force is generated in the photo sensor 25 in response to the intensity of the received light. The electromotive force is converted into a digital value and input to the control circuit 14 . The control circuit 14 retains data on the optimum maximum value and minimum value of the electromotive force. The stored data may be based on collected electromotive force data for the optical disc 1 . A determination is made as to whether the disc 1 is a good one or not based on whether the output signal value from the photo sensor 25 is between the maximum value and the minimum value.
[0044] Furthermore, the initializing apparatus 10 has a laser diode 26 for the focus servo. The laser beam radiated from the laser diode 26 is changed into a parallel beam by the collimator lens 27 and then goes to the polarizing beam split means 21 before reaching the optical disc 1 .
[0045] To initialize the recording layer 4 , the optical disc 1 is rotated by the rotating mechanism 12 and moved in a radial direction by the moving mechanism 13 . The focus position of the laser beam radiated from the laser diode 11 moves in a radial direction. The laser beam from the laser diode 11 is radiated on the optical disc 1 and the recording layer 4 is heated. The recording layer 4 transitions into the crystal condition by slowly cooling after heating.
[0046] If the thickness and other properties of the recording layer 4 are not uniform, there are portions that may require a higher laser beam power for adequate heating and melting and portions that require a lower laser beam power. Even if the cooling speed is equal, there may be crystal portions and amorphous portions. According to the present invention, in order to achieve a uniform property in the optical disc 1 , and to achieve the desired initialization, the reflective rate of the optical disc 1 is monitored during the initializing step and adjustments are carried out. The well melted portions of the optical disc 1 will be well crystallized and the reflective rate will be high. On the other hand, the reflective rate of the optical disc 1 is saturated when exceeding a certain initializing power. When the cooling speed is fast, the recording layer 4 becomes amorphous and the reflective rate is sharply reduced. It is thus possible to monitor the initialization process by correlating reflective rate with crystallized/amorphous portions. In the present embodiment, the control circuit 14 monitors the output from the photo sensor 25 to determine if it is between the predetermined maximum value and the predetermined minimum value, and determines if the initializing condition of the optical disc 1 is acceptable or not.
[0047] Instead of varying the laser beam intensity, or in addition to, adjustments to the driving power of the laser diode 11 by the laser diode power supplier 15 , and/or to the driving speed of the rotating mechanism 12 , and/or to the moving mechanism 13 can be carried out by control of the control circuit 14 . Thus, when the reflective rate is determined to be low, the control circuit 14 returns the results to the laser diode power supplier 15 to make the reflective rate higher. On the other hand, when the reflective rate is too high, the laser diode driving power supplier 15 can act to reduce the laser power. It is thus possible to raise or lower the reflective rate and ensure adequate initialization.
[0048] The whole surface of the optical disc 1 can be scanned to determine if the output of the photo sensor 25 exceeds the minimum value. For example, if there is a sharp decline in the reflective rate or if the average reflective rate of the optical disc 1 is under 70%, which shows the optical disc 1 is in a partially amorphous condition, the rotating mechanism 12 and the moving mechanism 13 can be adjusted accordingly. The rotating speed and the moving speed of the optical disc 1 can be adaptively slowed to prevent the recording layer 4 from transitioning to an amorphous condition.
[0049] If the control circuit 14 recognizes that there is an amorphous portion on the optical disc and/or the reflective rate is too high and/or too low based on the result of the monitoring after initializing once, the initializing process for the whole optical disc 1 can be repeated. The driving power of the laser diode 11 by the laser diode power supplier 15 and/or the rotating speed and/or the moving speed of the optical disc 1 by the rotating mechanism 12 and/or the moving mechanism 13 can be adjusted accordingly. Therefore, non-uniformity of the reflective rate is reduced and the generated amorphous portions are crystallized.
[0050] Alternately, since re-initialization is time consuming, the results of the initialization monitoring can be used to calculate the radial value of the optical disc 1 corresponding to amorphous, or potentially amorphous, regions. Parameters may be automatically determined to initialize only portions requiring re-initializing.
[0051] The photo sensor 25 of the present invention monitors a reflective light from the optical disc 1 for focusing servo. However, an exclusive light source for monitoring the initializing process also can be provided.
[0052] The efficiency of the present invention was determined experimentally. The results of the experiments are shown in FIGS. 3, 4 and 5 .
[0053] A first protective layer, a recording layer, a second protective layer and a reflective layer were continuously formed on a polycarbonate substrate of 1.2 mm thickness with grooves of 0.5 μm width and a depth of 35 nm by a spattering apparatus. In the next step, a hard coat layer and an over coat layer were formed using a spin coat method and a phase-change optical disc is made. The first protective layer and the second protective layer were composed of ZnS—SiO2. The reflective layer was composed of aluminum alloy. After the recording layer was initialized, a printing layer was formed on the over coat layer.
[0054] The error rate of the phase-change optical disc was examined by a valuing machine with an optical pick-up device of 780 nm wave and NA 0.5. Keeping the read power 1.0 mW, the error rate of every 20 tracks was examined in mode of 1200 rpm and CLV.
[0055] [0055]FIG. 3 shows a graph of the error rate when the disc was not cooling well after initializing and amorphous portions were generated around ATIP 70 min.
[0056] [0056]FIG. 4 shows the result of re-initializing the optical disc using different parameters. Amorphous portions generated around ATIP 70 min are restored perfectly.
[0057] [0057]FIG. 5 is a graph of the error rate of the initialized optical disc while adjusting the initializing conditions during initializing. This data indicates that this optical disc has low error rate on the whole surface.
[0058] As mentioned above, optical recording media can be uniformly produced. It is unnecessary to add another process examining an optical recording disc with amorphous portions. It is unnecessary to postpone the process time, and it is possible to remove errors.
[0059] In accordance with the present invention, initializing power can be adjusted in response to the reflective rate of the optical disc detected in the initializing process. Therefore, it is possible to manufacture and initialize optical recording media with a uniform reflective rate. It is possible to reduce error generation of recording and reproducing in a recording and reproducing apparatus.
[0060] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts and steps, or a combination of both within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
[0061] The entire disclosures of Japanese Patent Applications Nos. 09-325808 and 1060755, filed Nov. 27, 1997 and Mar. 12, 1998, respectively, are expressly incorporated herein by reference. | A method and apparatus for initializing optical recording media is provided that detects the intensity of a reflective light off of an optical recording media and analyzes the initializing condition based on the detected intensity during an initializing process. The light is radiated on a rotating phase-change optical recording medium. The light may be moved in a radial direction of the optical recording medium. The detected intensity of the reflected light may be used to identify crystallized portions and amorphous portions of the optical media. The initialization process can be adaptively controlled to ensure proper initialization. If desired, re-initalization can be limited to those areas detected to be outside of the predetermined parameters. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of cellular telephone accessories. More particularly, the invention relates to an apparatus for enforcing a user to use a stationary hands-free adapter while driving.
BACKGROUND OF THE INVENTION
[0002] Drivers who are using cellular phones may become distracted by the act of dialing, a conversation they are having, presence of a cellular phone in their hand while they attempt to turn corners, or engage in sudden driving maneuvers, and so forth. In the past there have been numerous cases where a driver, talking on a cellular phone, drove directly into the back of a stopped vehicle.
[0003] One of the devices that may reduce the probability of car accident while using a cellular phone during driving is the hands-free adapter.
[0004] There is a common believe that using a hands-free adapter while driving is safer than using a handheld phone, and some states even have forbidden the use of cellular phones while driving, unless the driver employs a hands-free adapter for this purpose. Nevertheless, from the technical point of view the decision as to whether to use the hands-free adapter is up to the user, and there is no technical way to enforce him to use it.
[0005] It is an object of the present invention to provide an apparatus for enforcing a cellular phone user to use a hands-free adapter while driving.
[0006] Other objects and advantages of the invention will become apparent as the description proceeds.
SUMMARY OF THE INVENTION
[0007] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods, which are meant to be merely illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other advantages or improvements.
[0008] The term “switching mechanism” refers herein to a sensor which detects at least two states, such as on/off, close/open, etc. The switching mechanism may further comprise additional circuitry, which performs some activity according to the detected state.
[0009] In one embodiment, the present invention is directed to a hands-free enforcing apparatus, comprising:
a hands-free adapter; and a switching mechanism for sensing presence/absence of a cellular telephone in the hands-free adapter, and affecting a circuit of the vehicle thereof according to the sensed state.
[0012] According to one embodiment of the invention, the circuit closes upon presence of a cellular telephone in the hands-free adapter, and opened upon absence of a cellular telephone in the hands-free adapter.
[0013] According to another embodiment of the invention, the circuit opens upon presence of a cellular telephone in the hands-free adapter, and closed upon absence of a cellular telephone in the hands-free adapter.
[0014] The apparatus may further comprise a delaying circuitry, for delaying the operation of affecting the circuit, thereby enabling a user thereof to return the cellular phone into the hands-free adapter.
[0015] The apparatus may further comprise a buzzer, for alerting the user, e.g., upon delaying the affecting, upon affecting the circuit, and so on. The loudness of the buzzer may be such that a user will not be able to perform a telephone conversation.
[0016] The circuit affected by the switching mechanism may be related to ignition of the vehicle, to controlling the hazard signal of the vehicle, and so forth.
[0017] According to a further embodiment of the invention, the apparatus comprises a circuitry for aborting an operation of a system of the vehicle upon sending a short message from the cellular telephone present in the hands-free adapter. Such a circuitry may comprise:
an antenna and a receiver, for receiving radio signals sent from the cellular telephone; a decoder, for analyzing the radio signals in order to detect a transmission of a short message.
[0020] According to one embodiment of the invention, the switching mechanism is operative while the vehicle is on (e.g., the motor of the vehicle is turned on).
[0021] According to another embodiment of the invention, the switching mechanism is operative while the vehicle is off (e.g., the motor of the vehicle is turned off).
[0022] According to one embodiment of the invention, the switching mechanism is embedded in the cellular telephone.
[0023] According to another embodiment of the invention, the switching mechanism is embedded in the hands-free adapter.
[0024] The hands-free adapter may be wired as well as wireless.
[0025] In one embodiment of the invention, the switching mechanism is adapted to turn on the vehicle only upon presence of a specific cellular telephone in said apparatus. The specific cellular telephone may be identified by a barcode reader installed in the hands-free adapter.
[0026] The switching mechanism may be implemented by elements such as a circuitry, a software module, hardware module, a computerized mechanism (i.e., code performed by CPU and memory), a combination of them, and so forth.
[0027] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the figures and by study of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings, in which:
[0029] FIG. 1 schematically illustrates a HFE installed in a vehicle, according to one embodiment of the invention.
[0030] FIG. 2 is a block diagram, which schematically illustrates a HFE installed in a vehicle, according to one embodiment of the invention.
[0031] FIG. 3 is a block diagram, which schematically illustrates the structure of a HFE and its connection to vehicle's systems, according to one embodiment of the invention.
[0032] FIG. 4 is a block diagram, which schematically illustrates the structure of a HFE and its connection to vehicle's systems, according to a further embodiment of the invention.
[0033] FIG. 5 is a block diagram, which schematically illustrates the structure of a HFE and its connection to vehicle's systems, according to a yet further embodiment of the invention.
[0034] It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims. It should be further understood that the drawings are not necessarily drawn to scale and that, unless otherwise indicated, they are merely intended to conceptually illustrate the structures and procedures described herein. Reference numerals may be repeated among the figures in order to indicate corresponding or analogous elements.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In some instances, well-known methods, procedures, components and circuits have not been described in detail, for the sake of clarity.
[0036] One of the major objects of a hands-free adapter is to free the user thereof from holding the handset of a cellular telephone while driving.
[0037] There are two forms of hands-free adapters: the mobile hands-free adapter, and the stationary hands-free adapter. The mobile hands-free adapter is a built-in mechanism installed in the handset of a cellular phone. The stationary hands-free adapter is an external device to a cellular phone, which is installed in a car.
[0038] A stationary hands-free adapter is usually embodied as a device which comprises a holder for the cellular telephone handset, and an audio amplifying system, for increasing the audio signal of the cellular telephone placed in the holder. It is usually installed in a position where the driver can reach the keypad, but can also view the display thereof.
[0039] The term “Hands-free Enforcer”, HFE, refers herein to an apparatus for enforcing a driver of a vehicle to use the stationary hands-free adapter installed in his vehicle.
[0040] The present invention is directed to a hands-free enforcer.
[0041] In order to enforce a driver to use the stationary hands-free adapter of his vehicle, according to embodiments of the present invention a HFE prevents igniting the vehicle thereof in the event a cellular telephone is not installed in the hands-free adapter of the vehicle.
[0042] Furthermore, while driving, if the cellular telephone is removed from the holder of a hands-free adapter, the HFE may interfere with the normal operation of one or more systems of the vehicle, such as slowing down its speed, limit its speed, activate the hazard lights of the vehicle, play an alarm sound, or even stop the vehicle's engine.
[0043] FIG. 1 schematically illustrates a HFE installed in a vehicle, according to one embodiment of the invention.
[0044] FIG. 2 is a block diagram, which schematically illustrates a HFE installed in a vehicle, according to one embodiment of the invention.
[0045] From the operational point of view, the vehicle is ignitable only when the cellular phone 2 is placed in the holder of the hands-free adapter 4 . Thus, a user cannot turn on the vehicle unless his cellular telephone is placed in the holder of the hands-free adapter.
[0046] Furthermore, upon removing the cellular telephone 2 from the hands-free adapter, the vehicle's engine stops.
[0047] FIG. 3 is a block diagram, which schematically illustrates the structure of a HFE and its connection to vehicle's systems, according to one embodiment of the invention.
[0048] The embodiment illustrated in FIG. 3 is characterized by its simplicity.
[0049] Numeral 12 denotes a casing, which comprises circuitry of the HSE.
[0050] The term “relay” refers in the art to a device that responds to a “small” current or voltage change by activating switches or other devices in an electric circuit. Thus, the “small” current or voltage is actually a trigger.
[0051] The circuitry of the HSE comprises a relay 32 , which connects/disconnects the contact between terminals 15 and 25 . Terminal point 15 is connected via cable 14 to the ignition switch 18 of the vehicle, and contact 25 is connected via cable 24 to an electric system of the engine 26 .
[0052] When a cellular telephone is placed in the holder of the stationary hands-free adapter 4 , the power of the battery of the cellular telephone is the trigger that turns the relay to the situation wherein terminals 15 and 25 are connected. When a cellular telephone is not placed in the hands-free adapter 4 , terminals 15 and 25 are not connected.
[0053] Thus, igniting the vehicle can be carried out only if a cellular telephone is placed in the holder of the stationary hands-free device of the vehicle. Furthermore, upon removing the cellular telephone from the stationary hands-free device, the vehicle stops.
[0054] Thus, a user is enforced to place his cellular telephone in the hands-free device of the vehicle while driving.
[0055] FIG. 4 is a block diagram, which schematically illustrates the structure of a HFE and its connection to vehicle's systems, according to a further embodiment of the invention.
[0056] According to this embodiment of the invention, a timer circuit 36 separates between relay 32 and the battery of the cellular telephone placed in the hands-free adapter 4 . Upon removing the cellular telephone from the hands-free adapter 4 , the timer retains the electric characteristics that keeps relay 32 in its current state for a “short” time period, e.g., 5 seconds. When the time period elapses, the timer stops to provide current to terminals 11 and 23 , and as a result the relay disconnects the connection between terminals 15 and 25 .
[0057] Thus, instead of aborting the operation of the engine of the vehicle at once, the driver is provided with a few seconds where he can regret and return the cellular telephone back to the hands-free adapter, thereby avoiding the unpleasant operation of stopping the engine his vehicle.
[0058] A buzzer 38 may be employed for playing an alert when the cellular telephone is removed from the hands-free adapter. This way the driver is provided with a warning of a few seconds before stopping his vehicle.
[0059] Since the timer requires electrical power for its operation and also for keeping the electrical characteristics, which retain relay 36 in the state where the engine continues to operate, it can be connected to the power supply of the hands-free adapter.
[0060] FIG. 5 is a block diagram, which schematically illustrates the structure of a HFE and its connection to vehicle's systems, according to a yet further embodiment of the invention.
[0061] According to this embodiment of the invention, the circuitry further comprises an antenna, for receiving signals transmitted by a cellular telephone, a receiver and a decoder which analyzes the transmitted signal in order to detect a transmission of a short message such as SMS. When an SMS transmission is detected, the circuitry disconnects wire 22 , thereby resulting with stopping the engine of the vehicle. An SMS transmission may be detected by a code associated with an SMS message which has been sent by the cellular telephone.
[0062] The circuitry has to be adjusted to receive a transmission only from a distance of a few cm, in order to prevent analyzing radio signals from any cellular telephone, except the one placed in the hands-free device 4 .
[0063] In the examples illustrated in FIGS. 1 to 5 , activating the relay results with closing a circuit. According to another embodiment of the invention (not illustrated), activating the relay of the HFE results with opening (rather than closing) a circuit. Such a circuit may be the circuit that activates the hazard signal of the vehicle (or the siren). Thus, instead of stopping the engine of the vehicle, the hazard signal of the vehicle may be activated. This act is less drastic than stopping the engine of the vehicle.
[0064] It should be noted that the ignition circuit and the hazard circuit are only examples, and the operation of other circuits may be interfered additionally or alternatively, such as a circuit that controls the radio, a circuit that blinks the signaling lights, and so on.
[0065] According to one embodiment of the invention, the HSE is adapted to turn on the engine of the vehicle only upon presence of a specific cellular telephone in the apparatus. This enables using the HFE as an immobilizer of the vehicle.
[0066] According to one embodiment of the invention, the switching mechanism is operative while the vehicle is on (i.e., after the switch of the vehicle has been turned on).
[0067] According to another embodiment of the invention, the switching mechanism is operative while the vehicle is off (i.e., after the switch of the vehicle has been turned off).
[0068] According to one embodiment of the invention, the switching mechanism is embedded in the cellular telephone.
[0069] According to another embodiment of the invention, the switching mechanism is embedded in the hands-free adapter.
[0070] The hands-free adapter may be wired as well as wireless.
[0071] The communication between the cellular telephone and the hands-free adapter may be carried out by wireless communication, such as according to the Bluetooth protocol, infrared, proximity communication, and so on.
[0072] In one embodiment of the invention, the switching mechanism is adapted to turn on the vehicle only upon presence of a specific cellular telephone in said apparatus. The specific cellular telephone may be identified by a barcode reader installed in the hands-free adapter.
[0073] In the figures and description herein, the following numerals have been mentioned:
numeral 2 denotes a cellular telephone; numeral 4 denotes a stationary hands-free adapter; numeral 6 denotes a connector of the cellular telephone 4 with the corresponding connector of a hands-free adapter; numeral 8 denotes a connector of the hands-free adapter 4 with the cellular telephone 2 ; numeral 10 denotes a cable that connects to the negative contact point of the battery of a cellular telephone placed in the hands-free device 4 ; numeral 11 denotes an input power terminal point of relay 32 ; numeral 12 denotes a casing which comprises circuitry of the HSE; numeral 14 denotes a cable that connects terminal point 15 of relay 32 to an electric system of the vehicle; numeral 15 denotes a terminal point of a switch of relay 32 ; numeral 16 denotes an ignition key; numeral 18 denotes an electric circuit of the ignition switch of the vehicle; numeral 20 denotes a steering wheel of the vehicle; numeral 22 denotes a cable that connects to the positive contact point of the battery of a cellular telephone placed in the hands-free device 4 ; numeral 23 denotes an input power terminal point of relay 32 ; numeral 24 denotes a cable that connects terminal point 15 of relay 32 to an electric system of the vehicle; numeral 25 denotes a terminal point of a switch of relay 32 ; numeral 26 denotes an electric circuit of the engine of the vehicle; numeral 28 denotes the battery of the vehicle; numeral 32 denotes a relay or another switching mechanism.
[0093] While certain features of the invention have been illustrated and described herein, the invention can be embodied in other forms, ways, modifications, substitutions, changes, equivalents, and so forth. The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. | In one embodiment, the present invention is directed to a hands-free enforcing apparatus, comprising: a hands-free adapter; and a switching mechanism for sensing presence/absence of a cellular telephone in the hands-free adapter, and affecting a circuit of the vehicle thereof according to the sensed state. The apparatus may further comprise a delaying circuitry, for delaying the operation of affecting the circuit, thereby enabling a user thereof to return the cellular phone into the hands-free adapter before interfering in the operation of the circuit, and a buzzer, for alerting the user upon delaying the affecting. The circuit affected by the switching mechanism may be related to the ignition of the vehicle, to controlling the hazard signal of the vehicle, and so forth. | 7 |
This is a division of application Ser. No. 921,294 filed July 3, 1978 and now U.S. Pat. No. 4,341,718.
BACKGROUND OF THE INVENTION
This invention comprises α-[(alkylamino)methyl]-β-aryloxy-benzeneethanols and the pharmacologically acceptable acid addition salts thereof, which in standard pharmacological tests with animals have exhibited antiarrhythmic activity.
Heretofore an α-[(alkylamino)methyl]ethanol substituted in the β-position by both a phenyl group and a phenoxy (or 1-naphthoxy) group has not been known. Recently, α-[(1-methylethylamino)methyl]-γ-phenyl-(γ-benzene)propanol was reported to have antiarrhythmic activity by Murphy et al. in The Pharmacologist, 18, 114 (1976). An earlier Derwent abstract No. 16,563, of French Pat. No. 1,394,771, published Sept. 4, 1965, disclosed certain alkanolamine derivatives to be β-adrenergic blockers. Among these was α-[(1-methylethylamino)methyl]-3-alkyl-(2-iodo)benzeneethanol.
A further aspect of the present invention is a process for the addition of an aryloxy group at the 3-position of a 3-phenyl-2-oxiranecarboxamide to produce an α-hydroxy-β-aryloxybenzenepropanamide, said process comprising contacting an alkali metal aryloxide with said 3-phenyl-2-oxiranecarboxamide in the presence of a crown ether. The preparation and use of "crown ethers" as metal ion complexing agents is reported in Fieser and Fieser, Reagents for Organic Synthesis, Vol. V, pp. 152-5, Wiley-Interscience (1975) and Knipe, J. Chem. Ed., 53, 618 (1976). The influence of dibenzo or dicyclohexyl-[3n]-crown[n] crown ethers on the reaction of potassium phenoxide and butyl bromide to form phenylbutyl ether is reported on by Thomassen et al., in J. Acta Chem. Scand, 25, 3024 (1971).
SUMMARY OF THE INVENTION
The compounds of the present invention are represented by the formula I: ##STR2## wherein R is hydrogen, halogen, lower alkyl, or lower alkoxy; X is phenyl, 1-naphthyl, or a phenyl group substituted by a halogen, a lower alkyl group, or a lower alkoxy group; and R 1 is a lower alkyl group.
A preferred group (A) of compounds of formula I are those in which the R substituent is in the 3-position on the phenyl ring.
A particularly preferred group (B) of compounds of formula I are those in which R is hydrogen, 3-chloro or 3-methoxy and X is phenyl, 1-naphthyl, or phenyl substituted by chlorine, a methyl group, or a methoxy group.
A most preferred group (C) of compounds of formula I are those in which R is hydrogen and X is phenyl, 1-naphthyl, or phenyl substituted by chlorine, a methyl group, or a methoxy group.
Also, particularly preferred is the compound (D) in which R is hydrogen and X is 1-naphthyl.
Particularly preferred are those compounds of formula I in which R 1 is a 1-methylethyl (i.e. isopropyl) group.
Another group of most preferred compounds (E) are those in which R is 3-chloro or 3-methoxy, and X is phenyl.
Included in the present invention are the pharmacologically acceptable acid addition salts of the compounds of formula I. The nitric acid, hydrochloric acid, and oxalic acid salts are particularly preferred salts.
With respect to the compounds of group C described above, the nitric acid and hydrochloric acid addition salts are particularly preferred salts. With respect to the compound D described above, the nitric acid salts are particularly preferred salts. With respect to the compounds of group E described above, the nitric acid and oxalic acid salts are particularly preferred salts.
A further aspect of the Applicants' invention is a process for the addition of an aryloxy group at the 3-position of a 3-phenyl-2-oxiranecarboxamide to produce an α-hydroxy-β-aryloxybenzenepropanamide, said process comprising contacting an alkali metal aryloxide with said 3-phenyl-2-oxiranecarboxamide in the presence of a crown ether. Said α-hydroxy-β-aryloxy-benzenepropanamide may then be reduced to produce a compound of the invention.
In this addition reaction, the preferred alkali metals are sodium and potassium, with sodium being most preferred, and the preferred crown ethers are non-aromatic 18-crown-6-ethers, with 18-crown-6 being most preferred.
As used herein, the term "aryloxy" means phenoxy, 1-naphthoxy, or phenoxy wherein the phenyl ring thereof is substituted with halogen, a lower alkyl group, or a lower alkoxy group. The term "lower alkyl" means an aliphatic hydrocarbon group containing 1-4 carbon atoms, e.g. methyl, ethyl, propyl, isopropyl, butyl, isobutyl, s-butyl, or t-butyl groups. The methyl group is especially preferred. The term "lower alkoxy" means an aliphatic oxy group having 1-4 carbon atoms, e.g. methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, s-butoxy, or t-butoxy groups. The methoxy group is especially preferred.
Further, as used herein, a reference to "a 3-phenol-2-oxiranecarboxamide" refers to a compound having the structural formula as shown for intermediate V of the flow diagram illustrated in the following section wherein the carbon atom of the carboxyl group is designated number 1, the amide group is substituted with an R 1 substituent, and the 3-phenyl group thereof may be substituted with R substituents as defined in reference to Formula I. Thus, the illustrative compound shown as intermediate V is named N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide. Referring still to the flow diagram, the precursors of said 3-phenyl-2-oxiranecarboxamides, namely the "N-(lower alkyl)cinnamoylcarboxamides (IV)", the "cinnamoylchlorides (III)", and the "cinnamic acids (II)" also may be substituted on the phenyl ring thereof with an R substituent as defined in reference to Formula I.
As used herein, a reference to "an α-hydroxy-β-aryloxybenzenepropanamide" refers to a compound having the structural formula for intermediate VI or VII of flow diagram wherein the carbon atom to which the hydroxyl group is attached is designated "α" and the amide group contains a lower alkyl substituent. The benzene ring thereof corresponds to the 3-phenyl ring of its precursor 3-phenyl-2-oxiranecarboxamide (V) and may be similarly substituted with an R substituent as defined in reference to Formula I. "Aryloxy" was defined above, and the aryl substituent of said β-aryloxy group is defined the same as the X substituent of Formula I. For example, the illustrative compound shown in the flow diagram as intermediate VI is named α-hydroxy-β-phenoxy-N-(1-methylethyl)benzenepropanamide.
DETAILED DESCRIPTION OF THE INVENTION
The general method of synthesis of the compounds of Formula I is illustrated in the flow diagram below which depicts the preparation of a specific embodiment of the invention for purposes of illustration, namely α-[(1-methylethylamino)methyl]-β-phenoxy-benzeneethanol: ##STR3##
Using flow diagram in which the compounds are given Roman numerals for identification and each step in the production of the compounds of the invention is given a capital letter designation, the description of the production of the compounds of the invention is as follows:
A. Cinnamic acid (II) is reacted with thionyl chloride to produce cinnamoyl chloride (III). The reaction is carried out in an inert organic solvent, such as benzene, at reflux. Although the use of thionyl chloride is preferred, those skilled in the art of chemistry will understand that other reagents, such as phosphorus trichloride and phosphorus pentachloride, may be used under known reaction conditions in order to form the cinnamoyl chloride desired. Similarly, it is preferred to form the cinnamoyl chloride, but other halides may be formed to serve the same function, as known to those skilled in the art.
B. Isopropylamine is then reacted with the resulting cinnamoyl chloride (III) in order to form N-(1-methylethyl)cinnamoylcarboxide (IV). This reaction is carried out in an inert organic solvent, such as benzene, for example first at room temperature and then under reflux heating to produce the N-(1-methylethyl)cinnamoylcarboxamide (IV). If it is desired to form a compound of the invention with an R 1 substituent other than the 1-methylethyl (i.e. isopropyl) group, then the appropriate lower alkylamine should be used instead of isopropylamine in this reaction.
C. The N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide (V) intermediate is formed by the epoxidation of the alkene bond of the N-(1-methylethyl)cinnamoylcarboxamide (IV) using an epoxidizing agent, such as m-chloroperbenzoic acid, in the presence of a radical inhibitor. This reaction is conveniently carried out according to the method of Kishi et al. in J.C.S. Chem. Comm., 64 (1972) using the preferred radical inhibitor 4,4'-thiobis-(6-t-butyl-3-methyl-phenol). The reaction is preferably performed using ethylene dichloride as an inert solvent and on the other of 1 percent by weight of the preferred radical inhibitor 4,4'-thiobis-(6-t-butyl-3-methyl-phenol) relative to m-chloroperbenzoic acid under gentle reflux for approximately 1 hour.
D. The addition of the phenoxy group to the 3-position of N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide (V) intermediate to form α-hydroxy-β-phenoxy-N-(1-methylethyl)benzenepropanamide (VI) is carried out in an inert organic solvent, acetonitrile being preferred, in the presence of a crown ether, such as 18-crown-6.
In order to prepare the sodium phenoxide reactant, phenol may be converted to its sodium salt by first dissolving the phenol in a freshly prepared sodium methoxide-methanol solution and subsequently evaporating the excess methanol. The resulting solid product is then added to a mixture of the solvent, e.g. acetonitrile, and the the crown ether. Conveniently, 0.01-1.0 moles (preferably 0.05-0.25 moles) of the crown ether to 1 mole of original phenol are used. The resulting mixture is then stirred at room temperature for 30 minutes to allow the crown ether to act upon the sodium phenoxide.
Thereafter, N-(1-methyl)-3-phenyl-2-oxiranecarboxamide (V) (0.8-1.1 moles to 1 mole of initial phenol) is added to the stirred mixture, and this reaction mixture is then heated under reflux for 1 to 10 hours (5-7 hours preferred) to produce the α-hydroxy-β-phenoxy-N-(1-methylethyl)benzenepropanamide (VI).
An alternative and preferred method of preparing the alkali metal aryloxide reactant is begun by suspending the alkali metal hydride in the solvent, e.g. acetonitrile, and then adding the arylalcohol and the crown ether to this suspension. The presence of the crown ether at this stage enhances the solubility of the alkali metal aryloxide and the corresponding alkali metal cation and aryloxide anion in the solvent. This mixture is stirred at room temperature for 10 minutes to 2 hours before addition of the 3-phenyl-2-oxiranecarboxamide (V) reactant.
Those skilled in the art of chemistry will appreciate that other alkali metal cations may be used with the subject aryloxy anions (i.e. the anions whose aryl group is represented by X in Formula I). Sodium and potassium are the preferred alkali metal cations for this process, and the sodium cation is particularly preferred. Other metal cations and ammonium cations which will form salts with the aryloxy anion may also be utilized in the process of the invention. Such alkali metal aryloxide ion pair may be formed in situ as described with the use of sodium hydride, or such aryloxy alkali metal ion pair may be added directly as a reactant. Generally, it will be preferable to add the crown ether to the reactant mixture of the alkali metal aryloxide in the solvent prior to addition of the 3-phenyl-2-oxiranecarboxamide (V) reactant to aid in solvation of the anion-cation pair.
In carrying out the nucleophilic addition of an aryloxy group to the 3-position of a 3-phenyl-2-oxiranecarboxamide (V), aprotic organic solvents such as acetonitrile, benzene, dioxane, and acetone are preferred because of the solubility of the 3-phenyl-2-oxiranecarboxamide reactant and of the α-hydroxy-β-aryloxybenzenepropane product therein.
Numerous crown ethers are known which will form stable complexes with the alkali metal cation (or other metal cation) of a reactant alkali metal cation-nucleophilic anion salt. For a review of such crown ethers reported on in the chemical literature through December, 1972, see Christensen et al., Chem. Rev., 74, 351 (1974). With respect to the Applicants' process invention, however, the saturated (i.e. non-aromatic) and the simple (i.e. cyclic ether ring not substituted) crown ethers are preferred because of their greater solubility in the preferred organic solvents. For example, dicyclohexyl-18-crown-6 (saturated), 15-crown-5 (simple), and 18-crown-6 (simple) crown ethers are particularly preferred for the process of the invention. Another reason these crown ethers are preferred is that their "hole" size corresponds most closely to the size necessary to form the most stable complex with the preferred sodium cation. As described in Knipe, supra, at 619, and more fully in Thomassen et al., supra, and in Pedersen, J. Am. Chem. Soc., 89, 7017 (1967), the optimum crown ethers for forming a stable complex with a particular metal cation will generally be those crown ethers having a "hole" size sufficient to fully enclose one such ion within one molecule of the crown ether. Thus, with alkali metal cations other than the preferred sodium cation, the preferred crown ethers will vary in size according to the size of the particular cation. One skilled in the art will readily be able to determine appropriate crown ethers for use in the process of the invention.
The formation of a stable complex of the metal cation with the crown ether accounts for the improved solvation of the aryloxy anion in an aprotic organic solvent and for an enhanced nucleophilic reactivity of the aryloxy anion. However, these factors do not foretell the selectivity of the aryloxy anion for the 3-position of the 3-phenyl-2-oxiranecarboxamide in Applicants' process invention.
As used herein, the term "crown ether" describes macrocyclic ethers, including such ethers which are polycyclic and those in which sulfur or nitrogen atoms are substituted for one or more of the oxygen atoms in the cyclic ring. This scope of the term "crown ether" is coextensive with that described by Knipe, supra, at 618-19.
The preparation of crown ethers is described in Pedersen, supra; Knipe, supra; and Fieser and Fieser, Vol. 5, supra. The preparation of 18-crown-6 is described in Greene, Tetrahedron Letters, 1793 (1972) and in Gokel et al., J. Org. Chem., 39, 2445 (1974). Many crown ethers are available commercially.
E. In order to obtain the α-[(1-methylethylamine)methyl]-β-phenoxy-benzeneethanol (Ia) compound of the invention, the amide of the α-hydroxy-β-phenoxy-N-(1-methylethyl)benzenepropanamide (VI) is reduced to the corresponding amine. This reduction may be accomplished by the method of Brown and Heim, J. Org. Chem., 38, 912 (1973), in which an excess of borane-tetrahydrofuran complex (diborane in tetrahydrofuran) at 0° C. in a dry nitrogen atmosphere is brought into contact with a solution of α-hydroxy-β-phenoxy-N-(1-methylethyl)benzenepropanamide (VI) in tetrahydrofuran, keeping the temperature at 0° C. during the addition of the reactant. Thereafter, the solution is brought to reflux temperature and the reaction is run at reflux temperatures until completion. Separation of the reduction product is facilitated by the addition of dilute hydrochloric acid and further reflux heating of the reaction mixture.
For pharmacological use, the compounds of Formula I (Ia or Ib) may be administered in the form of an acid addition salt of a non-toxic organic or inorganic acid. The salts may be prepared by methods well-known in the art. Such salts are included in the scope of the invention. Appropriate salts may be those formed from the following acids: hydrochloric, hydrobromic, sulfonic, sulfuric, phosphoric, nitric, maleic, fumaric, benzoic, ascorbic, pamoic, succinic, methanesulfonic, acetic, propionic, tartaric, citric, lactic, malic, mandelic, cinnamic, palmitic, itaconic, benzenesulfonic, and oxalic.
The compounds of the invention exhibit anti-arrhythmic effects in warm-blooded animals as evidenced by standard pharmacologic tests in animals. The anti-arrhythmic activity of the compounds can be demonstrated by following a test procedure described by Baum et al., in Arch. Int. Pharmacodyn., 193, 149 (1971), which is a generally accepted test for anti-arrhythmic agents. In this test, the heart of an anesthetized (pentobarbital, 30-35 mg. I.V.) dog is exposed by a left thoracotomy. Bipolar electrodes are sutured to the epicardial surface of the left ventricle. The heart is stimulated with square wave pulses of 3 msec. duration and frequency of 60 Hz. for periods of 5 sec. Voltage is increased until fibrillation ensues. The heart is then defibrillated by DC countershock and the procedure repeated at 10 minute intervals. Drugs are administered intravenously over periods of 3 minutes and fibrillatory threshold examined 15 minutes after start of injection of each dose. Effective anti-arrhythmic agents elevate the fibrillatory threshold.
The compounds of the invention increase the fibrillatory threshold when administered according to this procedure at doses of 20 mg. per kilogram of body weight or less. Preferred compounds would exert only minimal depressant activity on systemic blood pressure.
When used to treat arrhythmia in warm-blooded animals, the effective dosage will depend upon the stage and severity of the condition being treated, the subject being treated, and the particular compound being used, and will readily be determined by the attending physician. Therapy should be initiated at lower dosages, usually 10 mg/kg. per day or less, the dosage thereafter being increased up to 20 mg/kg., if necessary, until the desired anti-arrhythmic effect is obtained.
The following examples further illustrate the best mode contemplated by the inventors for the practice of the invention.
EXAMPLE 1
4-Chlorocinnamoyl Chloride
Thionyl chloride (28.6 g.) was added dropwise to a benzene (300 ml.) solution of p-chlorocinnamic acid (36.5 g.) under stirring. The resulting solution was heated under reflux for 1 hour, then the solvent was evaporated under reduced pressure on a rotary evaporator to give the product, which melted at 78°-80° and weighed 40 g.
Analysis for: C 9 H 6 Cl 2 O: Calculated: C, 53.76; H, 3.01. Found: C, 54.09; H, 2.75.
EXAMPLE 2
3-Methoxycinnamoyl Chloride
Thionyl chloride (38 g.) was added dropwise to a mixture of 3-methoxycinnamic acid (50 g.) and benzene (500 ml.), and the resulting mixture was heated under reflux for 1.5 hours, then evaporated under reduced pressure on a rotary evaporator to give an oil. The oil solidified on standing at room temperature, giving 59 g. of the product. Analytical sample (m.p. 43°-45°) was obtained by recrystallization from petroleum ether.
Analysis for: C 10 H 9 ClO 2 : Calculated: C, 61.08; H, 4.61. Found: C, 60.93; H, 4.52.
EXAMPLE 3
N-(1-Methylethyl)Cinnamoylcarboxamide
To a stirring mixture of isopropylamine (66 g.) and benzene (500 ml.) was added dropwise cinnamoyl chloride (84 g.) dissolved in benzene (100 ml.) under stirring. The stirring was continued for 2 hours at room temperature, then heated under reflux for 45 minutes. The reaction mixture was allowed to set at room temperature overnight. The precipitate which deposited was collected on a filter and washed with benzene, then discarded. The filtrate and washings were combined and washed with water, then dried over magnesium sulfate. Removal of benzene by evaporation on a rotary evaporator under reduced pressure gave a solid residue which was then recrystallized from ether, giving 96.5 g. of product, 105°-107°.
Analysis for: C 12 H 15 NO: Calculated: C, 76.15; H, 7.99; N, 7.40. Found: C, 76.03; H, 8.28; N, 7.35.
EXAMPLE 4
N-(1-Methylethyl)-3-Chlorocinnamoylcarboxamide
A mixture of 3-chlorocinnamic acid (25 g.), thionyl chloride (19.4 g.) and benzene (300 ml.) was heated under reflux for 2 hours, then evaporated under reduced pressure on a rotary evaporator to give an oil. The oil was dissolved in benzene (50 ml.), and the benzene solution was added slowly to a mixture of isopropylamine (25 g.) and benzene (300 ml.). The resulting mixture was allowed to stir at room temperature for 2 hours, and heated under mild reflux for 1 hour. It was then allowed to set at room temperature overnight. The precipitate thus separated was collected on a filter, and washed with benzene. The combined filtrate and washings were washed with water, then dried over potassium carbonate. Removal of benzene under reduced pressure on a rotary evaporator gave an oil which solidified on standing. The product melted at 92°-94°, and weighed 28 g.
Analysis for: C 12 H 14 ClNO: Calculated: C, 64.43; H, 6.31; N, 6.26. Found: C, 64.10; H, 6.14; N, 6.24.
EXAMPLE 5
N-(1-Methylethyl)-4-Chlorocinnamoylcarboxamide
4-Chlorocinnamoyl chloride (40 g.) dissolved in benzene (70 ml) was added slowly to a mixture of isopropylamine (26 g.) and benzene (450 ml.) under gentle heating. During the addition the mixture was stirred with a mechanical stirrer. The resulting mixture was heated under reflux for 1 hour, then allowed to stand overnight at room temperature. The precipitate thus separated was collected on a filter, and washed with benzene, then with water. The product melted at 183°-185°, and weighed 48 g.
Analysis for: C 12 H 14 ClNO: Calculated: C, 64.43; H, 6.31; N, 6.26. Found: C, 64.35; H, 6.35; N, 6.31.
EXAMPLE 6
N-(1-Methylethyl)-3-Methoxycinnamoylcarboxamide
This compound was prepared from 3-methoxycinnamoyl chloride (59 g.), isopropylamine (36.5 g.) and benzene (500 ml.) as described in Example 5. The compound melted at 82°-84° and weighed 64.5 g.
Analysis for: C 13 H 17 NO 2 : Calculated: C, 71.20; H, 7.82; N, 6.39. Found: C, 71.48; H, 7.58; N, 6.42.
EXAMPLE 7
N-(1-Methylethyl)-3-Phenyl-2-Oxiranecarboxamide (V)
A mixture of N-(1-methylethyl)cinnamoylcarboxamide (18 g.), m-chloroperbenzoic acid (23.6 g.), 4,4'-thiobis(6-tert-butyl-m-cresol) (0.3 g.) and ethylene dichloride (250 ml.) was heated under gentle reflux for 1 hour, then chilled in ice. A precipitate (m-chlorobenzoic acid) was separated by filtration and washed with ethylene dichloride. The filtrate and washings were combined, and evaporated under reduced pressure on a rotary evaporator to give an amber oil. The oil was dissolved in chloroform (300 ml.) and the chloroform solution was washed with 5% aqueous sodium bicarbonate solution twice, then with saline. The chloroform solution was dried over magnesium sulfate, then evaporated under reduced pressure in a rotary evaporator to give an oil. The oil solidified on standing. The solid mass was recrystallized from ether giving 8.4 g. of product, m.p. 114°-115°.
Analysis for: C 12 H 15 NO 2 : Calculated: C, 70.22; H, 7.37; N, 6.82. Found: C, 70.23; H, 7.23; N, 6.82.
EXAMPLE 8
N-(1-Methylethyl)-3-(3-Chlorophenyl)-2-Oxiranecarboxamide
This compound was prepared from N-(1-methylethyl)-3-chlorocinnamoylcarboxamide (22.4 g.), m-chloroperbenzoic acid (23.6 g.), 4,4'-thiobis(6-tert-butyl-m-cresol) (0.3 g.), and ethylene dichloride as described in Example 7, and purified by recrystallization from ether. The compound melted at 131°-133°, and weighed 14.5 g.
Analysis for: C 12 H 14 ClNO 2 : Calculated: C, 60.13; H, 5.88; N, 5.84. Found: C, 60.31; H, 5.87; N, 5.85.
EXAMPLE 9
N-(1-Methylethyl)-3-(4-Chlorophenyl)-2-Oxiranecarboxamide
This compound was prepared from N-(1-methylethyl)-4-chlorocinnamoylcarboxamide (18.3 g.), m-chloroperbenzoic acid (19.4 g.), 4,4'-thiobis(6-tert-butyl-m-cresol) (0.3 g.), and ethylene dichloride (250 ml.) as described in Example 7, and purified by recrystallization from ether. The compound melted at 139°-141°, and weighed 11.7 g. The analytical sample which was obtained by another recrystallization from ether melted at 143°-145°.
Analysis for: C 12 H 14 ClNO 2 : Calculated: C, 60.13; H, 5.89; N, 5.84. Found: C, 60.33; H, 5.93; N, 5.93.
EXAMPLE 10
N-(1-Methylethyl)-3-(3-Methoxyphenyl)-2-Oxiranecarboxamide
This compound was prepared from N-(1-methylethyl)-3-methoxycinnamoylcarboxamide (43.9 g.), m-chloroperbenzoic acid (46 g.), 4,4'-thiobis(6-tert-butyl-m-cresol) (0.6 g.), and ethylene dichloride (500 ml.) as described in Example 7. The compound obtained as an oil was used directly in the subsequent reaction.
EXAMPLE 11
α-Hydroxy-β-Phenoxy-N-(1-Methylethyl)Benzenepropanamide (VI)
Phenol (3.0 g.) was converted into its sodium salt by dissolving in a freshly prepared sodium methoxide-methanol solution (0.7 g. of metallic sodium in 50 ml. of absolute methanol), and subsequent evaporation of the excess methanol under reduced pressure on a rotary evaporator. The solid residue was dissolved in acetonitrile (250 ml.) by stirring with 18-crown-6 (0.9 g.) for 30 minutes at room temperature. N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide (6.16 g.) was added to the solution, and the resulting mixture was heated under reflux for 6 hours. After cooling to room temperature, it was filtered. The filtrate was evaporated on a rotary evaporator under reduced pressure to give a resinous material. Water (ca. 200 ml.) was added to the residue, and allowed to stand at room temperature. The white precipitate thus separated was collected on a filter and washed with water. The filter residue was dried in air, then recrystallized from ethanol, giving 2.5 g. of product, m.p. 166°-168°.
Analysis for: C 18 H 21 NO 3 : Calculated: C, 72.21; H, 7.07; N, 4.68. Found: C, 71.86; H, 6.95; N, 4.67.
EXAMPLE 12
α-Hydroxy-62 -(4-Methoxyphenoxy)-N-(1-Methylethyl)Benzenepropanamide
Sodium hydride (50% oil dispersion, 2.4 g.) was washed with pentane, then suspended in acetonitrile (500 ml.). 4-Methoxyphenol (6.2 g.) and 18-crown-6 (1.5 g.) was added to the suspension, and the resulting mixture was stirred at room temperature for 0.5 hours. To the mixture was added N-(1-methylethyl)-3-phenyl-3-oxiranecarboxamide (10.3 g.) and heated under reflux for 6 hours. The reaction mixture was filtered, and the filtrate was evaporated under reduced pressure on a rotary evaporator to give an oil. Treatment of the oil with water (ca. 300 ml.) caused separation of a white precipitate which was collected on a filter, and washed with water. The filter residue was dried, then recrystallized from ether, giving 4.6 g. of product, m.p. 134°-136°.
Analysis for: C 19 H 23 NO 4 : Calculated: C, 69.23; H, 7.04; N, 4.25. Found: C, 69.23; H, 6.96; N, 4.25.
EXAMPLE 13
α-Hydroxy-β-(3-Methoxyphenoxy)-N-(1-Methylethyl)Benzenepropanamide
This compound was prepared from N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide (10.3 g.), m-methoxyphenol (6.2 g.), sodium hydride (50% oil dispersion, 2.4 g.), 18-crown-6 (1.5 g.) and acetonitrile (500 ml.) as described in Example 12. The crude product (m.p. 118°-120°, yield 2.6 g.) was then recrystallized from ether with a small amount of tetrahydrofuran, giving 2.3 g. of the pure product, m.p. 132°-133°.
Analysis for: C 19 H 23 NO 4 : Calculated: C, 69.28; H, 7.04; N, 4.25. Found: C, 68.99; H, 7.00; N, 4.21.
EXAMPLE 14
α-Hydroxy-β-(4-Methylphenoxy)-N-(1-Methylethyl)Benzenepropanamide
This compound was prepared as in Example 12 from N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide (6.16 g.), p-cresol (3.3 g.), sodium hydride (50% oil dispersion, 1.5 g.), 18-crown-6 (0.9 g.) and acetonitrile (250 ml.). The product melted at 152°--152°, and amounted to 2.4 g.
Analysis for: C 19 H 23 NO 3 : Calculated: C, 72.82; H, 7.40; N, 4.47. Found: C, 72.89; H, 7.42; N, 4.49.
EXAMPLE 15
α-Hydroxy-β-(3-Methylphenoxy)-N-(1-Methylethyl)Benzenepropanamide
This compound was prepared as in Example 12 from N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide (6.16 g.), m-cresol (3.3 g.), sodium hydride (50% oil dispersion, 1.5 g.), 18-crown-6 (0.9 g.), and acetonitrile (250 ml.). The product which was recrystallized from ether melted at 158°-159°, and weighed 3.2 g.
Analysis for: C 19 H 23 NO 3 : Calculated: C, 72.82; H, 7.40; N, 4.47. Found: C, 72.57; H, 7.36; N, 4.42.
EXAMPLE 16
α-Hydroxy-β-(2-Methylphenoxy)-N-(1-Methylethyl)Benzenepropanamide
This compound was prepared from N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide (8.2 g.) o-cresol (4.3 g.), sodium hydride (50% oil dispersion, 1.9 g.), 18-crown-6 (1.0 g.), and acetonitrile (250 ml.) as described in Example 12. The compound after recrystallization from ether melted at 123°-124°, and weighed 1.25 g.
Analysis for: C 19 H 23 NO 3 : Calculated: C, 72.82; H, 7.40; N, 4.47. Found: C, 72.79; H, 7.24; N, 4.48.
EXAMPLE 17
α-Hydroxy-β-(4-Chlorophenoxy)-N-(1-Methylethyl)Benzenepropanamide
This compound was prepared from N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide (6.16 g.) p-chlorophenol (3.9 g.), sodium hydride (50% oil dispersion, 1.5 g.) 18-crown-6 (0.9 g.), and acetonitrile (250 ml.) as described in Example 12. The product melted at 148°-150°, and amounted to 2.7 g.
Analysis for: C 18 H 20 ClNO 3 : Calculated: C, 64.76; H, 6.04; N, 4.20. Found: C, 64.34; H, 5.81; N, 4.27.
EXAMPLE 18
α-Hydroxy-β-(3-Chlorophenoxy)-N-(1-Methylethyl)Benzenepropanamide
This compound was prepared from N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide (6.16 g.) m-chlorophenol (3.9 g.), sodium hydride (50% oil dispersion, 1.5 g.), 18-crown-6 (0.9 g.), and acetonitrile (250 ml.) as described in Example 12. The product which was purified by recrystallization from ether melted at 151°-153°, and weighed 1.4 g.
Analysis for: C 18 H 20 ClNO 3 : Calculated: C, 64.76; H, 6.04; N, 4.20. Found: C, 64.41; H, 6.22; N, 4.30.
EXAMPLE 19
α-Hydroxy-β-(1-Naphthoxy)-N-(1-Methylethyl)Benzenepropanamide.1/4 EtOAc
This compound was prepared from N-(1-methylethyl)-3-phenyl-2-oxiranecarboxamide (8.2 g.), 1-naphthol (5.8 g.), sodium hydrode (50% oil dispersion, 1.9 g.) and acetonitrile (250 ml.) as described in Example 12, except that the mixture of 1-naphthol, sodium hydride, 18-crown-6 and acetonitrile was allowed to stir at room temperature for 1 hour. The crude product was recrystallized from a small amount of ethyl acetate, giving 3.0 g. of the product which contained a 1/4 mole of ethyl acetate per mole of α-hydroxy-β-(1-naphthoxy)-N-(1-methylethyl)benzenepropanamide, m.p. 183°-185°.
Analysis for: C 22 H 23 NO 3 .1/4 EtOAc: Calculated: C, 74.37; H, 6.78; N, 3.77. Found: C, 74.14; H, 6.36; N, 3.88.
EXAMPLE 20
α-Hydroxy-β-Phenoxy-N-(1-Methylethyl)-3-Chlorobenzenepropanamide
This compound was prepared from N-(1-methylethyl)-3-(3-chlorophenyl)-2-oxiranecarboxamide (7.2 g.), phenol (3.0 g.), sodium hydride (50% oil dispersion, 1.6 g.), 18-crown-6 (0.9 g.) and acetonitrile (250 ml.) as described in Example 12. The crude product was recrystallized from ether. The compound melted at 160°-162°, and weighed 1.7 g.
Analysis for : C 18 H 20 ClNO 3 : Calculated: C, 64.76; H, 6.04; N, 4.20. Found: C, 64.52; H, 6.04; N, 4.18.
EXAMPLE 21
α-Hydroxy-β-Phenoxy-N-(1-Methylethyl)-4-Chlorobenzenepropanamide
This compound was prepared from N-(1-methylethyl)-3-(4-chlorophenyl)-2-oxiranecarboxamide (7.2 g.), phenol (3.0 g.), sodium hydride (50% oil dispersion, 1.6 g.), 18-crown-6 (0.9 g.), and acetonitrile (250 ml.) as described in Example 12. The crude product was recrystallized from ethanol, giving 2.3 g. of the compound, m.p. 175°-177°. Another recrystallization from ethanol gave analytical sample, m.p. 176°-178°.
Analysis for: C 18 H 20 ClNO 3 : Calculated: C, 64.76; H, 6.04; N, 4.20. Found: C, 64.44; H, 6.21; N, 4.08.
EXAMPLE 22
α-Hydroxy-β-Phenoxy-N-(1-Methylethyl)-3-Methoxybenzenepropanamide
This compound was prepared from N-(1-methylethyl)-3-(3-methoxyphenyl)-2-oxiranecarboxamide (14.3 g.), phenol (6.0 g.), sodium hydride (50% oil dispersion, 3.2 g.), 18-crown-6 (1.8 g.), and acetonitrile (500 ml.) as described in Example 12. The compound obtained as an oil was used directly in the subsequent reaction.
EXAMPLE 23
α-Hydroxy-β-(4-Chlorophenoxy)-N-(1-Methylethyl)-4-Chlorobenzenepropanamide
This compound was prepared from N-(1-methylethyl)-3-(4-chlorophenyl)-2-oxiranecarboxamide (9.56 g.), p-chlorophenol (5.2 g.), sodium hydride (50% oil dispersion, 2.0 g.) 18-crown-6 (3.0 g.), and acetonitrile (300 ml.) as described in Example 12, and purified by recrystallization from ether. The compound melted at 177°-179°, and weighed 0.76 g.
Analysis for: C 18 H 19 Cl 2 NO 3 : Calculated: C, 58.71; H, 5.20; N, 3.80. Found: C, 58.80; H, 5.24; N, 3.91.
EXAMPLE 24
α-[(1-Methylethylamino)methyl]-β-Phenoxy-Benzeneethanol (Ia)
Borane-tetrahydrofuran complex (1 M solution in tetrahydrofuran, 20 ml.) was transferred by a syringe to a 100 ml. three-neck flask equipped with a reflux condenser, a nitrogen gas inlet and a rubber septum. The reaction flask was then chilled in a mixture of ice and table salt. α-Hydroxy-β-phenoxy-N-(1-methylethyl)benzenepropanamide (1.9 g.) suspended in tetrahydrofuran (25 ml.) was added slowly keeping the temperature at ca. 0°. The solution thus obtained was brought to reflux and maintained there for 2.5 hours. The reaction mixture was cooled to room temperature, dilute hydrochloric acid (6 N HCl 3 ml.) and water (5 ml.) was added carefully, and the mixture was heated under reflux for 20 minutes. It was then evaporated on a rotary evaporator under reduced pressure to give a solid residue. The residue was treated with water. The water insoluble material was separated by collecting on a filter and washed with water. The filtrate and washings were combined and made alkaline by addition of 50% aqueous sodium hydroxide solution, then extracted with chloroform 3 times. The combined extract was dried over magnesium sulfate, and evaporated under reduced pressure to give an oil which solidified on standing. The crude product was recrystallized from ether and petroleum ether, giving 1.0 g. of product, m.p. 95°-96°.
Analysis for: C 18 H 23 NO 2 : Calculated: C, 75.75; H, 8.12; N, 4.91. Found: C, 75.92; H, 8.26; N, 4.92.
EXAMPLE 25
α-[(1-Methylethylamino)methyl]-β-(4-Methoxyphenoxy)Benzeneethanol, Nitrate
α-Hydroxy-β-(4-methoxyphenoxy)-N-(1-methylethyl)benzenepropanamide, (3.3 g.) was reduced with borane-tetrahydrofuran complex (1 M solution in tetrahydrofuran, 25 ml.) as described in Example 24 and treated with dilute hydrochloric acid (6 N, HCl, 5 ml.). The reduction product (3.7 g.) was obtained as an oil which failed to solidify. The oily product was dissolved in absolute ethanol, and filtered. Concentrated nitric acid (1.05 g.) was added with caution to the chilled filtrate. The resulting mixture was diluted with anhydrous ether (ca. 100 ml.), and chilled in ice. The precipitate thus separated was collected on a filter and washed with ethanol, giving 2.9 g. of product, m.p. 153°-155°.
Analysis for: C 19 H 25 NO 3 .HNO 3 : Calculated: C, 60.30; H, 6.93; N, 7.40. Found: C, 60.10; H, 7.09; N, 7.53.
EXAMPLE 26
α-[(1-Methylethylamino)methyl]-β-(3-Methoxyphenoxy)Benzeneethanol, Nitrate
This compound was prepared by reduction of α-hydroxy-β-(3-methoxyphenoxy)-N-(1-methylethyl)benzenepropanamide (2.2 g.) with borane-tetrahydrofuran complex (1 M solution in tetrahydrofuran, 16.6 ml.) as described in Example 24. The product which was obtained as an oil was converted into its nitric acid salt, and recrystallized from a small amount of ethanol and ether. The product melted at 107°-109°, and weighed 0.6 g.
Analysis for: C 19 H 25 NO 3 .HNO 3 : Calculated: C, 60.30; H, 6.93; N, 7.40. Found: C, 60.54; H, 6.93; N, 7.71.
EXAMPLE 27
α-[(1-Methylethylamino)methyl]-β-(4-Methylphenoxy)Benzeneethanol, Nitrate
This compound was prepared by reduction of α-hydroxy-β-(4-methylphenoxy)-N-(1-methylethyl)benzenepropanamide (1.6 g.) with borane-tetrahydrofuran complex (1 M solution in tetrahydrofuran, 13 ml.) as described in Example 24. The product was obtained as an oil which was converted into the nitrate salt in the following fashion: The oil was dissolved in a small amount of absolute ethanol, and the ethanol solution was made acidic by addition of concentrated nitric acid. Since addition of anhydrous ether and chilling in ice failed to cause separation by a precipitate, it was evaporated under reduced pressure on a rotary evaporator to give a resinous material. Addition of anhydrous ether to the residue gave a solid residue which melted at 138°-140°, and weighed 1.3 g.
Analysis for: C 19 H 25 NO 2 .HNO 3 : Calculated: C, 62.96; H, 7.23; N, 7.73. Found: C, 62.72; H, 7.30; N, 7.79.
EXAMPLE 28
α-[(1-Methylethylamino)methyl]-β-(3-Methylphenoxy)Benzeneethanol, Nitrate
This compound was prepared as in Example 24 from α-hydroxy-β-(3-methylphenoxy)-N-(1-methylethyl)-benzenepropanamide (1.6 g.) and borane-tetrahydrofuran complex (1 M solution in tetrahydrofuran, 13 ml.). The oily product was then converted into nitric acid salt, m.p. 127°-129°, yield 0.8 g.
Analysis for: C 19 H 25 NO 2 .HNO 3 : Calculated: C, 62.96; H, 7.23; N, 7.73. Found: C, 62.70; H, 7.37; N, 7.61.
EXAMPLE 29
α-[(1-Methylethylamino)methyl]-β-(2-Methylphenoxy)Benzeneethanol, Hydrochloride
This compound was prepared by reduction of α-hydroxy-N-(1-methylethyl)-β-(2-methylphenoxy)benzenepropanamide (1.8 g.) with borane-tetrahydrofuran complex (1 M solution in tetrahydrofuran, 13 ml.) and subsequent treatment with hydrochloric acid as described in Example 24. The crude product was purified by recrystallization from tetrahydrofuran. The product melted at 193°-195°, and weighed 0.75 g.
Analysis for: C 19 H 25 NO 2 .HCl: Calculated: C, 67.94; H, 7.80; N, 4.17. Found: C, 67.64; H, 7.65; N, 4.26.
EXAMPLE 30
α-[(1-Methylethylamino)methyl]-β-(4-Chlorophenoxy)Benzeneethanol, Nitrate
This compound was prepared as in Example 25 by reduction of β-(3-chlorophenoxy)-α-Hydroxy-N-(1-methylethyl)benzenepropanamide (1.4 g.) with borane-tetrahydrofuran complex (1 M solution in tetrahydrofuran, 10 ml.) and following salt formation with nitric acid. The product melted at 157°-159°, and weighed 0.55 g.
Analysis for: C 18 H 22 ClNO 2 .HNO 3 : Calculated: C, 56.46; H, 6.05; N, 7.32. Found: C, 56.39; H, 6.11; N, 7.20.
EXAMPLE 31
α-[(1-Methylethylamino)methyl]-β-(3-Chlorophenoxy)Benzeneethanol, Nitrate
This compound was obtained by reduction of α-hydroxy-β-(3-chlorophenoxy)-N-(1-methylethyl)-benzenepropanamide (1.6 g.) with borane-tetrahydrofuran complex (1 M solution in tetrahydrofuran, 12 ml.) and subsequent treatment of the oily product with nitric acid as described in Example 25. The product melted at 112°-114°, and weighed 0.55 g.
Analysis for: C 18 H 22 ClNO 2 .HNO 3 : Calculated: C, 56.46; H, 6.05; N, 7.32. Found: C, 56.44; H, 5.76; N, 7.19.
EXAMPLE 32
α-[(1-Methylethylamino)methyl]-β-(1-Naphthoxy)Benzeneethanol, Nitrate
This compound was prepared by reduction of α-hydroxy-β-(1-naphthoxy)-N-(1-methylethyl)benzenepropanamide (3.5 g.) with borane-tetrahydrofuran (1 M solution in tetrahydrofuran, 25 ml.) and subsequent treatment of the oily product with nitric acid as described in Example 25. The product melted at 157°-159°, weighed 1.25 g.
Analysis for: C 22 H 25 NO 2 .HNO 3 : Calculated: C, 66.31; H, 6.58; N, 7.03. Found: C, 65.93; H, 6.61; N, 7.02.
EXAMPLE 33
α-[(1-Methylethylamino)methyl]-β-Phenoxy-3-Chlorobenzeneethanol, Nitrate
This compound was prepared by reduction of α-hydroxy-β-phenoxy-N-(1-methylethyl)-(3-chlorobenzene)propanamide (1.6 g.) with borane-tetrahydrofuran complex (1 M solution in tetrahydrofuran, 12 ml.) and converting the oily product into nitric acid salt, as described in Example 25. The compound melted at 95°-97°, and weighed 1.05 g.
Analysis for: C 18 H 22 ClNO 2 .HNO 3 : Calculated: C, 56.46; H, 6.05; N, 7.32. Found: C, 56.34; H, 6.26; N, 7.13.
EXAMPLE 34
α-[(1-Methylethylamino)methyl]-β-Phenoxy-3-Methoxybenzeneethanol, 1/2 Oxalate, 1/4 Hydrate
This compound was prepared by reduction of α-hydroxy-β-phenoxy-N-(1-methylethyl)-3-methoxybenzenepropanamide and borane-tetrahydrofuran complex (1 M solution in tetrahydrofuran), and the oily product was converted into oxalic acid salt. The compound which was obtained as 1/2 oxalate, 1/4 hydrate melted at 187°-190° dec.
Analysis for: C 19 H 25 NO 3 .1/2 (CO 2 H 2 .1/4 H 2 O: Calculated: C, 65.83; H, 7.32; N, 3.84. Found: C, 65.80; H, 7.31; N, 4.10. | Disclosed herein are α-[(alkylamino)methyl]-β-aryloxy-benzeneethanols exhibiting antiarrhythmic activity and having the following formula: ##STR1## wherein R is hydrogen, halogen, lower alkyl, or lower alkoxy; X is phenyl, 1-naphthyl, or a phenyl group substituted by a halogen, a lower alkyl group, or a lower alkoxy group; R 1 is lower alkyl; and pharmacologically acceptable acid addition salts thereof. Also disclosed is a process for the addition of an aryloxy group at the 3-position of a 3-phenyl-2-oxiranecarboxamide to produce an α-hydroxy-β-aryloxy-benzenepropanamide, said process comprising contacting an alkali metal aryloxide with said 3-phenyl-2-oxiranecarboxamide in the presence of a crown ether. Such α-hydroxy-β-aryloxy-benzenepropanamides may then be reduced to produce the compounds of the invention. | 2 |
BACKGROUND
1. Technical Field
The present disclosure relates to hair styling systems, and, more particularly, relates to a system, method and apparatus for application of hairpins to the hair of a subject.
2. Description of Related Art
Hairpins such as “bobby pins” are known in the art. Hairpins are usually made from resilient material including metallic or polymeric legs connected through a hinge or bent portion. Generally, during application, hairpins are removed from the package, opened and applied to a length of hair. However, removal and opening of the hairpins often proves to be an awkward or cumbersome process.
SUMMARY
Accordingly, the present disclosure is directed to a method, apparatus and system for storing and distributing hairpins for application to the hair of a subject. In accordance with one embodiment, a hairpin storage and application system includes a support having a support surface, a plurality of hairpins releasably coupled to the support and an opener mounted to the support. The opener includes a base segment defining a longitudinal axis and having opposed generally diverging side segments. The base segment at least partially extends beyond the support surface of the support to orient the diverging side segments in position whereby legs of each hairpin may be advanced along the diverging side segments to displace the legs to cause opening thereof.
The opener may include a flange segment connected to the base segment. The flange segment is dimensioned to extend beyond the diverging side segments of the base segment to assist in retaining the hairpin relative to the diverging side segments as the legs of the hairpin are advanced therealong. The opener may includes first and second flange segments connected to the base segment, with the first flange segment dimensioned to assist in retaining the hairpin relative to the diverging side segments, and the second flange segment dimensioned to facilitate securement of the pin opener to the support. The second flange segment may be coupled to the support. The diverging side segments each have a tapered segment defining an asymmetric profile relative to the longitudinal axis.
In one embodiment, the support is a placard. The support may includes at least one opening extending therethrough dimensioned for storing the hairpins with the legs of each the pin extending through the at least one opening and respectively disposed adjacent on opposed surfaces of the support. The support may include a plurality of openings extending therethough dimensioned for storing the hairpins.
In accordance with another embodiment, a hairpin opener apparatus for opening a hairpin of the type having a pair of resilient legs interconnected by a hinge and being biased to a normally closed position. The hair pin opener apparatus includes a base segment defining a longitudinal axis and having opposed generally diverging side segments diverging with respect to the longitudinal axis from a front end of the base segment to a rear end of the base segment. The diverging side segments are arranged whereby the resilient legs of the hairpin may be advanced along respective diverging side segments to displace the legs relative to each other to cause at least partial opening thereof. The diverging side segments may define an asymmetric surface.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the present disclosure are described hereinbelow with references to the drawings, wherein:
FIG. 1 is a perspective view of the HAIRPIN OPENER AND APPLICATION SYSTEM in accordance with the principles of the present disclosure illustrating the pin support, a plurality of pins mounted to the support and the pin opener;
FIG. 2 is a perspective view similar to the view of FIG. 1 of the SYSTEM illustrating the pin opener removed from the pin support;
FIGS. 3-4 are first and second end elevation views of the SYSTEM;
FIGS. 5-6 are first and second side elevation views of the SYSTEM;
FIGS. 7-8 are first and second plan views of the SYSTEM;
FIG. 9 is a perspective view of the pin opener of the SYSTEM illustrating the base segment and the upper and lower flange segments connected to the base segment;
FIG. 10 is a side elevation view of the pin opener;
FIGS. 11-12 are front and rear axial views, respectively, of the pin opener;
FIG. 13 is a view of the inner side of the upper flange segment illustrating the mounting columns for connection to the lower flange segment;
FIG. 14 is a view of the inner side of the lower flange segment illustrating the mounting posts for connection to mounting columns of the upper flange segment; and
FIGS. 15-16 are views illustrating a sequence of operation of use of the SYSTEM.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to the drawings and, in particular, to FIGS. 1-8 , the hairpin and application system in accordance with the principles of the present invention is illustrated. The hairpin and application system 100 includes a hairpin support 102 , a plurality of hair clips or pins 104 mounted to the support 102 and a pin opener 106 . The pin support 102 includes a plurality of slots or openings 108 extending therethrough which receive the hairpins 104 . Four openings 108 are shown although more or less than four are contemplated. The openings 108 are spaced relative to each other to facilitate storage and removal of the hairpins 104 from the pin support 102 . It is contemplated that each opening 108 may contain a predetermined number of hairpins 104 specific to its intended use on the subject's hair. The pin support 102 may be in the form of a placard fabricated from any suitable rigid material including, e.g., cardboard, molded polymeric material, etc. The pin support 102 may have a supplemental opening 102 s to receive a display post of a display rack or the like. The pin support 102 defines an upper surface 102 u and a lower surface 102 l.
The hairpins 104 are of conventional design (e.g., bobby pins) incorporating a pair of resilient legs 110 interconnected by a hinge 112 ( FIGS. 3 and 4 ). The legs 110 are normally biased toward the closed position shown in the drawings. The legs 110 may be displaced relative to each other (e.g., pivoted outwardly about the hinge 112 ) and placed about a section of hair of the subject. Upon release of the displaced legs 110 , the legs 110 tend toward their normally closed position secured about the section of hair. The hairpins 104 may be fabricated from a resilient plastic or metallic material. The hairpins 104 are mounted to the pin support 102 by positioning one leg 110 through a respective opening 108 of the pin support 102 and advancing the hairpin 104 such that the hinge 112 is at least partially received within the opening 108 . The normal bias of the legs 110 toward the closed position will retain the hairpin 104 on the pin support 102 , i.e., the legs 110 securely engage the pin support 102 on the opposed upper and lower sides 102 u , 102 l thereof.
With reference now to FIGS. 9-14 , the pin opener 106 will be discussed. The pin opener 106 includes a base segment 114 and first (upper) and second (lower) flange segments 116 , 118 mounted on opposed ends of the base segment 114 . The base segment 114 defines a longitudinal axis “k” and has opposed generally diverging side segments 120 . The diverging side segments 120 taper outwardly relative to the longitudinal axis “k” from the front end 122 of the base segment 114 toward the rear end 124 of the base segment 114 . The diverging side segments 120 each may define an angle of taper “b” relative to the longitudinal axis “k” which continuously changes from the front end 122 of the base segment 114 toward the rear end of the base segment 114 . This provides a generally asymmetric, hyperbolic or parabolic profile to the diverging side segments 120 , which creates benefits with respect to opening of the hairpin 104 about the pin opener 106 as will be discussed. (See FIGS. 9 and 13 ) In the alternative, the diverging side segments 120 may define multiple angles relative to the longitudinal axis “k” or the angle of taper “b” may be constant. The diverging side segments 120 meet at the front end 122 of the base segment 114 to define a narrow profile about which the legs 110 of the hairpin 104 are positioned. The rear end 124 of the base segment 114 is generally round or arcuate.
The upper and lower flange segments 116 , 118 each may define an outer periphery generally corresponding in shape to the outer periphery of the base segment 114 . In embodiments, the upper and lower flange segments 116 , 118 are generally larger than the base segment 114 (when viewed in plan) such that the flange segments 116 , 118 extend beyond the outer periphery of the base segment 114 . This assists in maintaining the hairpin 106 relative to the base segment 114 during use of the pin opener 106 . The upper and lower flange segments 116 , 118 may be monolithically formed with the base segment 114 or may be separate components mountable to the base segment 114 through conventional means. In one embodiment best depicted in FIGS. 12-13 , in conjunction with FIG. 2 , at least the lower flange segment 118 is separate from the base segment 114 and the upper flange segment 116 is monolithically formed with base segment 114 . The inner side of the upper flange segment 116 includes a plurality of mounting columns 126 defining mounting openings 128 . The inner side of the lower flange segment 118 includes a plurality of mounting posts 130 . The mounting posts 130 are dimensioned and adapted to be passed through corresponding openings 132 with the support 102 ( FIG. 2 ) to be received with the mounting openings 128 of the mounting columns 126 to connect the components. A snap fit or frictional relationship established between the mounting posts 130 and the mounting columns 126 may maintain the components connected. In accordance with this embodiment, the mounting posts 130 may be secured within the mounting openings 128 through the establishment of a frictional relationship between the components, a snap fit relation, adhesives, cements, and/or combinations of any of these means etc.
With reference again to FIGS. 1-6 , the pin opener 106 is mounted to the pin support 102 in a manner to present the diverging side segments 120 of the base segment 114 to the user for application of the hairpin 104 . For example, the lower flange segment 118 may be secured to the lower surface 1021 of the pin support 102 such that major portions of the diverging side segments 120 are disposed above the upper surface 102 u of the pin support 102 . With this orientation, the diverging side segments 120 may be readily accessed to enable ready positioning of the legs 110 of the clip 104 about the front end 122 of the base segment 114 of the pin opener 106 . In particular, the legs 110 of each hairpin 106 may be advanced along the diverging side segments 120 to displace the legs 110 to cause opening thereof. The base segment 114 may extend for a distance above the upper surface 102 u of the pin support 102 ranging from about 2 millimeters to about 8 millimeters. The lower flange segment 118 may be secured to the pin support 102 with the use of adhesives or cements to also assist in securing the pin opener 106 to the pin support 102 , and maintaining the desired elevated orientation of the upper flange segment 116 relative to the pin support 102 .
Referring now to FIGS. 15-16 , the use of the system will now be discussed. The user removes a single hairpin 104 from the pin support 102 . The hairpin 104 is oriented relative to the pin opener 106 with the free ends of the legs 110 aligned with the front end 122 of the pin opener 106 . The hairpin 106 is advanced with respective legs 110 contacting the opposed diverging side segments 120 . Upon advancement onto the base segment 114 of the pin opener 106 , the legs 110 of the hairpin 104 slide on the diverging side segments 120 and move to an open position. The non-linear (e.g., hyperbolic or parabolic) profile of the diverging side segments 120 of the base segment 114 minimizes contact of the legs 110 with the diverging side segments 120 thereby reducing friction between the components and facilitating advancement of the hairpin 104 on the pin opener 106 . For example, the enlarged head 132 of the linear leg 110 of the hair clip 104 will contact the respective diverging side 120 and, due to the asymmetric profile of the diverging side 120 , contact is maintained generally with the enlarged head 132 while contact between the linear leg 110 l behind the enlarged head is minimized. Similarly with the bent leg 110 b , the enlarged head 134 and possibly the first bend apex 110 a contacts the diverging side 110 while contact of the remaining segment of the bent leg 110 b is minimized. During advancement of the hair clip 110 , the upper flange segment 116 and the upper surface 102 u of the clip support 102 will prevent the hairpin 104 from sliding off the base segment 114 during advancement of the hairpin 106 . Once opened, the hairpin 104 is grasped by the subject and applied to the hair in conventional manner.
The above description and the drawings are provided for the purpose of describing embodiments of the present disclosure and are not intended to limit the scope of the disclosure in any way. It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the disclosure. Thus, it is intended that the present disclosure cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents. | A method, apparatus and system for storing and distributing hairpins for application to the hair of a subject, includes a support having a support surface, a plurality of hairpins releasably coupled to the support and an opener mounted to the support. The opener includes a base segment defining a longitudinal axis and having opposed generally diverging side segments. The base segment at least partially extends beyond the support surface of the support to orient the diverging side segments in position whereby legs of each hairpin may be advanced along the diverging side segments to displace the legs to cause opening thereof. | 0 |
FIELD OF INVENTION
The present invention relates to ladder locking devices for ladders on motor homes, campers, vans, boats, construction sites, in schools, storage tanks, television and radio towers, tall buildings, silos, swimming pools, and other locations.
BACKGROUND OF THE INVENTION
It is often desirable to be able to prevent climbing access to ladders. This is especially true where ladders present an attractive nuisance to children, and where ladders provide ready access to vehicles, buildings, or towers. A child can be injured while climbing any ladder. There is a need for some type of ladder guard for preventing unauthorized use of ladders. The prior art includes several ladder guards.
In U.S. Pat. No. 2,880,829 (1959) Watkins discloses a shield used to cover the horizontal cross bars of a triangular tower. The triangular shield is self supported by a hook on its upper end that slips over a horizontal cross bar, thus suspending the device over a number of cross bars to effectively prevent ascension of the tower. Watkins' shield is only suited to triangular towers.
In U.S. Pat. No. 3,225,863 Ludlow (1965) discloses a hinged attachment to be affixed to a ladder to prevent the unauthorized use of the ladder. This device consists of a smooth panel covering several horizontal cross bars of a ladder which is side hinged to swing out allowing use of the ladder. Ludlow's construction is much more elaborate than the present invention and must be permanently installed.
In U.S. Pat. No. 3,311,195 Singer (1967) discloses a ladder guard designed primarily for use with above ground swimming pools. This is a safety device consisting of a flat panel covering several ladder steps to prevent small children from climbing up the ladder into the pool area. The Singer ladder lock employs hooks in a manner similar to the present invention, but does not allow for locking, and thus may be easily removed by children and others. The Singer device also is not adaptable for different sized ladders.
In U.S. Pat. No. 3,372,772 Singer (1968) discloses a device similar to his first but with the additional feature of a self-latching support mechanism which latches via a spring loaded tongue to the underside of the horizontal cross bars of the ladder. Singer's device is not adjustable and may be removed by anyone by merely pushing the spring-loaded tongues.
In U.S. Pat. No. 3,968,857 (1976) Bryan discloses a safety shield and support mechanism that can be attached to any type of ladder with horizontal cross members. The device consists of a support mechanism attached to the cross bars of the ladder. The support mechanism is bolted to the cross bars and thus is designed to be permanently affixed. A flat shield is locked onto the support mechanism. The flat shield covers several cross bars of the ladder to prevent ascension. Bryan's shield is very elaborate and must be permanently bolted to the ladder.
In U.S. Pat. No. 4,126,206 (1978) Becnel discloses a ladder guard consisting of two flat plates which are hinged together at the mid-point. The upper plate has a hook which slips over a horizontal cross bar of the ladder. The hinge allows the plates to be pulled outward from the ladder and to slip the lower plate between two cross bars and behind the ladder. This allows access to a locking device from the front of the ladder. Becnel's guard must be custom manufactured to fit a particular ladder.
In U.S. Pat. No. 4,181,195 (1980) Clarke discloses a ladder guard for use with recreational vehicles. The device consists of a flat panel that slips over an upper cross bar of the ladder and is suspended over the lower cross bars. The invention discloses a keyed locking mechanism that secures the ladder guard to a lower cross bar on the ladder. Clarke's guard is not adjustable and will not fit right for ladders with different rung spacing. The Clarke ladder lock also is not adaptable to different sized ladders, and few stores can afford the space to effectively display such a huge device.
In U.S. Pat. No. 4,450,937 (1984) Broughton discloses a step ladder with a flat panel on one side. This device can be attached, with the flat panel facing outward, to an existing ladder such as those found on recreational vehicles. The flat panel prevents the ascension of the ladder in order to prevent the theft of items stored on top of the recreational vehicle. The ladder can also be removed to provide a separate step ladder. Broughton's step ladder addresses a different need than the present invention.
In U.S. Pat. No. 4,579,197 (1986) Spurling discloses a safety device for use with above ground swimming pools. The flat shield is gravity supported at the base of the ladder. It rests up against the ladder and is secured by a locking bar that slips through two holes in the sides of the shield and behind the ladder. Spurling's device will not accommodate wide or narrow ladders. It also must rest on the ground and thus will not work on mobile ladders.
In summary the present invention solves two problems. First it is no longer necessary to custom fit a ladder guard to a particular ladder. Second it is no longer necessary to permanently mount a ladder guard to a particular ladder. The present invention is both portable and universally adaptable to all ladders.
SUMMARY OF THE INVENTION
The primary object of the present invention is to prevent unauthorized ladder use.
Another object of the present invention is to accommodate any ladder rung size and shape.
Another object of the present invention is to accommodate any ladder rung spacing.
Another object of the present invention is to provide simple construction for ease of manufacturing.
Another object of the present invention is to provide for ease of installation, removal, and use.
Another object of the present invention is to provide for portability.
Another object of the present invention is to provide for easy locking and unlocking.
Another object of the present invention is to allow use with a standard padlock.
Another object of the present invention is to provide a tool tray for use with a ladder.
Other objects of this present invention will appear from the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
The present invention is preferably made of two metal sheets bolted together. Each sheet has a hook assembly meant to wrap around a ladder rung. The two hook assemblies engage the top and bottom rungs to be covered. To attach to a ladder, the user first hooks the top of the ladder guard over the top rung to be protected, then loosens the nuts, thereby lowering the bottom sheet. The user then raises the bottom sheet to the point where the lower hook assembly engages the lower rung to be protected, then tightens the nuts. A standard padlock can then be used to lock the ladder guard in place.
A tool tray may also be mounted. In this arrangement the device serves as a holder for construction tools, paint or the like. The tool tray has a pair of a projecting bolts which easily fasten into slots in the sheets.
The hook assemblies can be constructed in two ways. In the first method, each sheet has a distal tongue, which is bent in the shape of a hook. The entire device then consists of only two metal sheets bent to shape, and connecting bolts.
In the second method, the two main sheets each have a distal tongue bent substantially perpendicular. An angled plate is bolted to the tongue, forming the hook assembly. The angle plates can be adjusted closer to or farther away from the main sheets. In this way any ladder may be accommodated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the ladder guard.
FIG. 2 is a front view of the ladder guard mounted on a wide ladder.
FIG. 3 is a front view of the ladder guard mounted on a narrow ladder.
FIG. 4 is a cross-sectional side view of the ladder guard mounted on a wide ladder viewed from 4--4 on FIG. 1.
FIG. 5 is a perspective view of the ladder guard with the tool tray in operation.
FIG. 6 is a perspective view of the tool tray.
Before explaining the disclosed embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown, since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1 a perspective view of the ladder guard 10 is shown. The ladder guard is extendible and may be mounted to as few as two or as many as four ladder rungs. In operation the ladder guard 10 prevents a would-be ladder climber from placing a foot on all but the top rung covered by the ladder guard 10. This has been found to be effective at preventing ladder use.
The ladder guard 10 is constructed of a metal top sheet 20 and a bottom sheet 22. The sheets are fastened with two connecting bolts 30. The bottom sheet 22 is configured with sheet slots 36 which allow the sheets to extend to span many rungs or to contract to span few rungs, depending on the needs of the user. The connecting bolts 30 are preferably carriage bolts, which have a square cross section near the non-threaded end. This square cross section then fits into a square hole in the top sheet 20. The connecting bolts 30 include normal hexagon shaped nuts or wing nuts. If wing nuts are used, the bolt ends are preferably ground or bent so that the wing nuts cannot be removed. Washers are also employed.
The top and bottom of the ladder guard 12 end in hook assemblies. In the preferred embodiment each hook assembly is adjustable so as to accommodate any ladder. The top sheet 20 includes the top tongue 21 and attaches to the top angled plate 24. The bottom sheet 22 includes the bottom tongue 23 and attaches to the bottom angled plate 26.
When the ladder guard 10 is attached to the ladder, a padlock 28 may be used to prevent removal. The padlock 28 prevents the top sheet 20 from moving relative to the bottom sheet 22. The padlock 28 is mounted through aligned holes in the top sheet 20 and the bottom sheet 22. The holes may be drilled during manufacture or by the user. One pair of padlock holes work, but two are preferred. If the two connecting bolts 30 are removed by a would-be ladder climber, two padlock holes provide more security. The padlock holes must be placed near the edge; otherwise the padlock could not be fastened.
An alternate embodiment (not shown) eliminates top angled plate 24 and bottom angled plate 26. Top tongue 21 and bottom tongue 23 are then shaped like a "U" or a "V" so as to hook onto rungs. While this alternate embodiment may not be as versatile, it is less expensive. Custom versions may be made for specific types of ladders, like those found on vans and motor homes.
Another alternate embodiment (not shown) employs lateral tabs on the top sheet 20, wrapping around the bottom sheet 22. This allows the two sheets to slide up and down but not to be tightened. A padlock is used to lock the ladder guard as with the preferred embodiment. This use of side tabs is conventional.
Referring next to FIG. 2 the ladder guard 10 is shown mounted on a wide ladder 60. The ladder guard 10 fits between the side rails 61 of the wide ladder 60 while still preventing use.
Most ladders are no wider than 13 inches between the outside of the side rails. The ladder guard 100 is preferably 13 inches wide. Some older wooden ladders are as wide as 16 inches, but only at the base, which is lower than the ladder guard would normally be mounted. In testing the device, the inventor has found that children were unable to ascend a ladder with as much as one inch of rung space. Thus even the widest ladders in common use cannot be ascended with the ladder guard 100 installed.
Referring next to FIG. 3 the ladder guard 100 is shown mounted on the narrow ladder 64. The ladder guard 100 completely overlaps the side rails 65 of the narrow ladder 64, thereby preventing ascension. The preferable sheet width d71 of the ladder guard 10 is 13 inches. Most recreational vehicles have a ladder width of 13 inches. The preferable tongue width d72 is 8 inches. This allows the ladder guard to fit ladders with inside rails as narrow as 8 inches. The length d70 ranges from 22 inches to 29 inches when fully extended.
Referring next to FIG. 4 a cross-sectional side view of the ladder guard 10 is shown. Top angled plate 24 and bottom angled plate 26 engage the rungs 620 of wide ladder 600. The padlock 28 prevents removal of the ladder guard 10. Dimensions are detailed in Table 1.
The top sheet 20 has a top tongue 21 that extends inward and is bent 70 degrees to form a 110 degree angle. The top angled plate 24 is bent 110 degrees to form a 70 degree angle. The most distal plane of the top angled plate 24 is therefore parallel with the plane of the top sheet 20 and the bottom sheet 22. The top angled plate 24 is attached to the top tongue 21 with two top hook bolts 32. Slots permit adjustment for wider or narrower rungs.
The bottom sheet 22 has a bottom tongue 23 that extends inward and is bent 110 degrees to form a 70 degree angle. The bottom angled plate 26 is bent 70 degrees to form a 110 degree angle. The most distal plane of the bottom angled plate 26 is therefore parallel with the plane of the top sheet 20 and the bottom sheet 22. The bottom angled plate 26 is attached to the bottom tongue 23 with two bottom hook bolts 34. Slots permit adjustment for wider or narrower rungs.
The 70 degree and 110 degree angles in the hook assemblies are formed so that the ladder guard 10 fits well on standard ladders, which are meant to be used at a 70 degree angle and have rungs angled at 70 degrees.
This angled construction ensures a good fit on the rungs of most ladders, and also works well on ladders with round rungs. The top hook bolts 32 and bottom hook bolts 34 further act to prevent lateral motion when in place by digging in to the surface of the engaged rungs.
Referring next to FIG. 5 an alternate use of the ladder guard 10 with tool tray 42 is shown. The tool tray 42 supports paint can 44, and can accommodate other construction tools. The ladder guard 10 is not meant to be locked in place while being used for holding tools. Only the top hook assembly needs to engage a ladder rung. The ladder guard works well as a tool tray holder without gripping the bottom rung.
The tool tray 42 can be mounted on the front side of the ladder guard 10 as shown, or alternatively mounted on the back side (not shown) depending on the needs of the user.
Referring next to FIG. 6 details of the tool tray are shown. The tool tray 42 is attached to the ladder guard 10 with mounting bolts 46, which fit into key shaped slots (not shown) in the top sheet 20 or the bottom sheet 22. The mounting bolts 46 are not meant to be tightened in use, and may be rivets. This construction is a well known means of fastening objects. Alternatively connecting bolts 30 could be used to mount the tool tray 42.
The front angled mounting plate 47 allows for the tool tray 42 to remain level for use on a standard angled ladder. Most ladders are angled 70 degrees while in use. The tool tray 42 may be mounted on the back side of the top sheet 20 and the bottom sheet 22, in which the back angled mounting plate 48 is used instead of the front angled mounting plate 47.
Although the present invention has been described with reference to preferred embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred.
Table 1--Ladder Guard Dimensions
d70--working length--varies from 22 inches to 29 inches
d71--sheet width--13 inches
d72--tongue width--8 inches
d73--tongue length--2.5 inches
d74--proximal angled plate length--2.0 inches
d75--distal angled plate length--1.5 inches | The invention is a ladder guard which prevents unauthorized access to a ladder. Preventing injury to children is a primary goal of the invention. The ladder guard has a top and a bottom hook extending from two metal sheets. The hooks can be adjusted to go between two to four ladder rungs, thus preventing use of the covered rungs. The top and bottom hooks are adjustable to fit any size rungs. The metal sheets may be locked to prevent removal. A tool tray is also mountable when the ladder is in use. The invention works with all known ladders. It is, therefore, a removable universal fitting ladder guard. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 11/038,780, filed Jan. 18, 2005, which claims the benefit of U.S. Provisional Application No. 60/537,153, filed Jan. 16, 2004, the disclosures of which are hereby expressly incorporated by reference in their entirety.
BACKGROUND
[0002] Blasting technologies have expedited mining operations, such as surface mining and subterranean mining, by allowing the strategic and methodic placement of charges within the blasting site. Despite this, blasting technologies still carry safety risks that should be minimized. Effective blasting requires not only well-placed detonators, but also timed detonation of the charges, preferably in a predetermined sequence. Accordingly, accurate and precise control and firing of the detonators is important for effective and efficient blasting. The more precise and accurate control of the detonators also leads to an increase in safety of the system overall. Thus, it is desirable to have a blasting system that effectively and efficiently controls the detonation of various types of charges while simultaneously increasing the overall safety of the system.
SUMMARY
[0003] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0004] In accordance with the disclosed subject matter, a remote firing system, a controller device, a remote device, and a method for remotely detonating explosives is provided. The system form of the disclosed subject matter includes a remote firing system that comprises a set of remote devices. Each remote device is capable of communicating a safety data structure that contains a system identifier for identifying the remote firing system from other remote firing systems and a device identifier for identifying a remote device from other remote devices. The remote firing system further includes a controller device for causing the set of remote devices to trigger detonators. The controller device is capable of selecting a subset of the set of remote devices for triggering detonators and further being capable of communicating the safety data structure that contains a system identifier for identifying the remote firing system from other remote firing systems and device identifiers for identifying the subset of remote devices to control.
[0005] In accordance with further aspects of the disclosed subject matter, a device form of the disclosed subject matter includes a controller device that includes a set of selection and information panels that correspond with a set of remote devices. A subset of selection and information panels is selectable to cause a corresponding subset of remote devices to be selected for detonating explosives. The controller device further includes a communication module for transmitting and receiving safety communication. The communication module is capable of communicating with the subset of remote devices to indicate their selection for detonating explosives by the controller device.
[0006] In accordance with further aspects of the disclosed subject matter, a remote device that includes a communication module for transmitting and receiving a safety data structure that contains a system identifier for identifying a remote firing system that comprises the remote device and a device identifier for identifying the remote device. The remote device also includes a memory for recording state changes of the remote device. The remote device further includes a switch for selecting either shock-tube detonator initiation or electric detonator initiation.
[0007] In accordance with further aspects of the disclosed subject matter, a method for remotely detonating explosives. The method includes selecting a subset of a set of selection and information panels on a controller device to cause a corresponding subset of remote devices to be selected for detonating explosives. The method further includes issuing an arming command by the controller device to the subset of remote devices to cause the subset of remote devices to prepare for detonation. The method yet further includes issuing a firing command by the controller device to the subset of remote devices by simultaneously selecting dual fire switches together on the controller device to cause the subset of remote devices to detonate explosives.
DESCRIPTION OF THE DRAWINGS
[0008] The foregoing aspects and many of the attendant advantages of the disclosed subject matter will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0009] FIG. 1 is a pictorial diagram showing a plan view of an open pit surface mine, wherein conventional blasting techniques are employed;
[0010] FIG. 2 is a pictorial diagram showing a cross-sectional illustration of a subterranean mining operation;
[0011] FIG. 3 is a pictorial diagram illustrating a remote firing system using safety communication according to one embodiment;
[0012] FIG. 4 is a pictorial diagram of a controller device user interface, in accordance with one embodiment;
[0013] FIG. 5 is a pictorial diagram illustrating a remote device user interface, in accordance with one embodiment;
[0014] FIG. 6 is a block diagram showing various inputs, outputs, and internal control modules for a controller device, in accordance with one embodiment;
[0015] FIG. 7 is a block diagram showing various inputs, outputs, and internal control modules for a remote device, in accordance with one embodiment;
[0016] FIG. 8 is a block diagram showing various inputs, outputs, and internal modules for a blasting machine, in accordance with one embodiment;
[0017] FIG. 9 is a process diagram illustrating a method for communicating by a controller device using secure communication, in accordance with one embodiment; and
[0018] FIG. 10 is a process diagram illustrating a method for receiving and processing by a remote device messages containing security protocol information, in accordance with one embodiment.
DETAILED DESCRIPTION
[0019] FIG. 1 depicts a plan view of surface mining in an open pit mine 100 . By way of example, there may exist one or more groups of explosives 102 , known as shots. Although not shown, other shots may be situated in various locations throughout the mine depending on where the blasting will occur. The shot 102 (and all of the detonators within the shot) may be tethered to a blasting machine 104 , or it may be tethered directly to a remote device 106 . The blasting machine 104 is further tethered to the remote device 106 , which is in communication with a controller 108 . The blasting system is controlled by an operator 110 at the controller 108 . The operator 110 may initiate a blasting sequence by transmitting one or more signals using the controller 108 to the remote device 106 , which may command the blasting machine 104 to initiate the detonators in the shot 102 depending on the type of detonators. While FIG. 1 shows the blasting machine 104 , the remote device 106 , and the controller 108 in communication wirelessly or by wire, one of skill in the art will appreciate that any type of communication link may also be used between the varying devices.
[0020] In the open pit mine 100 , a danger area 112 is associated with loose rock, known as fly rock, which can be thrown great distances by the explosive force released upon detonation of the shot 102 . To ensure safety, the blasting machine 104 , the remote device 106 , the controller 108 , and the operator 110 is suitably be located outside the perimeter of the danger area 112 . Similarly, vehicles and other mine employees (not shown) are suitably also be located outside the perimeter of the danger area 112 . Although mine personnel (not shown), known as spotters, guard areas of ingress to the mine that cannot be observed by the operator 110 , there still exists a danger that someone or something will enter the danger area 112 . There also exists a risk of third-party access to any of the communication links between the devices. Accordingly, various embodiments of the disclosed subject matter, as discussed in more detail below, provide for additional safety features within the controller 108 and the remote device 106 to mitigate the safety risks.
[0021] FIG. 2 depicts a cross-sectional view of blasting carried out in a subterranean mine 200 . As in surface mining (as seen in FIG. 1 ), a blasting machine 204 and a lead line 203 are used to detonate explosives in headings 202 A-D. As with surface mining, shots containing the explosive charges are placed in the headings 202 A-D of working shafts 214 A-B. The working shafts 214 A-B connect to a main shaft 212 . The main shaft 212 leads to the surface and carries the lead line 203 from the blasting machine 204 located at the surface, to the headings 202 A-D. Due to the dangers of cave-ins for subterranean mining, entire mines are generally shut down and evacuated prior to detonation of explosives. This requires evacuation of both an operator 210 and other mine personnel (not shown) to the surface. As in surfacing mining, the safety features of the various embodiments of the disclosed subject matter decrease the risk associated with blasting operations.
[0022] FIG. 3 depicts a generalized view of a blasting system 300 as used in surface mining ( FIG. 1 ), subterranean mining ( FIG. 2 ), or the like. A group of explosives 302 include various detonators. Depending on the type of detonator in the group of explosives 302 , it may be coupled directly to a remote device 306 , or it may be coupled to a blasting machine 304 , which in turn is coupled to the remote device 306 . The remote device 306 is in communication with a controller 308 , which receives inputs 310 from an operator, such as the operator 110 in FIG. 1 , or from some other input source. As noted above, while FIG. 3 depicts various communication links between devices as either wired or wireless, one of skill in the art will appreciate that any type of communication link may be used as long as the information transmitted is accurate.
[0023] According to various embodiments of the disclosed subject matter, the detonators in the group of explosives 302 are detonated by the blasting machine 304 or the remote device 306 when an ARM (enables the initiator or charging mechanism in the detonator) and/or a FIRE (releases the initiator or charging mechanism in the detonator) command is sent. The blasting machine 304 or the remote device 306 may also discharge the initiator or charging mechanism in the detonator upon receiving a DISARM command from the remote device 306 . The DISARM command may initiate in the controller 308 or in the remote device 306 , as discussed in more detail below. If the blasting machine 304 receives a STATUS command from the remote device 306 , information relating to the status of a detonator in the group of explosives 302 will be sent to the remote device 306 . Status information includes, for example, arming/disarming of the detonator, or a status error in firing of the detonator.
[0024] The remote device 306 sends messages to the blasting machine 304 as previously noted, but also sends and receives messages by way of the controller 308 . According to various embodiments of the disclosed subject matter, and as will be discussed in more detail below, the remote device 306 and controller 308 communicate using a security protocol, such as a code word embedded in the transmitted signal, to ensure authenticity of the message communicated and so that third-parties cannot interfere with messages received or sent. Additionally, the controller 308 receives the inputs 310 to manage the blasting operation by configuring to send arming, disarming, and firing commands from the controller 308 to the remote device 306 , which may in turn send the commands to the blasting machine 304 for firing or disarming of the detonators in the group of explosives 302 .
[0025] FIG. 4 illustrates an exemplary front panel for a controller device user interface 400 in accordance with one embodiment of the disclosed subject matter. Any suitable number of remote devices (not shown) are controllable from the controller device user interface 400 . The left portion of the controller device user interface 400 includes selection and remote device panels 402 A-H for eight remote devices. Each remote device panel 402 A-H includes membrane switches 404 A-H that allows selection or deselection of an associated remote device. Further, each remote device panel 402 A-H includes labeling and light indicators, such as LEDs or the like, for a READY state 406 , ARMED state 407 , battery condition 408 , and selected state 409 of the associated remote device.
[0026] The right portion of the controller device user interface 400 includes a controller device interface, an informational interface, and a user input section interface. The controller device interface includes an external antenna connection port 410 , an electronic key interface 412 , and a programming port 414 . The informational interface includes a controller device battery status panel 420 , including labeling and light indicators, such as LEDs or the like, for a slow charge 421 , a fast charge 422 , a 20% remaining battery capacity 423 , a 40% remaining battery capacity 424 , a 60% remaining battery capacity 425 , a 80% remaining battery capacity 426 , and a 100% remaining battery capacity 427 . These percentages of remaining battery capacity are arbitrarily selected and other percentages, or different styles of display, can be substituted in other embodiments without departing materially from the scope of the disclosed subject matter.
[0027] The informational interface includes a panel 430 containing labeling and indicator lights, such as LEDs or the like, for a device power 432 , an electronic key status 434 , a device transmitting 436 , and a device receiving 438 . Additionally, the user input selection interface comprises panels 440 , 444 , 450 , 453 , 460 , 463 , 470 , and 473 . The panel 440 is used for placing a controller device in the ON state with the membrane switch 442 . The panel 444 is used for placing a controller device in the OFF state with the membrane switch 446 . The panel 450 is used for selecting a status query operation with the membrane switch 452 . The panel 453 is used for placing the controller device battery status panel 420 in an ON or OFF state by cycling the membrane switch 455 . The panel 460 is used for selecting an ARM command operation with the membrane switch 462 . The panel 463 is used for selecting a DISARM command operation with the membrane switch 465 . The dual panels 470 and 473 are used for selecting a FIRE command operation with the dual membrane switches 472 and 475 .
[0028] The panels 450 , 453 , 460 , 463 , 470 , and 473 further include labeling and indicator lights 451 , 454 , 461 , 464 , 471 , and 474 , respectively, such as LEDs or the like. Combinations of the aforementioned light indicators can be used to indicate device conditions. One example is flashing of all light indicators when the device is placed in the ON state, which also indicates the initiation of a self-testing operation. Other suitable combinations are possible as well.
[0029] FIG. 5 illustrates an exemplary front panel 500 for a remote device user interface 502 . The remote device user interface 502 includes an external antenna port 504 and a programming port 506 . The remote device user interface 502 further includes an electronic initiator port (not shown) connected to the blasting machine, as well as a lead line connection port 508 for connecting lead lines directly to the detonators. The electronic initiator port may be located on the side of the remote device 306 or other suitable location. One of ordinary skill will also appreciate that the electronic port may be a serial port or other suitable port, and it may use a suitable communication protocol when communicating with the blasting machine. For example, the blasting machine and the electronic initiator port may communicate using protocol RS232, or the like.
[0030] As further seen in FIG. 5 , the lead line connection port 508 is shown on the face of the remote device user interface 502 , but may be located on the left sidewall of the remote device or other suitable location on the remote device. An output select switch 509 selects an initiation method associated with panels 510 , 520 , or 530 . In accordance with one embodiment, the output select switch 509 may be a mechanical toggle switch. In other embodiments, the output select switch 509 may be a pushbutton switch, or other switch capable of selecting one initiation method at a time. The panels 510 , 520 , or 530 each correspond to different types of detonators. The panel 530 is used for electronic detonators connected to the blasting machine 304 through the electronic initiator port. The panel 510 is used for electric detonator initiation, and the panel 520 is used for shock tube detonator initiation. Both types of detonators are connected to the remote device 306 through the lead line connection port 508 .
[0031] The electric detonator panel 510 , the shock tube initiator panel 520 , and the electronic initiator panel 530 all include labeling and light indicators 512 , 514 , 522 , 524 , 532 , and 534 , respectively, such as LEDs or the like, for READY and ARMED status. The remote device user interface 502 further includes an electronic key panel 540 and a battery charger panel 550 . The electronic key panel 540 includes a connection port 548 to couple to an electronic key; three light indicators 542 , 544 , and 546 , such as LEDs or the like, which indicate remote device transmission, electronic key status, and remote device receiving in accordance with safety communication ability of various embodiments of the disclosed subject matter. A battery charger panel 550 includes a labeling and light indicator 552 , such as an LED or the like, for indicating connectivity to a battery charger. Two additional light indicators 554 and 556 with labeling, indicate slow and fast charging rates.
[0032] A power panel 560 on the remote device user interface 502 is used for placing the remote device in an ON or OFF state, and includes a labeling and light indicator 562 , such as an LED or the like, and a remote device power switch 564 . A remote device battery status panel 570 includes a switch 574 for activating a battery status display 572 , such as a digital voltmeter, for example. In accordance with one embodiment, switches 564 and 574 may be mechanical momentary push button switches, or other suitable switches.
[0033] In one embodiment of the disclosed subject matter, combinations of the aforementioned light indicators on the remote device user interface 502 are used to indicate various device conditions. One such example is the slow charge light indicator 554 being lit and the fast charge light indicator 556 being dark to indicate a fully charged battery. Given that there is not an exhaustive list of all combinations of light indications for various other conditions experienced while operating a blasting operation in accordance with the disclosed subject matter, other combinations of light indicators are possible.
[0034] FIG. 6 is a block diagram of internal functional modules, inputs, and outputs for a controller device 600 . Inputs to the controller device 600 can be received as information stored on an electronic key 602 , information from an interlock device 604 , information from user inputs 606 , and information from an antenna 608 . The internal functional modules are coupled to the electronic key 602 , interlock device 604 , and user inputs 606 , and include an electronic key module 610 , programming port module 612 , self-test module 614 , battery status module 616 , controller device user interface module 618 , timer module 620 , remote device selection module 622 , controller device mode module 624 , controller device command module 626 , and communications module 628 for transmitting and receiving safety communication. Safety communication is preferably achieved by transmitting and receiving safety data through the external antenna 608 coupled to the communications module 628 . Other devices, including but not limited to radio repeaters and leaky feeder systems, can be connected in place, or in addition to, the external antenna 608 without departing materially from the scope of the disclosed subject matter.
[0035] The electronic key module 610 serves as a coupling interface between the controller device 600 and external electronic key 602 . Information stored on the electronic key 602 is read into the internal memory (not shown) of the controller device 600 for processing. The controller device 600 may also write information onto the electronic key 602 through the electronic key module 610 .
[0036] The programming port module 612 serves as a coupling interface between the controller device 600 and an external programming device, such as a digital computer or the interlock device 604 . The external programming device may allow, for example, information stored in certain memory locations (not shown) to be read out of the controller device 600 , information to be written into certain memory locations (not shown) in the controller device 600 , or modification of settings for the controller device 600 , among others. Many operations can be conducted through the programming port module 612 , and it may be implemented using a 14-pin DIN type connector or other suitable connectors, designating various conductors for functionality such as battery charger contacts, the interlock device 604 input contacts, programming function contacts, and contacts for additional future functionality, among others.
[0037] The self-test module 614 tests the internal circuitry and functionality of the controller device 600 for faults. The self-test module 614 indicates component failures by flashing indicator lights, such as LEDs or the like, on the controller device 600 , as discussed previously. Other suitable methods of indicating self-test results can be used without departing from the scope of the disclosed subject matter.
[0038] The battery status module 616 displays the status and condition of a battery (not shown) in the controller device 600 . The battery status module 616 may include a battery capacity display, such as a gas-gauge style digital display, battery condition indicators, such as the previously discussed flashing indicator light 454 on the controller device user interface panel 400 , and recharge rate indicator lights, such as LEDs, on the panel 420 , among others. Other suitable displays and indicators can be used without departing from the scope of the disclosed subject matter.
[0039] The controller device user interface module 618 handles all user input for the controller device 600 not handled by the remote device selection module 622 , controller device mode module 624 , or controller device command module 626 . Functions carried out by the controller device user interface module 618 include functions such as turning a battery meter ON or OFF, among others.
[0040] The timer module 620 can be implemented mechanically, with discrete electronics, with software, or by some combinations thereof. Preferably, the timer module 620 is used for the controller device 600 features requiring elapsed time information. For example, the timer module 620 may have a countdown timer that triggers the execution of a DISARM command as an automatic safety feature. When the controller device 308 , as seen in FIG. 3 , transmits an ARM command to the remote device 306 , the timer module 620 may begin a countdown sequence in which the controller 308 must initiate a FIRE command to the remote device 306 . If there is no fire command initiated before the timer module 620 ends the countdown sequence, a DISARM command will be sent to the remote device 306 , and the detonators will be disarmed.
[0041] The remote device selection module 622 serves as an interface for the operator 110 allowing specific remote devices to be either selected or deselected. Preferably, multiple remote devices can be contemporaneously selected and operated from a single controller device. Additionally, it is preferable that the controller device command module 626 serve as the operator interface to selectively initiate command signals. The available commands may include ARM, FIRE, DISARM, and STATUS (querying the status of remote devices), among others. Other suitable commands can be used without materially departing from the scope of the disclosed subject matter.
[0042] The controller device mode module 624 serves as the operator interface for selecting the operating mode of the controller device 600 . The controller device mode module 624 may include NORMAL (signifying normal operation mode), PROGRAMMING (signifying programming mode), and QUERY (signifying safety communication query mode, such as the SAFETY POLL™ query facility offered by Rothenbuhler Engineering Co.), among others. The NORMAL mode is preferably the default mode and is used for detonating explosives. The PROGRAMMING mode preferably allows the controller device 600 to function as a programming device for programming electronic keys, or other programmable options. The QUERY mode is preferably used to automatically test safety communication between the controller device 600 and selected remote devices (not shown). Additional suitable modes or suitable modifications of the listed modes can be included in the controller device mode module 624 without departing from the scope of the presently disclosed subject matter.
[0043] The communications module 628 serves to enable safety communication between the controller 308 and other system devices through a transmission medium. Preferably, the communications module 628 includes a 5-watt maximum power radio transceiver for transmission and reception of radio frequency signals in the kHz to MHz range. Any suitable power or frequency range can be used for the transceiver without departing materially from the scope of the disclosed subject matter, and other suitable methods of communication besides wireless communication may also be used.
[0044] FIG. 7 is a block diagram of the internal functional modules, inputs, and outputs for a remote device 700 . Inputs to the remote device 700 include information contained on an electronic key 702 , information received from user inputs 704 , safety communications can be received or transmitted by an external antenna 706 , and signals initiating a shot are output to a blasting machine (not shown) by a lead line interface 708 . The internal functional modules include modules such as an electronic key module 710 , remote device user interface module 712 , self-test module 714 , programming port module 716 , battery status module 718 , memory module 720 , timer module 722 , communications module 724 , remote device output mode module 726 , and remote device operating mode module 728 , among others.
[0045] The electronic key module 710 serves as a coupling interface between the remote device 700 and electronic key 702 . Further, information stored on the electronic key 702 can be read into the memory module 720 for processing by the remote device 700 through the electronic key module 710 . Additionally, it is preferable that the remote device user interface module 712 handle all user input received by the remote device 700 not handled in the remote device operating mode module 728 , or remote device output mode module 726 . The remote device user interface module 712 further includes functions such as turning a battery meter ON by depressing a momentary switch, among others.
[0046] The self-test module 714 tests the internal circuitry and functionality of the remote device 700 for faults. The self-test module 714 indicates component failures by flashing indicator lights, such as LEDs or the like, on the remote device user interface 502 as previously discussed. Other suitable methods to indicate self-test results can be used.
[0047] The programming port module 716 serves as a coupling interface between the remote device 700 and an external programming device (not shown), for example a digital computer. The external programming device may allow, for example, information stored in certain memory locations to be read out of the remote device 700 , information to be written into certain memory locations on the remote device 700 , or modification of internal remote device settings, among others. Many other suitable operations can be conducted through the programming port module 716 , and the programming port module 538 may also be implemented using a 14-pin DIN type connector or other suitable connectors, designating various conductors for functionality such as battery charger contacts, programming function contacts, and contacts for additional future functionality, among others.
[0048] The battery status module 718 displays the status and condition of a battery (not shown) in the remote device 700 . The battery status module 718 may include a battery capacity display, such as a digital display, battery condition indicators, such as the previously discussed flashing indicator lights on the remote device user interface 502 , and recharging rate indicator lights, such as LEDs or the like, among others. Other suitable displays or indicators can be used.
[0049] The memory module 720 may be implemented in the remote device 700 as an internal memory. In addition to the information that may be read from and written to the memory module 720 as discussed above, the memory module 720 stores a history log (not shown) of each remote device 700 . The history log of each remote device 700 records state changes in the remote device 700 and the time those changes occur. For example, if the remote device 700 is in an ARMED state and subsequently issues a FIRE command to initiate detonation, a state change from ARMED to FIRE will be recorded, with the time of the change, in the history log. By recording each change in state for each remote device 700 , better and more accurate diagnostics may be performed to evaluate timing problems or other errors during operation. The history log of each remote device 700 may also be password protected so as to prevent unauthorized access.
[0050] The timer module 722 can be implemented mechanically, with discrete electronics, with software, or by some combination thereof. Preferably, the timer module 722 is used for remote device features requiring elapsed time information. For example, as with the timer module 620 of the controller device 600 as above, the timer module 722 may initiate a countdown timer that, when finished, will trigger a DISARM command to disarm the remote device 700 if the remote device 700 has been ARMED and not FIRED within a specified time period. Preferably, the timer module 722 serves as a backup to the timed disarm sequence in the timer module 620 in the controller device 600 as previously discussed.
[0051] The communications module 724 serves to enable safety communication between the remote device 700 and other system devices via a transmission medium. Preferably, the communications module 724 includes a 1-watt maximum power radio transceiver for transmission and reception of radio frequency signals in the kHz to MHz range. Any suitable power or frequency range may be used for the transceiver without departing materially from the scope of the presently disclosed subject matter. Further, other suitable methods of communication may be used.
[0052] The remote device output module 726 serves as an interface for the operator 110 that allows method selection for initiating a remote detonation (such as electric detonators, shock tube initiators, or electronic initiators, among others). Additionally, it is preferable that the remote device operating mode module 728 serve as an interface to select the operating mode of the remote device 700 . The remote device operating mode module 728 may include NORMAL (signifying normal operation mode) and PROGRAMMING (signifying programming mode), among others. The NORMAL mode is preferably the default mode and is used for detonating explosives. The PROGRAMMING mode preferably allows the remote device 452 to be programmed with a semi-permanently assigned device identifier. Additional suitable modes or suitable modifications of the listed modes can be included in the remote device operating mode module 728 .
[0053] FIG. 8 is a block diagram of various components in a blasting machine 800 in accordance with aspects of the presently disclosed subject matter. A remote device interface 802 is coupled to the remote device 306 , for example, for communication between the blasting machine 800 and remote device 306 . A central processing unit 804 carries out processing functions of the blasting machine 800 , including communication with the remote device 306 and sending commands to detonators. A memory 810 of the blasting machine 800 may be used in conjunction with the central processing unit 804 , but may also store data on attached detonators for further communication. A self-test module 806 tests the internal circuitry and functionality of the blasting machine 800 for faults. If the self-test module 806 detects failures, the blasting machine 800 will communicate the fault information to the remote device 306 , which will in turn communicate the fault information to the controller 308 . Depending on the fault detected by the self-test module 806 of the blasting machine 800 , indicator lights, such as LEDs or the like, on the controller device user interface 502 , as previously discussed, may indicate an error. Other suitable methods to indicate self-test results may also be used.
[0054] A battery status module 808 monitors and communicates the status and condition of the battery (not shown) in the blasting machine 800 . The battery status module 808 may include a battery capacity display, such as a digital display, battery condition indicators, such as the previously discussed flashing indicator lights on the remote device user interface 502 , and recharging rate indicator lights, such as LEDs or the like, among others. Other suitable displays or indicators may be used.
[0055] A lead line interface 812 of the blasting machine 800 connects to each detonator in the group of explosives 302 , and communicates with each detonator in the group of explosives 302 . This includes sending initiation commands when the blasting machine 800 receives a FIRE command from the remote device 306 , and also includes receiving status information about each detonator in the group of explosives 302 . As discussed above, status information about each detonator in the group of explosives 302 may, in turn, be communicated to the remote device 306 and stored in the history log in the memory module 720 .
[0056] FIG. 9 is a flow chart describing a preferred method 900 for the controller 308 to securely communicate with the remote device 306 . Since the remote device 306 is the only point of entry for commands to the blasting machine 304 and to the group of explosives 302 , it is important that there be established a way of ensuring the commands received at the remote device 306 are from the controller 308 . According to a preferred method in accordance with the presently disclosed subject matter, at a block 902 , the controller 308 initializes a code word to be sent with every data packet message communicated to the remote device 306 . The code word preferably consists of 32 bits, but may have more or less bits depending on the communication protocol between the controller 308 and remote device 306 , and the level of security desired for communications from the controller 308 .
[0057] At a block 904 , the initialized code word from block 902 is inserted into the outgoing data packet message and sent to the remote device 306 . After the controller 308 has sent the data packet message with the initialized code word, the code word is incremented at a block 906 by the controller 308 . This newly incremented code word will be inserted into the next data packet message sent to the remote device 306 from the controller 308 . One of skill in the art will recognize that any type of incrementing will work, and need not be expressly communicated to the remote device 306 , as long as the code word is incremented in some way from the initialized code word.
[0058] FIG. 10 is a flow chart describing a preferred method 1000 of receiving a message at the remote device 306 and validating the source of that message. The remote device 306 receives a data packet message at a block 1002 . The entire data packet message may be checked for accuracy using error correcting techniques, such as CRC error checking or the like. In a block 1004 , the remote device 306 must check to see if the received data packet message is the first received message from the controller 308 . One of skill in the art will appreciate there may be a number of ways to do this. By way of example, the remote device 306 may have a data packet message counter that counts the number of valid messages received. Initially such a counter would be at zero, but after receiving the data packet message with the initialized code word from the controller 308 , the remote device 306 would recognize the data packet message as a first message, increase the message count, and store the code word in the remote device 306 , as in a block 1006 . Any other suitable method for determining if a data packet message is a first message may be used, however, without departing from the scope of the presently disclosed subject matter.
[0059] If the data packet message received is not a first message, then the code word from the received message is compared against the stored code word in the remote device 306 , as in a block 1008 . If the received code word is incremented compared to the stored code word, then in a block 1012 the data packet message is accepted as valid from the controller 308 and executed. The new code word received from the valid data packet message is then stored in the remote device 306 as the new code word as in a block 1006 . If the code word received is not incremented compared to the stored code word, then the data packet message is ignored, as in a block 1010 . By comparing received code word and stored code word in a block 1008 to see if the code word has been incremented, the blasting system introduces a level of safety that works to prevent third-party access to the remote device 306 and thus to the explosives.
[0060] While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the disclosed subject matter. | A remote firing system for remotely detonating explosive charges includes features that provide safety and efficiency improvements. These features include safety communication among multiple remote devices and multiple controller devices, a polling functionality permitting rapid deployment of system devices, electronic key systems, programmable remote devices for easy replacement of failing remote devices, and an event history log for the remote devices for efficient diagnostic evaluation. | 5 |
FIELD
The present disclosure relates generally to systems and methods for photosensitive pixels with gain stage, and more specifically to photosensitive pixels with gain stage with linear and logarithmic output modes.
BACKGROUND
Photosensitive pixels are frequently used in devices that detect light stimuli. For instance, photosensitive pixels may be used in devices that detect light stimuli of various intensities. For instance, some light stimuli are often very weak, whereas others are often very strong. A photosensitive pixel may be implemented to detect the light stimuli and amplify a resultant electronic signal. However, many such photosensitive pixels are configured for sensitivity to weak stimuli or for tolerance to strong stimuli, hindering the functioning of such photosensitive pixels under a variety of operating circumstances and providing inadequate sensitivity and/or inadequate dynamic range.
SUMMARY
The forgoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated herein otherwise. These features and elements as well as the operation of the disclosed embodiments will become more apparent in light of the following description and accompanying drawings.
A photosensitive pixel with gain stage is disclosed. The photosensitive pixel with gain stage may include a photodetector module configured to receive an input light stimulus and induce a detection current into a detection node in response to the magnitude of the input light stimulus, a current mirror module including a mirrored current node and configured to induce a mirrored current on the mirrored current node in response to the detection current, and a mode threshold control module including an output node and configured to induce at a current on the output node corresponding to a combination of the magnitude of the input light stimulus and an amplifier mode.
A photosensitive pixel with gain stage may include a photodetector module configured to receive an input light stimulus and induce a detection current into a detection node in response to a magnitude of the input light stimulus, a current mirror module having a mirrored current node and configured to induce a mirrored current on the mirrored current node in response to the detection current, and a mode threshold control module with an output node and configured to induce a current on the output node corresponding to a combination of the magnitude of the input light stimulus and an amplifier mode. The photodetector module may include a detector configured to detect the magnitude of the input light stimulus, a bias control amplifier connected to the detector, and a bias control transistor connected to the bias control amplifier and configured to induce the detection current into the detection node in response to the magnitude of the input light stimulus. The detector may include a reverse biased light sensitive diode having an anode and a cathode. The amplifier mode may include at least one of a linear integral correlation to the magnitude of the input light stimulus and a logarithmic correlation to the magnitude of the input light stimulus, and wherein the current mirror module has two n-channel field effect transistors.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements.
FIG. 1 illustrates a dual-mode photosensitive pixel with gain stage according to various embodiments; and
FIG. 2 illustrates example behavior of a dual-mode photosensitive pixel with gain stage according to various embodiments.
DETAILED DESCRIPTION
The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice embodiments of the disclosure, it should be understood that other embodiments may be realized and that logical changes and adaptations in design and construction may be made in accordance with this invention and the teachings herein. Thus, the detailed description herein is presented for purposes of illustration only and not limitation. The scope of the disclosure is defined by the appended claims. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact.
Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Surface shading lines may be used throughout the figures to denote different parts but not necessarily to denote the same or different materials.
As mentioned throughout, an input light stimulus may be in form of electromagnetic radiation. For example, the input light stimulus may be a light stimulus. In various embodiments, the input light stimulus is a collimated light stimulus, such as laser light. In further embodiments, the input light stimulus is any type of electromagnetic radiation, such as gamma rays, ultraviolet light, infrared light, X rays, or any other electromagnetic radiation.
With reference to FIGS. 1 and 2 , an example dual-mode photosensitive pixel with gain stage 2 is disclosed ( FIG. 1 ) and various circuit behaviors 40 of the dual-mode photosensitive pixel with gain stage 2 are disclosed ( FIG. 2 ). A dual-mode photosensitive pixel with gain stage 2 may be a modified dual-mode current amplifier architecture disclosed herein. As such, the dual-mode photosensitive pixel with gain stage 2 may comprise a photodetector module 10 , a current mirror module 20 , and a mode threshold control module 30 .
A photodetector module 10 may receive an input light stimulus 8 and may establish a detection current into a detection node 15 of the photodetector module 10 . Similarly, the current mirror module 20 may monitor the detection node 15 and may further induce a mirrored current on a mirrored current node 25 . The mirrored current may be amplified or attenuated relative to the detection current on detection node 15 The mirrored current may be sinked/sourced from a mode threshold control module 30 . In response to the magnitude of the mirrored current, the mode threshold control module 30 may provide an output voltage on an output node 3 . The output voltage may vary in response to the mirrored current at least one of linearly and logarithmically, depending on the instantaneous mode of operation of the dual-mode photosensitive pixel with gain stage 2 . More specifically, output node 3 is reset to an initial voltage, V RESET . The mirrored current at mirrored current node 25 will sink charge from output node 3 and the voltage at output node 3 will decrease until a threshold is met. The dual-mode photosensitive pixel with gain stage 2 will be operating in a linear (integrating) mode. After the threshold (inflection point 45 on FIG. 2 ) is met, the output voltage at output node 3 will be a substantially instantaneous function of the mirrored current on mirrored current node 25 . Thus, the dual-mode photosensitive pixel with gain stage 2 will be operating in a logarithmic (substantially instantaneous) mode.
A photodetector module 10 may comprise a detector 11 , a bias control amplifier 12 , and a bias control transistor 13 . The photodetector module 10 may receive the input light stimulus 8 and induce a detection current in the detection node 15 in response.
A detector 11 may comprise an optical detection device. For instance, the detector 11 may comprise a light sensing diode having an anode and a cathode. The light sensing diode may be reverse biased by a voltage, D SUB , and may conduct an illumination response current in response to the presence of an input light stimulus 8 .
A bias control amplifier 12 may comprise an operational amplifier or any other amplifier device. For instance, the bias control amplifier 12 may be electrically connected in series with the detector 11 . The bias control amplifier 12 may have a first input 51 , a second input 52 , and an output 53 . The detector 11 may be connected to the first input 51 . A bias control transistor 13 may also be connected in series with the detector 11 , such as along a drain-source path of the bias control transistor 13 , and the bias control transistor 13 may be connected to the output 53 of the bias control amplifier 12 . For instance, the gate of the bias control transistor 13 may be connected to the output 53 of the bias control amplifier 12 , thus the drain-source path of the bias control transistor 13 and the first input 51 of the bias control amplifier 12 may be connected in parallel. The bias control amplifier 12 may receive a reference voltage, V REF , such as at the second input 52 , and may induce an output 53 in response to a first comparison of the first input 51 and the second input 52 . For instance, the first comparison may comprise the voltage received from the detector 11 being greater than or less than/equal to V REF . In further embodiments, the first comparison may comprise the voltage received from the detector 11 being greater than/equal to or less than V REF . For instance, the induced output 53 might may toggle between relatively higher and lower voltages/currents and/or impedances. For instance, in response to the voltage received from the detector 11 being less than V REF (e.g., first comparison), the output 53 of the bias control amplifier 12 may be induced to a lowered voltage. The resistivity of the drain-source path of the bias control transistor 13 may change in response. More specifically, the bias control amplifier 12 may monitor the first input 51 (connected to detector 11 ) and provide a negative feedback path to control the impedance of bias control transistor 13 in response to the detector current at first input 51 , such that the first input 51 connected to detector 11 may always be biased as a reference voltage, V REF .
A bias control transistor 13 may comprise a field-effect transistor (FET). The bias control transistor 13 may comprise a P-channel FET as illustrated in FIG. 1 . However, in further embodiments, the bias control transistor 13 may comprise an N-channel FET, or may comprise any transistor as desired.
The bias control transistor 13 may comprise a P-channel FET having a gate, drain, and source. The gate may be connected to the output of the bias control amplifier 12 so that the bias control amplifier 12 provides feedback inducing the resistivity of the drain-source path to change. For, instance, when the output of the bias control amplifier 12 is transitions to a lower voltage, the resistivity of the drain-source path may also transition to a lower resistivity, such as according to a ratio of the change in drain current to the change in gate voltage over a defined interval (e.g., according to the transconductance of the FET).
The source of the bias control transistor 13 may be connected in series with the detector 11 . In this manner, the current flowing from the detector 11 , may pass through the source-drain path of the bias control transistor 13 , subject to the effect of feedback from the bias control amplifier 12 . The current flowing through the drain-source path may be varied by the detector 11 , for instance, in response to the magnitude of the input light stimulus 8 . This current may exit the bias control transistor 13 via detection node 15 .
The current mirror module 20 may comprise a current mirror transistor connected to detection node 15 . The current mirror module 20 may receive the detection current present at detection node 15 and may draw a corresponding mirrored current at mirrored current node 25 . The corresponding mirrored current at mirrored current node 25 may be amplified and/or attenuated relative to the detection current at detection node 15 .
The current mirror module 20 may comprise a first current mirror transistor 21 and a second current mirror transistor 22 . The first current mirror transistor 21 may receive a current from detection node 15 . The first current mirror transistor 21 may interoperate with a second current mirror transistor 22 to induce a mirrored current on the mirrored current node 25 that corresponds to the current at the detection node 15 .
A first current mirror transistor 21 and/or a second current mirror transistor 22 may comprise a field-effect transistor (FET). The first current mirror transistor 21 and/or second current mirror transistor 22 may each comprise an N-channel FET as illustrated in FIG. 1 . However, in further embodiments, the first current mirror transistor 21 and/or second current mirror transistor 22 may each comprise a P-channel FET, or may comprise any transistor as desired.
A mode threshold control module 30 may comprise a current integrator 34 , a cascode limit transistor 33 , and logarithmic current amplifier 31 , and an integration reset switch 32 . For instance, the mode threshold control module 30 may be connected to the mirrored current node 25 of the current mirror module 20 . Thus a current may be impelled through at least a portion of the mode threshold control module 30 (e.g., the mirrored current), the current corresponding to that detector current passing through the detection node 15 of the current mirror module 20 , which corresponds to the illumination response current flowing from the detector 11 , such that, the mirrored current impelled through at least a portion of the mode threshold control module 30 corresponds to the magnitude of the input light stimulus 8 . The mode threshold control module 30 may induce a corresponding voltage on output node 3 . This voltage may be related to the magnitude of the input light stimulus 8 by various mathematical relations. For instance, the mode threshold control module 30 may alternately induce a voltage on output node 3 that is linearly related to the integrated value of the input light stimulus 8 over the time duration from when integration reset switch 32 is operated to when output node 3 voltage is observed, and at other times, induce a voltage on output node 3 that is logarithmically related to the substantially instantaneous magnitude of the input light stimulus 8 .
The mode threshold control module 30 may comprise a current integrator 34 . A current integrator 34 may comprise a capacitor with a component value of C INT . The current integrator 34 may be disposed between an output node 3 and a circuit ground. Thus, the current integrator 34 may integrate the current flowing into the current integrator 34 and produce an output voltage that comprises the integral of the current over the time duration from when the integration reset switch 32 is operated to when output node 3 voltage is observed. In various embodiments, the current integrator 34 integrates the current flowing into the current integrator 34 and produces a corresponding output voltage over the linear region 41 ( FIG. 2 ) of operation of the dual-mode photosensitive pixel with gain stage 2 .
A cascode limit transistor 33 may be disposed in connection to the mirrored current node 25 and may be configured to enhance the linearity of response of the dual-mode photosensitive pixel with gain stage 2 over the linear region 41 ( FIG. 2 ). The source voltage of the cascode limit transistor 33 may be set in response to V CASC . This, in turn, maintains a constant drain voltage on second current mirror transistor 22 , improving the linearity of the voltage response when operating in linear integrating mode.
The voltage V log at the drain of logarithmic current amplifier 31 may be used to set a threshold for the mode transition from linear response to logarithmic response. The threshold may correspond to an output voltage at output node 3 that crosses a mode transition point (inflection point 45 ( FIG. 2 )) comprising the transition point wherein an output voltage on one side of the mode transition point is a linear function of light stimulus integrated from the time an integration reset switch 32 is operated (e.g., opened) and an output voltage on the other side of the threshold is a logarithmic function of the instantaneous light stimulus. The voltage present at output node 3 at the mode transition point (inflection point 45 ( FIG. 2 )) may be called V CROSS . Thus, stated differently, the amplifier mode may comprise a logarithmic correlation to the magnitude of the input light stimulus in response to the magnitude of the input light stimulus causing an output voltage on the output node to exceed V CROSS and a linear function of the magnitude of the input light stimulus integrated over a first period (e.g., from the time an integration reset switch 32 is operated, for example, is opened) in response to the magnitude of the input light stimulus causing an output voltage on the output node to not exceed V CROSS .
In various embodiments, V CROSS may be mathematically determined according to component parameters, such that the transition of the dual-mode photosensitive pixel with gain stage 2 from linear to logarithmic modes may be predicted. For instance:
V CROSS = V RESET - I PHOTO · t int C INT = V log - V T · ln I PHOTO I 0
V T represents the threshold voltage of logarithmic current amplifier 31 in the cases where it is implemented as an NFET transistor. A cascode limit transistor 33 may comprise a field-effect transistor (FET). The cascode limit transistor 33 may comprise an N-channel FET as illustrated in FIG. 1 . However, in further embodiments, the cascode limit transistor 33 may comprise a P-channel FET, or may comprise any transistor as desired. I PHOTO represents the mirrored photocurrent seen at the drain of current mirror transistor 22 . I 0 is a constant parameter quantifying the current-carrying capacity of logarithmic current amplifier 31 . t int represents the integration time, which is the time from when the integration reset switch 32 is opened until the voltage at output node 3 is observed. C int represents the capacitance of the current integrator 34 .
A logarithmic current amplifier 31 may be disposed in connection to the cascode limit transistor 33 and a voltage source, V log . The logarithmic current amplifier 31 may interoperate further with the cascode limit transistor 33 to compel inflection point 45 ( FIG. 2 ) and further to impel a logarithmic relation between output voltage at output node 3 and the magnitude of the input light stimulus 8 over logarithmic region 42 ( FIG. 2 ). In various embodiments, the logarithmic current amplifier 31 comprises an N-channel FET with the gate and source connected together, and wherein the source-drain path extends in series from a voltage source, V log to output node 3 and further in series with the drain-source path of cascode limit transistor 33 . In further embodiments, the logarithmic current amplifier 31 may comprise a P-channel FET or any suitable device as desired.
Finally, integration reset switch 32 may be disposed between output node 3 (the shared node of the current integrator 34 and the cascode limit transistor 33 ) and a voltage source, V RESET . Integration reset switch 32 may be selectably induced to reset the integration of the current passing into the current integrator 34 and further may drive the output node 3 to a voltage equal to V RESET such as depicted by reset boundary 43 of FIG. 2 . Thus, with additional reference to FIG. 2 , the dual-mode photosensitive pixel with gain stage 3 may 1) produce an output at output node 3 corresponding to, V RESET in response to no input light stimulus 8 being detected by detector 11 , 2) produce an output corresponding linearly to the magnitude of input light stimulus 8 across linear region 41 in response to the magnitude of the input light stimulus 8 being insufficient to cause the output voltage on output node 3 to reach V CROSS (inflection point 45 ), and 3 ) produce an output corresponding logarithmically to the substantially instantaneous magnitude of input light stimulus 8 across logarithmic region 42 in response to the magnitude of the input light stimulus 8 being sufficient to cause the output voltage on output node 3 to reach/exceed V CROSS (inflection point 45 ). The dual-mode photosensitive pixel with gain stage 2 may produce an output at output node 3 that reflects a difference relative to V log that is a logarithmic function of the substantially instantaneous mirrored current through logarithmic region 42 . As such, a dual-mode photosensitive pixel with gain stage 2 may have a configurable gain and a configurable linear-mode/logarithmic mode transition point (e.g., inflection point 45 of FIG. 2 ).
Various benefits and advantages have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, and any elements that may cause any benefit or advantage to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C.
The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, the following description and drawings are intended to be exemplary in nature and non-limiting.
Systems, methods and apparatus are provided herein. In the detailed description herein, references to “various embodiments”, “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.
Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. | A photosensitive pixel with gain stage is disclosed. The photosensitive pixel with gain stage may receive an input light stimulus and output a corresponding output voltage in response to the input light stimulus. The output voltage may correspond linearly to the magnitude of the input light stimulus over a linear operating region and logarithmically to the magnitude of the input light stimulus over a logarithmic operating region. In this manner, the photosensitive pixel with gain stage may be both sensitive to input light stimuli over the linear operating region and may exhibit dynamic range enabling non-saturated response to input light stimuli over the logarithmic operating region. | 7 |
BACKGROUND OF THE INVENTION
In the operation of electronic equipment, such as data processors, it is often necessary to provide an indication of the state of various lines carrying electrical signals. For example, in applications involving an RS-232 type interface, test procedures may be implemented to obtain a visual indication of the state of each control and data line, including minimum operating voltage thresholds. Often, a large number of parallel interfaces must be monitored simultaneously, and the visual indication, discernible at a considerable distance from the monitor.
Present day monitoring circuits generally embody two separate amplifiers for signal voltage levels respectively above and below zero volts. Two separate voltage reference sources are required, along with a pair of output isolation elements, interposed between the respective output terminals of the amplifiers and the LED indicating device. The last mentioned device is driven by the monitor circuit, but its electrical characteristics do not play an active role in the monitor circuit design parameters.
It is apparent from the foregoing considerations that present day circuits used to monitor a large plurality of interfaces simultaneously, require a correspondingly large number of discrete components, along with LED indicators of comparatively large physical size. Power requirements for such an arrangement are also large. What is desirable is a monitor circuit with a minimal parts count and low power requirement. In fact, such a circuit is mandated in portable test equipment of the "suitcase" type, where space is extremely limited. The LED monitor circuit of the present invention fills such a need.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a monitor circuit comprised of a dual LED indicating device and a non-inverting operational amplifier. Both the input impedance of the circuit and the switching thresholds of the amplifier may be predetermined by selecting the resistance values of an input network. Such values in turn determine the input voltage applied to an amplifier input terminal for a given signal voltage applied to the monitor circuit.
The amplifier gain characteristic passes through three distinct operating regions, as the level of the input signal traverses acceptable limits. The output of the amplifier is coupled via a current limiting resistor to a terminal common to a pair of inversely connected LED components. The other terminal of the dual LED device is connected to a second input terminal of the operational amplifier. As will be considered in detail hereinafter, the operating characteristics of the dual LED device form part of the monitor circuit parameters. Thus, the device is not merely driven by the circuit, but is instead an integral, essential part thereof. The foregoing circuit arrangement uses approximately half the number of components employed in the aforementioned present day circuit.
In operation, the monitor circuit of the present invention responds to predetermined positive and negative threshold voltages. Assuming that the dual LED device is a two-color indicator, a first color may be observed upon attainment of a positive threshold by the amplifier and a second color, upon attainment of a negative threshold. The former may represent an "ON" condition for the line being monitored; the latter, an "OFF" condition. If neither color indication is observed, the input signal level is less than the minimum threshold.
Other features and advantages of the signal monitor of the present invention will become apparent in the detailed description of the invention which follows.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 2 is a schematic diagram of the monitor circuit of the present invention.
FIG. 2 is a graph illustrating the three distinct regions of the gain of the operational amplifier of FIG. 1, as a function of the input signal level to the monitor.
FIG. 3 is a graph of the amplifier output voltage versus signal input voltage for an actual operative circuit embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference to the electrical schematic of FIG. 1 reveals the presence of two active elements, namely, a dual LED indicator 10 having a pair of inverse-connected LED's and a non-inverting operational amplifier 12.
The input signal V IN to be monitored is applied to one extremity of a resistive divider comprised of resistors 14 and 16. The opposite extremity of the divider is connected to ground. The voltage V 1 at the common point of the last mentioned resistors is applied to the positive (+) input terminal of amplifier 12. Amplifier 12 is coupled to respective positive and negative sources, +V and -V of supply potential. The output voltage V 0 of the amplifier 12 is applied via resistor 18 to one of a pair of terminals of LED indicator 10, the last mentioned terminal being connected to the negative (-) input terminal of amplifier 12. The voltage appearing on the amplifier negative input terminal is designated ΔV REF . The other terminal of LED indicator 10 is grounded.
The input impedance and the switching thresholds of the circuit of FIG. 1 are predetermined in accordance with selected values for resistors 14 and 16. Moreover, such values determine the amplifier input voltage V 1 for a given value of signal voltage V IN . ΔV REF is a function of V 1 , the amplifier gain, and the forward voltage (V F ) characteristic of the LED's in indicator 10. As indicated by the graph of FIG. 2, for low absolute voltage values of V 1 , the gain of operational amplifier 12 is approximately one. That is, the absolute value of V 1 is equal to or less than the absolute value of V REF , which in turn is less than V F of the LED's of indicator 10. In effect, for |V 1 |<V F , the LED indicator 10 is out of the circuit, and the amplifier output V 0 ≃V 1 .
When |V 1 | begins to exceed V F , ΔV REF becomes fixed at the value of V F . The gain of amplifier 12 begins to increase exponentially toward infinity with increasing absolute values of V 1 . This results in increasing current flow through the forward biased LED of the indicator 10. The latter LED turns "ON". In summary, the forward biased LED of indicator 10 is "OFF" when |V 1 |≦|V REF |≦V F and is "ON" when |V 1 |>|V REF |=V F .
Therefore, if the forward voltage characteristics of the LED devices are known, a proper selection of the values of resistors 14 and 16 will provide the desired input impedance and positive/negative switching thresholds for the monitor circuit of FIG. 1. It should be observed that the circuit permits not only an observation of the "ON" and "OFF" states of the interface being monitored, but also provides an indication of whether or not minimum voltage thresholds on the interface are being met. For example, assuming that the dual LED indicator includes a red LED and a green LED, the monitor circuit arrangement may be such that when the red LED is "ON", the interface is "ON"; when the green LED is "ON", the interface is "OFF". On the other hand, with both LED's "OFF", the minimum absolute threshold voltage has not been attained. These conditions are illustrated graphically in FIG. 2.
As noted hereinbefore, an electrical characteristic, specifically V F , the forward voltage of the LED's of indicator 10 plays an important role in the monitor circuit design. Since ##EQU1## if V IN is equal to "V IN desired switching threshold"; V 1 is equal to V F of the LED's; and Z IN impedance=R 1 +R 2 , then the following three design equations are used to determine the values of R 1 , R 2 and R 3 in FIG. 1. ##EQU2## wherein V 0 is the clamp voltage of amplifier 12 and
I is the maximum desired LED current
In an actual operative circuit embodiment, indicator 10 is a dual color light emitting diode (type MV 9471) having a V F of approximately 2.0 volts. The operational amplifier (1/4 of Fairchild 4136) has an output which is "lock-up" proof and has a maximum output swing V 0 of approximately ±8 volts for supply potentials V of ±12 volts. That is, ±8 volts is equal to the clamp voltage. The desired input resistance was chosen as 9500 ohms and the LED devices are to switch "ON" respectively at plus and minus 5.5 volts. Moreover, the desired LED current through indicator 10 was limited to 25 milliamperes.
Using the foregoing parameters in equations (1), (2) and (3), the calculated values of R 1 , R 2 and R 3 resulted in practical values of 3300 ohms, 6340 ohms, and 330 ohms respectively.
In FIG. 3, the output voltage V 0 of amplifier 12 is plotted against the input voltage V IN of the operative monitor embodiment. For a V IN of approximately 5.0 to 5.5 volts, plus or minus, a respective LED in indicator 10 is turned "ON".
In conclusion, the monitor circuit of the present invention provides a saving of at least fifty percent of the parts count for circuits which provide a similar function, with concomitant savings in electrical power and physical space requirements. The circuit elements and parameters associated therewith, as presented hereinbefore, refer to an actual operative monitor; are submitted solely for purposes of example; and are not to be construed as limitative of the invention. Changes and modifications of the monitor circuit organization presented herein may be needed to suit particular requirements. In view of the foregoing, all changes and modifications as are within the skill of the circuit designer, insofar as they are not departures from the true scope and spirit of the invention, are intended to be covered by the following claims. | A circuit for monitoring the status of electrical signals, such as those present on the control and data lines of an RS-232 interface, includes a single operational amplifier and a dual-color LED indicator. The electrical characteristics of the LED's form a significant part of the circuit parameters. The monitor design provides a predetermined circuit input impedance and positive/negative switching thresholds to effect the selective illumination of the LED's. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority to United Kingdom Patent Application No. GB1117511.4, filed Oct. 11, 2011, and titled DOWNHOLE VALVE ASSEMBLY, the contents of which are expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a downhole valve assembly. In particular, the present invention relates to a downhole valve assembly that provides a contingency/back-up device in the event that another downhole valve has failed to open.
2. Description of the Related Art
Well completion involves various downhole procedures prior to allowing production fluids to flow thereby bringing the well on line. One of the downhole procedures routinely carried out during well completion is pressure testing where one downhole section of the well is isolated from another downhole section of the well by a closed valve mechanism such that the integrity of the wellbore casing/liner can be tested.
Well completion generally involves the assembly of downhole tubulars and equipment that is required to enable safe and efficient production from a well. In the following, well completion is described as being carried out in stages/sections. The integrity of each section may be tested before introducing the next section. The terms lower completion, intermediate completion and upper completion are used to describe separate completion stages that are fluidly coupled or in fluid communication with the next completion stage to allow production fluid to flow.
Lower completion refers to the portion of the well that is across the production or injection zone and which comprises perforations in the case of a cemented casing such that production flow can enter the inside of the production tubing such that production fluid can flow towards the surface.
Intermediate completion refers to the completion stage that is fluidly coupled to the lower completion and upper completion refers to the section of the well that extends from the intermediate completion to carry production fluid to the surface.
During testing of the intermediate completion stage the lower completion is isolated from the intermediate completion by a closed valve located in the intermediate completion. When the integrity of the tubing forming the intermediate completion section is confirmed the upper completion stage can be run-in.
Generally the completion stages are run-in with valves open and then the valves are subsequently closed such that the completion stages can be isolated from each other and the integrity of the production tubing and the well casing/wall can be tested.
Typically, the valves remain downhole and are opened to allow production fluids to flow. By opening the valves the flow of production fluids is not impeded.
In the event that a valve fails to open, for example where the valve or an actuating mechanism operable to open the valve becomes jammed, remedial action is generally required because a failed valve effectively blocks the production path.
Remedial action often involves removing the valve. The valve may be removed by milling or drilling the valve out of the wellbore to provide a free flowing path for production fluid.
It will be appreciated that resorting to such remedial action can result in costly downtime because production from the well is stopped or delayed. The remedial action may result in damage to the well itself where milling or drilling the valve or valves from the wellbore may create perforations in the production tubing or the well casing or well lining. As a result such actions would preferably be avoided.
It is desirable to provide a downhole device such that production downtime due to a failed valve is reduced.
It is further desirable to provide an improved downhole valve assembly that helps to avoid using remedial actions such as milling or drilling to remove a failed valve from an intermediate or upper completion section of a wellbore.
It is desirable to provide a downhole valve assembly that provides a contingency or back-up system when there is a failed valve located in the wellbore.
BRIEF SUMMARY OF THE INVENTION
A first aspect of the present invention provides a downhole valve assembly operable to control production fluid flow around an obstruction in a production tubing string; wherein the valve assembly comprises a tubular body comprising an axial passage extending through the body; one or more ports extending substantially radially through the body; and one or more actuating members operable to move relative to the body to selectively open the ports such that a fluid flow path through the ports is defined between an annulus region outside of the valve assembly and the axial passage.
The obstruction in the production tubing string may comprise a downhole valve assembly that is closed due to failure to open.
The valve assembly according to the present invention may comprise a mechanically actuated actuating member.
The mechanically actuated actuating member may be adapted for mechanical engagement with a removable downhole tool such that upon removal of the downhole tool the actuating member may be moved from a first position to a second position. When the mechanically actuated actuating member is in the second position the valve assembly may be in a primed state.
Mechanical engagement of the mechanically actuated actuating member with a downhole tool such as a stinger or a washpipe may comprise coupling the mechanically actuated actuating member to the downhole tool. Accordingly, the mechanically actuated actuating member may comprise a coupling member adapted to couple with a corresponding coupling member on the downhole tool. Removal of the downhole tool, for example using a sliding action of the downhole tool in a generally uphole direction, may engage the coupling member of the actuating member with the coupling member of the downhole tool such that the actuating member may be displaced and may disengage from the downhole tool leaving the valve assembly in the primed state.
In the primed state the ports remain closed until a subsequent event, for example, when fluid pressure is applied via the axial passage to the valve assembly. The applied fluid pressure may be within a predetermined range such that unnecessary actuation may be avoided.
The valve assembly may further comprise a hydraulic actuator, comprising at least a piston member and an inlet and an outlet. The inlet of the hydraulic actuator may be in fluid communication with the axial passage of the body. The outlet may be in fluid communication with a hydraulically actuated actuating member that moves when fluid pressure is applied via the inlet.
The inlet of the hydraulic actuator may be closed when the mechanically actuated actuating member is arranged in the first position and may be opened when the mechanically actuated actuating member is arranged in the second position. When the mechanically actuated actuating member is in the second position the inlet of the hydraulic actuator may be open, wherein the hydraulic actuator may be in fluid communication with the axial passage of the body. The inlet of the hydraulic actuator may be in fluid communication with the axial passage when the valve assembly is in the primed state.
The hydraulic actuator may be operable to open the one or more ports upon application of fluid pressure via the inlet when the valve assembly is in the primed state. Hydraulic actuation may be provided by fluid pressure applied via production tubing or annulus such that pressurised fluid enters the inlet of the hydraulic actuator and applies pressure upon the piston member, which acts to displace the hydraulically actuated actuating member thereby opening the ports. The hydraulic actuator may comprise, for example, a spring, an electronically controlled pump, or a hydraulic piston.
The mechanically actuated actuating member and the hydraulic actuator may be arranged within the tubular body. The mechanically actuated actuating member and the hydraulic actuator may be adapted to move by sliding in an axial direction relative to the body.
The hydraulic pressure required to actuate the hydraulic actuator may be applied via the inlet due to fluid pressure from the axial passage or from the annulus.
The hydraulic actuator may comprise one or more fluid openings that each may be aligned with a corresponding port on the tubular body to define the flow path between an annulus region outside of the valve and the axial passage.
The ports through the body may be inclined relative to the axis of the body. The direction of the incline of the ports through the body may correspond substantially with the direction of fluid flow.
The downhole valve assembly according to the present invention provides an alternative flow route for fluid in the event that another downhole valve assembly, for example a barrier valve, has failed to open. Therefore, a valve assembly according to the present invention maintains production flow such that remedial actions such as milling or drilling to remove the obstruction are avoided.
A valve assembly according to a first embodiment of the present invention may restore normal axial flow of fluid following a diversion of fluid flow around the obstruction using the annulus region defined between the inside wall of the well/reservoir and the outside of the tubing mounted completion assembly.
The valve assembly according to the first embodiment of the present invention may be located uphole of the potential obstruction such that restoration of fluid flow passes from the annulus to the axial passage. It will be appreciated that the valve assembly restores normal axial flow before the annulus flow is blocked by a packer.
The valve assembly according to the first embodiment may comprise ports through the body, wherein the ports incline in an uphole direction from outside to inside the body. Therefore the direction of incline may correspond substantially with the direction of fluid flow. Fluid flow through the valve according to the first embodiment of the invention may be from the annulus region outside the body to inside the axial passage. Alternatively, fluid flow through the valve according to a second embodiment may be from inside the axial passage to the annulus region outside of the body.
In respect of the valve assembly according to the first embodiment, annulus flow is necessary to bypass the obstruction. Annulus flow may be generated by fluid flow through perforations in the production tubing in a region downhole of the potential obstruction. Annulus flow may be created by production or injection fluid flowing through the perforations into the annulus region defined between the outside of the production tubing and the inside wall of the well/reservoir.
Alternatively, annulus flow from a region downhole of the valve assembly may be created by a disconnection in the production tubing, for example one tubing mounted completion assembly may be disconnected from another tubing mounted completion assembly such that when production fluid flows it divides at the disconnection to generate flow through the axial passage and in the annulus region.
Alternatively, annulus flow may be created by a valve assembly according to a second embodiment of the invention. The valve assembly according to a second embodiment may be located in a region of the well that is downhole of a potential obstruction.
A valve assembly according to the second embodiment may comprise ports through the body, wherein the ports incline from inside to outside in an uphole direction. Therefore, the direction of incline may correspond substantially with the direction of production fluid flow where production fluid flow through the valve according to a second embodiment of the invention may be from the axial passage inside the body to the annulus region outside the body.
The valve assembly according to the second embodiment may be utilised to create annulus flow such that an obstruction uphole of the valve assembly can be bypassed. Hydraulic actuation of the valve assembly according to the second embodiment of the invention may be provided by annulus flow entering the inlet of the hydraulic actuator and acting upon the piston member, which acts to displace the hydraulically actuated actuating member thereby opening the ports for fluid to flow. The valve assembly according to the second embodiment may be utilised to create annulus flow.
Annulus flow is required to bypass an obstruction in the production tubing. However, in a tubing mounted completion assembly comprising a packer, production fluid flow via the annulus is prevented beyond the packer because the packer seals the annulus region defined between the outside of the production tubing and the inside wall of the well. Therefore, a valve assembly according to the first embodiment may be utilised to restore normal flow by diverting annulus flow back into the axial passage and beyond a packer.
The valve assembly according to embodiments of the invention and all its associated control lines and actuators may be contained within the wellbore as part of a tubing mounted completion assembly and as such operation of the valve assembly may be by application of fluid pressure from uphole or downhole of the valve. Therefore, a valve assembly according to embodiments of the invention does not require any control lines to surface to operate.
The valve assembly according to the present invention may provide a back-up or contingency device to a downhole valve assembly that has failed to open.
A second aspect of the present invention provides a method of controlling and diverting fluid flow around an obstruction in a production tubing string, wherein the method comprises the steps of:
locating a valve assembly in a wellbore, wherein the valve assembly comprises a tubular body comprising an axial passage extending through the body, one or more ports extending substantially radially through the body; and one or more actuating members operable to move relative to the body to selectively open the ports such that a fluid flow path through the ports is defined between an annulus region outside of the valve and the axial passage; and
moving the one or more actuating members relative to the body to open the ports such that a fluid flow path for production fluid is defined; wherein the fluid flow path is defined between an annulus region outside of the valve and the axial passage.
The valve may comprise a mechanically actuated actuating member, wherein the method comprises the step of engaging the mechanically actuated actuating member with a retrievable downhole tool, moving the mechanically actuated actuating member from a first position to a second position and disengaging the mechanically actuated actuating member from the retrievable downhole tool. The retrievable downhole tool may be, for example a washpipe or stinger. When the mechanically actuated actuating member is in the second position the valve assembly may be in a primed state.
The valve assembly may further comprise a hydraulic actuator comprising at least a piston member, a fluid inlet and a fluid outlet, wherein the method may further comprise applying fluid pressure via the axial passage or annulus and the inlet such that the fluid pressure may act upon the piston to selectively open the ports such that a fluid flow path for production fluid is defined through the body of the valve assembly.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic representation of a wellbore assembly comprising a downhole valve assembly in accordance with an embodiment of the present invention;
FIG. 2 is a schematic representation of the wellbore assembly of FIG. 1 showing a production flow path during normal operation of a producing well;
FIG. 3 is a schematic representation of the wellbore assembly of FIG. 1 showing a modified production flow path of a producing well in accordance with an embodiment of the present invention;
FIG. 4 is a schematic representation of a closed downhole valve assembly in accordance with an embodiment of the present invention;
FIG. 5 is a schematic representation of a closed downhole valve assembly in accordance with an embodiment of the present invention;
FIG. 6 is a schematic representation of an open downhole valve assembly in accordance with an embodiment of the present invention;
FIG. 7 is a schematic representation of a wellbore downhole completion assembly comprising a lower completion assembly, intermediate completion assembly, an upper completion assembly and including a downhole valve assembly in accordance with an embodiment of the present invention;
FIG. 8 is a schematic representation of a wellbore assembly comprising a downhole valve assembly in accordance with a second embodiment of the present invention;
FIG. 9 is a further schematic representation of a wellbore assembly comprising a downhole valve assembly in accordance with a second embodiment of the present invention;
FIG. 10 is a schematic representation of a closed downhole valve assembly in accordance with a second embodiment of the present invention; and
FIG. 11 is a schematic representation of an open downhole valve assembly in accordance with a second embodiment of the present invention
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , a partial longitudinal view of a wellbore completion arrangement 100 is illustrated. The wellbore completion arrangement 100 comprises a first downhole valve assembly 10 , a second downhole valve assembly 12 and a packer assembly 14 .
The second downhole valve assembly 12 is representative of a downhole valve assembly in accordance with embodiments of the present invention. The downhole valve assembly 12 will be hereinafter referred to as a bypass valve assembly 12 such that it is distinguishable from the first downhole valve assembly 10 , which may be for example a barrier valve.
In the illustrated example, a wellbore 16 is lined with a casing 18 , which in the illustrated embodiment is held in place with cement 20 .
The downhole valve assembly 10 , the bypass valve assembly 12 and the packer assembly 14 are all run into the casing 18 as part of the well completion assembly 100 on a running string that may include a stinger or washpipe (not illustrated).
For illustrative purposes, FIG. 1 does not indicate any specific form or type of downhole valve assembly 10 . Suitable valve assemblies 10 will be discussed further below with respect to the action of the bypass valve assembly 12 according to embodiments of the present invention.
The packer assembly 14 provides a seal in the annulus region 23 defined between the outside diameter of the production tubing 22 and the inside diameter of the casing 18 .
In the illustrated embodiment the downhole valve assembly 10 is run-in in an open state and is subsequently closed when it has reached its location downhole. Once closed, fluid pressure can be applied from above the downhole valve assembly 10 to check the integrity of the production tubing 22 and the well completion assembly 100 . Following successful testing, the downhole valve assembly 10 can be opened such that production fluid can flow unimpeded through the downhole valve assembly 10 when the well is brought on line.
The downhole valve assembly 10 can be opened by suitable means, for example fluid pressure from control lines to surface (not illustrated), mechanical actuation (not illustrated) or remote electronic actuation (not illustrated). Examples of suitable valves are ball valves and flapper valves.
FIG. 2 illustrates a producing well 200 comprising a downhole valve assembly 10 , a bypass valve assembly 12 and a packer assembly 14 , where the well is online and production fluid is flowing from a downhole location towards the surface as indicated by arrows 26 . The normal path for production fluid is to flow in the uphole direction, through the axial bore of the production tubing 22 and to pass unimpeded through the open axial bore of the downhole valve assembly 10 and to continue to flow through the axial bore of the production tubing 22 towards the surface as indicated by arrows 26 .
FIG. 3 illustrates a producing well 200 in the event that the downhole valve assembly 10 has failed to open and remains closed regardless of further attempts to open the downhole valve assembly 10 . In this situation, the bypass valve assembly 12 , according to a first embodiment of the present invention, can be used to facilitate a diversion of production fluid flow around the failed valve assembly 10 as illustrated in FIG. 3 and described further below.
Normal flow 26 from a producing well is illustrated in FIG. 2 , however in the example illustrated in FIG. 3 , the normal flow path 26 for production fluids towards the surface is prevented due to the blockage provided by the closed or failed downhole valve assembly 10 .
In the illustrated embodiment, annulus flow, as indicated by arrows 32 , is provided from a region downhole of the downhole valve assembly 10 .
Perforations 28 through the production tubing 22 in the region downhole of the downhole valve assembly 10 enables annulus flow 32 from the production flow 26 . The annulus flow 32 is created by the production flow 26 in the axial bore of the production tubing 22 flowing through the perforations 28 into the annulus 30 . Annulus flow 32 is therefore allowed in the particular completion assembly, for example intermediate or upper completion up to the packer assembly 14 , which provides an annulus seal and therefore prevents further uphole passage of annulus fluid flow 32 beyond the packer assembly 14 .
As is illustrated in FIG. 3 , the annulus flow 32 provides a flow path around the failed downhole valve assembly 10 .
With reference to FIGS. 3, 4, 5 and 6 , the bypass valve assembly 12 , according to an embodiment of the invention, facilitates diverting the annulus flow 32 of production fluid 26 from the annulus 23 back into the axial bore of the production tubing 22 in a location uphole of an obstruction caused by the closed valve assembly 10 .
FIG. 4 illustrates a bypass valve 12 in accordance with embodiments of the invention. The bypass valve 12 is shown in the closed state.
The bypass valve 12 comprises a tubular body 300 , which includes an axial bore 320 between an inlet end 340 and an outlet end 360 . The inlet 340 and the outlet 360 each comprise a threaded connector for attachment to a tubing mounted completion assembly or to the production tubing 22 of a downhole assembly.
The body 300 includes flow ports 380 extending through the body 300 in a substantially radial direction such that fluid can flow from outside the bypass valve 12 to inside the bypass valve 12 (see FIG. 6 ) as indicated by arrows 400 .
The bypass valve assembly 12 includes a mechanically actuated sleeve 420 that moves by the action of retrieval/withdrawal of a washpipe or stinger from the completion assembly.
The washpipe or stinger (not illustrated) includes a mechanical coupling device such as collet fingers that are operable to engage with a profiled section 425 of the sleeve 420 such that the washpipe or stinger engages with and pulls the sleeve 420 as the washpipe or stinger is pulled from the completion assembly.
When the sleeve 420 reaches a stop 460 inside the body 300 the washpipe or stinger disengages from the sleeve 420 . At the limit of its movement the sleeve 420 exposes and opens a port 440 to the axial passage 320 such that the bypass valve assembly 12 is in a primed state, wherein it is ready for operation in the event that the downhole valve assembly 10 fails to open.
The bypass valve assembly 12 comprises an internal hydraulic actuation mechanism 470 , illustrated simply in FIG. 5 as a piston 480 , a spring 490 and hydraulic fluid 500 .
In the event that the downhole valve assembly 10 fails to open, the bypass valve 12 can be actuated by applying downhole tubing pressure 510 (see FIG. 4 ) which acts on the piston 480 via the port 440 such that movement of the piston 480 due to fluid pressure 510 displaces the hydraulic fluid 500 contained within the bypass valve 12 to cause a mechanism 515 to move which causes a compressed spring 490 to be released such that the spring 490 extends to complete the movement of the sleeve 525 by mechanical force exerted by the spring 490 on the sleeve 525 such that the flow ports 380 of the body 300 and corresponding ports 385 through the sleeve 320 are aligned (see FIG. 6 ). Alignment of the flow ports 380 , 385 provides a flow path 400 through the bypass valve 12 to facilitate the diversion of fluid flow from the annulus 23 to fluid flow in the axial passage 320 of the bypass valve 12 and the production tubing 22 towards the surface.
As is illustrated in each of FIGS. 4, 5 and 6 the flow ports 380 are angled downwards from the inside to the outside of the bypass valve for smooth uninterrupted passage of production fluid from the downhole region of the production tubing towards the surface.
As described above with reference to FIGS. 3, 4, 5 and 6 annulus flow 32 is required such that production fluid can flow around an obstruction, such as a closed valve. Therefore, to restore production flow the bypass valve 12 diverts the annulus fluid flow 32 back into the axial passage 320 and the production tubing 22 beyond.
As described above with reference to FIG. 3 annulus flow 32 may be created by having a perforated joint 29 in the production tubing in a region below the area of a potential obstruction such as the downhole valve assembly 10 .
FIG. 7 illustrates a wellbore assembly 600 comprising a lower completion assembly 610 , an intermediate completion assembly 620 and an upper completion assembly 630 . The intermediate completion assembly 620 and the upper completion assembly 630 each comprise a downhole valve assembly 10 , a bypass valve assembly 12 and a packer assembly 14 as described above with reference to FIGS. 1 to 6 .
The lower completion assembly 610 and the intermediate completion assembly 620 are fluidly coupled and comprise a perforated joint 635 , which comprises perforations 28 (see FIG. 3 ) to allow production fluid 26 to flow from inside the production tubing 22 to the annulus 23 .
As can be seen from FIG. 7 the intermediate completion assembly 620 and the upper completion assembly 630 are not physically coupled together. Instead, a gap 660 is present between the intermediate completion assembly 620 and the upper completion assembly 630 such that the production fluid 400 exiting the intermediate completion 620 divides at the gap 660 to produce annulus flow 432 that can flow around the obstruction caused by the valve 10 failing to open.
The gap 660 or the distance between the intermediate completion 620 and the upper completion 630 may be in the region of nine to twelve meters (30-40 feet), but can be whatever distance that is deemed necessary.
Annulus flow is controlled and contained between zones 610 , 620 , 630 because of the sealing arrangement provided by each packer assembly 14 .
The intermediate completion assembly 620 is generally engaged with a washpipe and run into the well/casing whilst the valve 10 is open. Upon completion of the intermediate completion assembly 620 and prior to installing the upper completion assembly 630 the washpipe is removed. Upon removal of the washpipe the bypass valve 12 is primed and ready as discussed above with reference to FIGS. 4, 5 and 6 .
The upper completion assembly 630 is generally engaged with and run in to the well with a downhole tool such as a stinger (not shown). For workover of a well the stinger is removed and the valve 10 is closed, either mechanically upon removal of the stinger or in some other way, for example by electronic or hydraulic actuation. Upon removal of the stinger all control lines from the surface to the upper completion assembly 630 are disconnected and the bypass valve 12 according to embodiments of the invention is primed and ready for use to divert annulus flow 432 to tubing flow 260 . Therefore, following workover of a well, the bypass valve 12 can be used to restore a flow path 260 for production fluid as described above if attempts to reopen the valve 10 fail.
An advantage of the bypass valve 12 according to embodiments of the invention may be that production downtime due to a downhole obstruction, for example a failed valve, is minimal compared with the remedial methods described above. This is because the bypass valve 12 is primed for use on routine removal of a washpipe or stinger and the subsequent application of fluid pressure from the region uphole of the failed valve 10 opens the ports 380 such that annulus flow can bypass the obstruction and restores production flow.
FIG. 8 illustrates a partial longitudinal view of a wellbore completion arrangement 800 showing an application of a downhole valve assembly 812 according to a second embodiment of the present invention. Similar reference numerals have been applied and prefixed by the number eight.
The well completion arrangement 800 comprises a first downhole valve assembly 810 and a second downhole valve assembly 812 .
The second downhole valve assembly 812 is representative of a downhole valve assembly in accordance with a second embodiment of the present invention. Therefore, the downhole valve assembly 812 will be hereinafter referred to as a bypass valve assembly 812 .
Comparing FIG. 8 (of the second embodiment) with FIG. 1 (of the first embodiment) it is to be noted that in the well completion arrangement illustrated in FIG. 8 the packer assembly is omitted and that the bypass valve assembly 812 is located below the downhole valve assembly 810 .
In the second embodiment a guide arrangement (not illustrated) is provided uphole of both the downhole valve assembly 810 and the bypass valve assembly 812 such that annulus flow is allowed, if and when required.
In FIG. 8 the wellbore 816 is constructed in the same way as the wellbore 16 illustrated in FIG. 1 , where the wellbore 816 is lined with a casing 818 , which is securely held in place with cement 820 .
The downhole valve assembly 810 and the bypass valve assembly 812 are run into the well as part of the well completion assembly 800 on a running string that may include a stinger or washpipe (not illustrated).
In the illustrated embodiment the downhole valve assembly 810 is run-in in an open state and is subsequently closed when it has reached its location downhole. Once closed, fluid pressure can be applied from above the downhole valve assembly 810 to check the integrity of the tubing 822 and the well completion assembly 800 . Following successful testing, the downhole valve assembly 810 can be opened such that production fluid can flow unimpeded through the downhole valve assembly 810 when the well is brought on line.
Primarily, the downhole valve assembly 810 can be opened by suitable means, for example fluid pressure from control lines to surface (not illustrated), mechanical actuation (not illustrated) or remote electronic actuation (not illustrated). Examples of suitable valves are ball valves and flapper valves.
As in the first embodiment, where the well is a producing well 800 comprising a downhole valve assembly 810 and the bypass valve assembly 812 according to a second embodiment of the invention, production fluid flows from a downhole location towards the surface as indicated by arrows 826 . The normal path for production fluid is to flow, in the direction indicated by arrows 826 , in the uphole direction, through the axial passage of the production tubing 822 and to pass unimpeded through the axial passage of the bypass valve assembly 812 and through the open axial passage of the downhole valve assembly 810 and continue to flow through the axial passage of the production tubing 822 towards the surface.
In the event that the downhole valve assembly 810 fails to open, and remains closed regardless of further attempts to open the downhole valve assembly 810 , the bypass valve assembly 812 can be used to facilitate a diversion of production fluid flow past the failed valve assembly 810 .
In the illustrated example the bypass valve 812 is located below the obstruction created by the closed valve 810 (as illustrated in FIG. 8 and FIG. 9 ).
Fluid pressure 831 applied via the annulus activates the internal mechanism of the annulus bypass valve 812 such that the annulus bypass valve 812 is actuated and opened and creates annulus flow, as indicated by arrows 832 , in a region downhole of the downhole valve assembly 810 .
The bypass valve assembly 812 facilitates diverting the production flow 826 through the open ports 880 in the body of the annulus bypass valve 812 to create annulus flow 832 that allows the flow of production fluid to continue uphole via the annulus region around the obstruction created by the closed downhole valve 810 .
In the illustrated example, a packer is omitted from the tubing mounted completion assembly 800 and as such annulus flow 832 can continue, unimpeded to surface.
The bypass valve 812 according to the second embodiment comprises the same components as the bypass valve 12 according to the first embodiment and for clarity the features of the second embodiment are described by the following with reference to FIG. 10 . Like reference numerals have been applied.
The bypass valve 812 comprises a tubular body 300 , which includes an axial passage 320 between an inlet end 340 and an outlet end 360 . The inlet 340 and the outlet 360 each comprise a threaded connector for attachment to other components of a tubing mounted completion assembly or the production tubing of a downhole assembly.
In the second embodiment, the body 300 includes flow ports 380 extending through the body 300 in a substantially radial direction such that production fluid can flow from inside the bypass valve 812 to outside the bypass valve 812 as indicated by arrow 401 .
The bypass valve assembly 812 includes a mechanically actuated sleeve 420 that moves by the action of retrieval/withdrawal of a washpipe or stinger from the completion assembly to prime the bypass valve assembly 812 . The bypass valve assembly 812 is prepared (primed) for operation in the event that the valve assembly 810 fails to open and is operational upon application of hydraulic pressure to open the ports in the body of the valve.
The washpipe or stinger (not illustrated) includes a mechanical coupling device such as collet fingers that are operable to engage with the profiled section 425 of the sleeve 420 such that the washpipe or stinger engages with and pulls the sleeve 420 as the washpipe or stinger is pulled from the completion assembly. When the sleeve 420 reaches a stop 460 inside the body 300 the washpipe or stinger disengages from the sleeve 420 . At the limit of its movement the sleeve 420 opens a port 440 such that the bypass valve assembly 812 is primed and ready for operation in the event that the downhole valve assembly 10 fails to open.
The bypass valve assembly 812 comprises an internal hydraulically actuated mechanism 470 , which includes a piston 480 , a spring 490 and hydraulic fluid 500 (see FIGS. 9, 10 and 11 ). A more detailed view of the components of the bypass valve is illustrated in FIG. 10 and FIG. 11 .
Referring to FIGS. 10 and 11 , in the event that the downhole valve assembly 810 fails to open, the bypass valve 812 is actuated by pressure applied via the annulus/upper production tubing. FIG. 10 illustrates the bypass valve 812 prior to actuation and FIG. 11 illustrates the bypass valve 812 when actuated. The fluid pressure is applied to the inside of the bypass valve 812 and the fluid acts upon the piston 480 via the port 440 . The piston 480 is displaced such that the hydraulic fluid 500 contained within the bypass valve 812 is displaced, which subsequently causes a mechanism 515 to move which allows a compressed spring 490 to be released. The spring 490 extends to complete the movement of the sleeve 525 , which operates to move to open the ports 380 such that a flow path 401 is defined through the bypass valve 812 to facilitate the diversion of production fluid flow from the axial passage 320 to the annulus.
Whilst specific embodiments of the present invention have been described above, it will be appreciated that departures from the described embodiments may still fall within the scope of the present invention. | A downhole valve assembly operable to control production fluid flow around an obstruction in a production tubing string. The obstruction may be caused by another valve or valve assembly located in the production tubing string, where the valve is closed and blocks flow through the production tubing. The downhole valve assembly comprises a tubular body that includes an axial passage extending through the body and one or more ports extending substantially radially through the body. The downhole valve assembly also includes one or more actuating members operable to move relative to the body. Movement of the actuating members selectively opens the ports such that a fluid flow path through the ports is defined between an annulus region outside of the valve assembly and the axial passage such that the blockage can be bypassed. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention is in the field of miniature mouthpieces for enhancing athletic performance by repositioning the user's mandible.
[0003] 2. Description of the Related Art
[0004] Mouthpieces and mouthguards are often used in sports to prevent injury to the teeth, as well as to help treat temporomandibular joint disorders (TMD). Many athletes, in sports such as baseball, basketball, boxing, football, hockey, rugby, skiing, water polo and the like wear mouthguards to both help protect the teeth and reduce the incidence of concussion. Such considerations are discussed in the book by Julian Hodges entitled “Mouthguards & Sport Safety: No-Nonsense Resource for Everyone Who Recommends or Should Wear a Mouthguard”, published in 2009 by Good Innovations Pty Ltd., Avalon, Australia.
[0005] Examples of such prior art mouthguards include Westerman, U.S. Pat. No. 6,036,487, who taught the utility of making mouthguards out of orally acceptable plastics materials containing a plurality of airtight cavities. Other examples of prior art in this area include Ackervall, US patent application 2009/0038624, who taught the use of “U” shaped thermoplastic materials formed from perforated plastic sheets.
[0006] Prior art mouthguards generally wrapped around both the user's anterior teeth (i.e. incisors) and posterior teeth (i.e. molars and premolars). In particular, especially for athletic applications, covering the user's posterior teeth (molars) was considered to be advantageous because such mouthguards could help cushion or reduce the transmission of shocks from the user's lower (Mandibular) molars to the user's upper (Maxillary) molars, and thus help prevent mouth and even brain damage under high impact situations.
BRIEF SUMMARY OF THE INVENTION
[0007] The invention is based, in part, on the insight that although protecting the user's molars by placing material between the molars is indeed advantageous under certain situations, in other situations, actually placing material between the molars it is less advantageous and/or unnecessary. Indeed other methods of providing a space between the molars may suffice. According to the invention, for such situations, it can be advantageous to use a “mini” mouthpiece that is configured to primarily or exclusively work with the user's anterior central and lateral incisors, and not to cover either the user's molars or premolars.
[0008] Thus, in some embodiments, the invention may be a miniaturized mouthpiece for repositioning the user's mandible, thereby creating an edge to edge relationship of the user's anterior teeth, which are the user's most anterior two or four teeth (central incisors only or central incisors and lateral incisors). The invention's miniaturized mouthpiece can reposition the user's mandible so that the user's anterior teeth are aligned atop of each other, without covering or extending to the user's posterior teeth. The bite is edge to edge. Once the user has the mouthpiece in the engaged position, it creates an interocclusal (space) of about 0.5-8 mm between the user's posterior teeth (e.g. molars). In other words, when worn, the device creates an interocclusal gap that does not allow the user's molars to touch each other. In some embodiments, this miniaturized mouthpiece may be formed from a substantially trapezoidal mouthpiece blank having major and minor sides that are substantially parallel to one another. These major and minor sides may be connected by two equal length non-parallel sides, thus forming a roughly trapezoidal structure. This blank will typically have a contact area, of which at least portions of this area will run in a substantially parallel direction to the blank's major and minor sides. The contact area is usually gently curved in order to follow the curvature of the user's anterior upper and lower dental arches. The curve is based on the Curve of Monson, which is described as a portion of a sphere having a radius of about 101 mm (this radius varies somewhat, with an SD of approximately 24 mm, according to the size of the user's jaw, thus the 2SD range for this radius would be approximately 50 to 150 mm). This contact area will generally be located in the central portion of the mouthpiece blank between the major and minor sides of the blank. The blank will often be made of a thermoplastic material, so that upon application of heat, the blank can be deformed around the user's maxillary incisors.
[0009] This contact area will be designed to accommodate the user's anterior teeth, and will generally have oppositely disposed top and bottom areas with sufficient widths to accommodate the user's maxillary and mandibular anterior teeth. The contact area will have a slight curve to permit contact of the user's anterior teeth, which are generally in an arch form. These areas will be raised platforms of the device which the teeth will contact. In some embodiments, the blank may also have a plurality of perforations having dimensions substantially smaller than the dimensions of a tooth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows an overview of one embodiment of the invention's miniature mouthguard blank.
[0011] FIG. 2 shows how the invention's miniature mouthguard blank may have a substantially trapezoidal structure.
[0012] FIG. 3 shows both front and side views of the invention's miniature mouthguard blank, showing the raised contact area.
[0013] FIG. 4 shows some of the typical dimensions of the invention's miniature mouthguard blank.
[0014] FIG. 5 shows how the invention's miniature mouthguard blank may be configured into a folded shape to fit around the user's anterior teeth.
[0015] FIG. 6 shows a schematic side view of how the miniature mouthguard, when worn, works with the user's jaw bone and anterior and posterior teeth to provide an interocclusal gap between the user's posterior teeth.
[0016] FIG. 7 shows a close up of the bite region of the mouthguard, showing one embodiment where the top is molded to the teeth and is retentive, and the bottom is molded to the teeth when formed and acts as an alignment channel when engaged.
DETAILED DESCRIPTION OF THE INVENTION
[0017] As previously discussed, in one embodiment, the invention may be a miniaturized mouthpiece for repositioning the user's mandible, thereby creating an edge to edge relationship of the user's anterior teeth. Thus the invention will reposition the mandible so that the user's maxillary and mandibular anterior teeth are aligned atop of each other, while at the same time, the invention will not cover or extend to the user's posterior teeth (e.g. molars). By virtue of forcing the anterior teeth somewhat apart, and the fact that the anterior teeth and posterior teeth are of course connected by the user's jaw, the invention will also operate to create a 0.5-8 mm interocclusal gap or space in the posterior teeth. Generally, the invention will only cover the user's incisors.
[0018] The invention's mouthpiece blank will generally create a mouthpiece in a curved, three dimensional configuration that will cover the user's maxillary anterior teeth in use. This mouthpiece will be formed from a substantially trapezoidal blank material, often made from an oral compatible material about 0.5-5 mm thick, which is shown in FIG. 1 ( 100 ). In an optional embodiment, this blank material may have a plurality of perforations ( 102 ). These perforations will typically be cylindrical in nature, with a diameter substantially smaller than the dimensions of the user's teeth, often on the rough order of 0.5-2 mm. These perforations will often extend completely through the blank, thus creating a hollow hole, through which saliva may flow.
[0019] The blank will have overall dimensions designed to fit, when folded into a three dimensional shape, around the user's maxillary anterior teeth (e.g. the user's central incisor teeth and optionally the user's central incisor teeth and the user's lateral incisor teeth) and be worn comfortably in the mouth.
[0020] As shown in FIG. 2 , this blank ( 100 ) generally both roughly resembles a trapezoid, and also generally fits within trapezoid ( 200 ). The substantially trapezoidal blank ( 100 ) will have major ( 202 ) and minor ( 204 ) sides that are substantially parallel to one another. These major ( 202 ) and minor ( 204 ) sides are connected by two equal length non-parallel sides ( 206 ), ( 208 ). Although the major sides and the minor sides need not be straight, and instead may be formed from one or more curved surfaces, the outer boundary of the sides will still generally fit within a trapezoidal outline ( 200 ).
[0021] The blank ( 100 ) will further have a contact area ( 210 ) that runs substantially parallel to the major ( 202 ) and minor sides ( 204 ), and disposed in the blank ( 100 ) in-between the major and minor sides ( 202 ), ( 204 ). This contact area is designed to accommodate the user's anterior teeth, and will generally have oppositely disposed top and bottom areas with sufficient widths to accommodate the tips of the user's maxillary central incisors and optionally lateral incisors on one side, and the tips of the user's mandibular central incisors and optionally lateral incisors on the other side. This gently curved shape thus accommodates the anterior portion of the user's teeth. The curve is based on the Curve of Monson, which is described as a portion of a sphere with a radius generally varying between approximately 50 and 150 mm, often approximately 101 mm, with an SD of 24 mm, again varying somewhat with the user's particular jaw size and shape. In for some unusual jaws, +/−3SD limits for the Curve of Monson may be required.
[0022] As shown in FIG. 3 , which shows a side view of the blank ( 300 ), the contact area ( 210 ) will have a material ( 312 ) which is generally thicker than the remainder of the device, usually thick enough to cause an interocclusal gap of between 0.5 to 8 mm when the device is worn. The contact area ( 210 ), will generally have a width ( 306 ) of between 1-10 mm, and may have abrupt or rounded edges ( 308 ), ( 310 ). This width ( 306 ) is designed so that the device, when three dimensionally folded around the user's maxillary anterior teeth, will thus form an area that can accommodate the width of the user's maxillary and mandibular anterior teeth (incisors).
[0023] The thickness of the contact ( 312 ) area will generally be at least 0.5-4 mm thicker than the rest of the blank ( 314 ), and may be up to 1 cm thicker. Thus if the blank is generally 3 mm thick ( 314 ), then the thickness ( 312 ) of the contact area will generally be at least 3.5-9 mm. Thus, as previously discussed, in some embodiments, the thickness of the contact area will be thick enough so that the device when worn will cause the user's molars to be positioned with an interocclusal gap of between 0.5 to 8 mm. In this way, the device helps to minimize lower molar to upper molar shock transfer, while not actually providing any material between the molars. This is shown in more detail in FIG. 6 .
[0024] To provide this interocclusal gap, it may be necessary to optimize the thickness of the contact area ( 312 ) to different values depending upon the characteristics of the user's mouth. Thus in some embodiments, some fitting may be required. In particular, it may be necessary to select or adjust the thickness of the contact area so as to create a 0.5 to 8 mm high interocclusal gap between the molars of a given user.
[0025] In some embodiments, the major side of the blank, rather than being straight, will be composed of one or more curved regions, such as two equal length connected arcs ( 320 ), ( 322 ). In this particular embodiment, a line drawn through the uppermost portion of both arcs will be substantially parallel to the blank's minor side, as shown in FIG. 2 ( 202 ), ( 204 ). This type of equal length, connected arcs, embodiment can be useful because the two arcs help the mouthguard, when folded into its operating three dimensional shape, to better conform to the gum line of anterior portion of the user's upper jaw. Other shapes may also be used for this region as well, however. The major side of the blank is often termed the labial or “lip side” of the device.
[0026] The minor side of the device ( 204 ), which in use will be folded into a position that is facing the tongue (lingual) side of the user's mouth, need not be straight either. Generally the regions where the minor side ( 204 ) contacts the non-parallel sides ( 206 ), ( 208 ) may often be gently rounded to avoid creating sharp corners that might cause mouth irritation. In some embodiments, the minor side ( 204 ) may be gently rounded or curved ( 212 ) so as to create an arc or indentation between 1-5 mm deep. However generally when the minor side ( 204 ) is an arc, it will be an arc with rounded edges at the region where the minor side ( 204 ) contacts the equal length non-parallel sides ( 206 ), ( 208 ), and often a line drawn through both rounded edges will be substantially parallel to the major side ( 202 ).
[0027] The dimensions of the mouthpiece blank are further shown in FIG. 4 . Typically the width ( 400 ) of the blank at the major side is between 25 and 50 mm, and the distance ( 402 ) between the major and minor side is between 20 and 40 mm.
[0028] The length ( 404 ) between the minor side ( 204 ) and the lower side of the contact area ( 310 ) is often between about 5-25 mm. Similarly, the length ( 406 ) between the major side ( 202 ) and the upper side of the contact area ( 308 ) is often between 5-25 mm as well. The length ( 408 ) of the minor side is often between 5 and 15 mm long.
[0029] Note that the center of the contact area ( 410 ) is positioned in the central region of the blank at distances ( 412 ) ranging between ⅓ to ⅔ of the distance between the major and minor sides ( 202 ), ( 204 ). As previously discussed, the contact area ( 210 ) will generally have a width ( 306 ) between 1-10 mm (often 2-5 mm), and the overall length of the contact area is usually long enough to accommodate the user's central incisors and often the user's lateral incisors as well. This will vary according to the shape and size of the user's teeth, but will usually be between about 10 to 35 mm long. The radius of this contact area ( 420 ) at the center ( 410 ) will vary according to the curve of Monson, as previously discussed, typically between 50 to 150 mm.
[0030] FIG. 5 shows how the invention's miniature mouthguard blank may be configured into a folded shape to fit around the user's anterior teeth.
[0031] FIG. 5 ( 500 ) shows the mouthguard configured into a folded shape ( 502 ), and fitting around the maxillary central incisors ( 504 ) and lateral incisors ( 506 ). The outline of the user's mouth and lips ( 508 ), as well as some of the user's lower anterior teeth ( 510 ) are also shown.
[0032] FIG. 5 ( 520 , 522 , 524 ) shows the folded form of the mouthguard from various rotated perspectives, showing the relative positions of the major arcs ( 320 ), ( 322 ) of the major side, the positions of the minor side ( 204 ), and the position of the contact area ( 210 ).
[0033] Here, to facilitate the folding process, the mouthpiece blank ( 100 ) can be made from a thermally flexible orally acceptable material, such as polycaprolactone, that is capable of being softened in hot water (˜70° C.), and then bent to conform to the mouth and teeth of a user. When cooled down to body temperature (˜37° C.), the material can then maintain a rigid configuration.
[0034] When the blank is configured into a folded shape to fit about the user's anterior teeth in this manner, the blank may either be held in place purely by friction, or else by a retentive gel which can be applied to the mouthpiece prior to placement into the mouth of a user.
[0035] Other orally compatible materials and other folding methods (e.g. molding based on mouth and teeth impressions) may also be used.
[0036] In some configurations, shown in FIG. 5 ( 526 ), when the blank ( 100 ) is configured into a folded shape that fits around the user's anterior teeth, it is useful to fold the portion of the blank proximate the minor side of the blank in an arc away from the major side of the blank so as to create a resting shelf for the user's bottom teeth when the mouthguard is worn in the disengaged position.
[0037] FIG. 6 shows a schematic side view of how the miniature mouthguard, when worn, works with the jaw bone and the anterior and posterior teeth to provide an interocclusal gap between the user's posterior teeth. In this respect, the user's jaw and teeth act like a lever, and the mouthguard, by providing force at the end of the lever (at the anterior teeth) helps keep the posterior teeth separated. In FIG. 6 , the width of the mouthguard ( 312 ) is exaggerated, and some of the other dimensions are also distorted in order to better convey this lever concept.
[0038] In practice, the mouthguard blanks may be manufactured in a number of standard sizes, such as various standard sized blanks for adults and children. The blanks need not be made out of a single material, but rather may be a composite of two or more different materials. These two or more different materials may either be present as different layers (e.g. along the thickness of the mouthguard), or alternatively may be in various regions of the device, such as different types of materials on the major side of the device, minor side of the device, and in the central contact area of the device.
[0039] As shown in FIG. 7 , in some embodiments, when formed, there may be two channels for the teeth to fit into ( 700 ), ( 702 ), such as a top ( 702 ) that is molded to the teeth and is retentive, and a bottom ( 700 ) that is molded to the teeth when formed and acts as an alignment channel when engaged.
[0040] In this embodiment, the top part of the contact area of the mouthpiece is formed with a top channel ( 702 ) that is molded to fit the user's upper anterior teeth, and is also configured to adhere to said upper anterior teeth. Further, the bottom part of the contact area ( 700 ) is formed with a bottom channel that is molded to fit the user's bottom anterior teeth. This channel ( 700 ) further acts as a mouthpiece alignment channel when, for example, the mouthpiece is engaged in the mouth of a user ( 500 ). | A miniaturized mouthpiece for repositioning the user's mandible, thereby creating an edge to edge relationship of the user's anterior teeth, without covering or extending to the user's posterior teeth. This miniaturized mouthpiece may be formed from a substantially trapezoidal mouthpiece blank having major and minor sides that are substantially parallel to one another. These major and minor sides may be connected by two equal length non-parallel sides. This blank will typically have a gently curved and raised contact area that follows the curvature of the user's anterior dental arches. The mouthpiece blank will often be made of a thermoplastic material, so that upon application of heat, the blank can be deformed around the user's maxillary central incisors and often the user's maxillary lateral incisors as well, thus creating a mouthpiece that does not cover the user's molars or premolars, yet which creates an interocclusal gap when worn. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a clutch assembly and method for limiting torque transmission particularly applicable in an electrically energized starter for an internal combustion engine.
Electric starter motors are widely utilized for cranking small gasoline engines such as those utilized in garden tractors, lawn mowers, snow blowers, outboard motors for boats and the like. In such a starter, a pinion drive provides the means for momentarily engaging the engine flywheel to transfer power from the electric starting motor to the internal combustion engine and then disengaging the starter motor from the flywheel once the engine has started to prevent damage to the starter motor. The most common way to facilitate engagement and disengagement of the pinion with the flywheel is to mount the pinion gear to a shaft so that it is rotatably driven by the motor and is simultaneously moved axially along the shaft. The axial movement allows full engagement of the pinion gear with the flywheel during cranking and complete disengagement once the engine has started. The axial travel of the pinion gear is generally facilitated by one of two means. The pinion gear is either forced along the shaft by a solenoid or by inertia of the pinion gear interacting with the accelerating motor shaft by means of mating helical threads on the pinion gear and the associated shaft.
Exemplary starter assemblies are illustrated and described in U.S. Pat. Nos. 3,690,188 and 4,255,982.
In a typical starter assembly, the flywheel of the associated internal combustion engine has gear teeth formed about the outer periphery thereof and a spring biased pinion gear adapted to selectively drivingly engage the flywheel gear teeth is coupled to the output shaft of a starting motor through a torque limiting friction clutch and a helical spline.
When the starting motor is energized and commences to rotatingly drive the output shaft, the inertia of the pinion gear resists rotation and the helical spline causes the pinion gear to translate axially along the starting motor output shaft and thence into engagement with the gear teeth of the flywheel.
The engine is then cranked until the speed of the engine surpasses the speed at which it is driven by the starting motor. When the engine speed surpasses the starting motor speed, the helical spline causes the pinion gear to disengage from the flywheel gear teeth. Simultaneously, an associated anti-drift helical spring urges the pinion gear out of engagement and toward its normal rest position.
It is readily apparent that during the starting of an internal combustion engine, the starting motor including the associated pinion, is subjected to considerable shock and loading stresses as it initially engages and disengages from the flywheel gear teeth of the engine.
Such stresses are inherent as the starting motor armature and pinion are rotating as the pinion gear engages the relatively large mass of the engine flywheel and associated engine components which are at rest.
An ever present problem encountered in the design of an electric starting motor for cranking internal combustion engines is providing the starting motor components with means to absorb or decrease the torsional shock when the pinion gear of the starting motor initially engages the flywheel gear teeth of the associated engine. At the time of the engagement, the armature, drive shaft, and pinion are rotating at a relatively high speed and the flywheel of the engine is not rotating. The moment the pinion gear of the starting motor engages the flywheel gear teeth, a sudden torsional shock is imparted to the flywheel as well as to the starting motor pinion gear and associated armature. The resultant torsional shock may result in damage to either the starting motor or the flywheel, or both.
Various schemes over the years have been developed in an attempt to solve or minimize the problem. Some attempts have been directed to mechanisms to soften or decrease the torsional shock upon engagement, while other attempts have utilized a slip-clutch of some configuration.
SUMMARY OF THE INVENTION
It is an objective of the present invention to produce a slip-clutch arrangement that is very effective, simple in design and economical to manufacture.
Another objective of the invention is to produce a clutch mechanism for a starting motor for an internal combustion engine which contains components which may be highly automatable from a production standpoint.
Another object of the invention is to produce a clutch assembly for a starting motor for an internal combustion engine provided with a predetermined amount of slip torque to prevent damage to the associated components.
Still another object of the invention is to produce a slip clutch for a starting motor for starting an internal combustion engine which will limit the maximum torque transfer between the starting motor and the associated internal combustion engines.
The above as well as other objects of the invention may typically be achieved by an electric motor having a rotatable shaft; a pinion gear mounted for driving a flywheel of an engine; and a clutch assembly for transmitting torque between the shaft of the motor and the pinion gear, the clutch assembly comprising a driving member coupled to the shaft of the motor for rotational movement, a spline rotatingly mounted to the shaft of the motor for slight axial movement relative to the shaft, and a housing for coupling the driving member and the spline for fictionally transmitting torque between the driving member and the spline.
BRIEF DESCRIPTION OF THE DRAWINGS
The above as well as other objects and advantages of the invention will become readily manifest to one skilled in the art from reading the following detailed description of the preferred embodiment of the invention when considered in the light of the attached drawings, in which:
FIG. 1 is an elevational view of an engine starter assembly embodying the features of the present invention;
FIG. 2 is an enlarged sectional view of the clutch assembly of the starter assembly illustrated in FIG. 1;
FIG. 3 is an exploded view of the clutch assembly illustrated in FIG. 2; and
FIG. 4 is a sectional view taken along line 4--4 of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, there is illustrated an engine starter motor 10, a pinion gear 12, a friction clutch 14, a spline 16 extending from the clutch assembly 14, an anti-drift spring 18, and a retainer 20.
The motor 10 is a conventional starter motor having a housing 22 and an armature shaft 24 extending outwardly from the housing 22. The pinion gear 12 is journalled on the spline 16 which, in turn, is journalled on the armature shaft 24. The pinion gear 12 is adapted for rotational movement and axial displacement along the pinion gear 12 to engage and disengage with a flywheel 26 of an associated internal combustion engine.
The clutch assembly 14 includes the spline 16 provided with an external helical thread 30 adapted to threadably engage with internal threads 32 of the pinion gear 12. The assembly 14 further includes a housing cover 34 having an aperture in the side wall thereof through which the threaded portion 30 of the spline 16 is adapted to extend. Also, the spline 16 is provided with a flanged portion 36, one surface of which is adapted to seat against the inner surface of the housing wall through which the threaded portion 30 of the spline extends.
Within the housing 34, adjacent the opposite side of the flange 36 of the spline 16, is a clutch washer 38. The clutch washer 38 has diametrically opposed outwardly extending tabs 40 which are caged within diametrically opposed channels 42 formed in the housing 34.
Next, a wave washer 48 is disposed to reside adjacent the side of the clutch washer 38 opposite that facing the flange 36 of the spline 16.
A base plate 50 having diametrically opposed outwardly extending tabs 52 is positioned within the housing 34 such that the tabs 52 are received within the channels 42.
Finally, the peripheral marginal edges of the housing 34 are crimped over the base plate 50. During the final crimping operation, the base plate 50 is forced inwardly of the housing 34 until the plate bottoms on a shoulder 54 formed in housing 34 at which time the wave washer will be sufficiently compressed. Thus, pressure is provided between the base plate 50, the wave washer 48, the clutch washer 38, the flange 36 of the spline 16, and the inner wall of the housing 34.
The base plate 50 is provided with a double "D" hole which mates with a corresponding outer configuration of the shaft 24 of the starter motor as clearly illustrated in FIGS. 2 and 4. Accordingly, the base plate 50 is, in effect, keyed to and is therefore driven by the shaft 24.
The wave washer 48, the clutch washer 38, and the spline 16 are each provided with openings that are larger than the outer diameter of the shaft 24 and, therefore, tend to "float" freely on the shaft 24. More specifically, since the clutch assembly 14 is housed within the housing 34 which is maintained, in effect, coaxially of the shaft 24 by the base plate 50, the wave washer 48, the clutch washer 38, and inner bore of the spline 16 are maintained in axial relation with the shaft 24.
In operation, it will be appreciated that the armature shaft 24 drives the base plate 50 which, in turn, drives the spline 16 upon which the pinion gear 12 is keyed via the spline or threads 30. The pinion gear 12 is free to rotate on the spline 16. Any relative rotational movement between the pinion gear 12 and the spline 16 results in axial movement of the pinion gear 12. As the starter motor 10 is energized, the fast acceleration of the clutch assembly acting with the inertia of the pinion gear 12 causes the pinion gear 12 to move outwardly along the longitudinal axis of the spline 16 until engagement with the flywheel ring gear 26 of the associated engine which is to be started.
Upon initial engagement with the stationary flywheel, the sudden loading will result in a slippage in the clutch assembly 14. As the back loading on the spline 16 occurs due to loading, the wave washer 48 will be caused to become even more compressed. Thus, enough precalculated pressure in addition to the back loading pressure will start the engine flywheel to rotate and will continue causing the flywheel to rotate until the engine starts. When the engine starts, the pinion gear 12 will back away from the flywheel 26 and come to rest in the normal "at rest" position, which necessarily is free and clear of engagement with the flywheel gear teeth 26. The anti-drift spring 18 militates against drifting movement of the pinion gear 12 caused by engine vibration and thereby prevents contact between the pinion gear 12 and the associated rotating ring gear 26.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be understood that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | An engine starter drive clutch assembly which comprises a starter motor with an armature shaft, pinion gear for engaging and disengaging an engine drive gear, a spline for transmitting axial rotational movement to the pinion gear, and a clutch assembly for transmitting torque between the armature shaft and the pinion gear. | 8 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.